enhance naphtha value and gasoline reformer performance

Enhance Naphtha Value and Gasoline Reformer Performance Using UOP’s

MaxEneTM Process

Enhance Naphtha Value and Gasoline Reformer Performance Using UOP’s

MaxEneTM Process

© 2011 UOP LLC. All rights reserved.

1st IndianOil Petrochemical ConclaveMarch 16, 2012Gurgaon, India

UOP 5614D-1

Mark Turowicz

UOP IPL, A Honeywell Company

Mark Turowicz

UOP IPL, A Honeywell Company

Contents

MaxEne Technology Introduction

Market Drivers for MaxEne Projects

MaxEne Case Studies

MaxEne Commercial Experience

UOP 5614D-2

Refining-Petrochemical Integration

The MaxEne Process delivers benefits in an integrated facility and can also provide substantial benefits to the stand-alone refiner

The MaxEne Process was developed to help optimize the integration of refining and petrochemical facilities

– Normal paraffins are the preferred feed to naphtha crackers for optimized yields of light olefins (ethylene + propylene)

– Catalytic reforming yields increase significantly (octane barrels and aromatics yield) when paraffins are removed from the feed

In an optimally integrated complex with MaxEne Process:

– N-paraffins are fed to the cracker resulting in:

• Upto a 30% increase in ethylene and propylene yield

– Paraffin depletion (and enriching of napthenes/ aromatics) in the feed to the Platformer results in:

• 4-6% increase in C5+ yield at constant octane

• 2-3% increase in aromatics yield

Full Range

Naphtha

Full Range

NaphthaNaphthaCracker

MaxEneUnit

CatalyticReformer

Full Range

Naphtha

Full Range

Naphtha

NaphthaCracker

CatalyticReformer

Typical

Integrated

Complex

Typical

Integrated

Complex

UOP 5614D-3

How Does the MaxEne Process Work?

Pumparoundpump

AdsorbentChamber

ExtractColumn

RaffinateColumn

Feed to reformer

n-Paraffins feed to steam

crackerDesorbent

Naphtha

Feed

RotaryValve

Adsorptive separation

Based on SorbexTM Technology

The adsorbent has greater affinity for n-paraffins

Simulates a moving bed

The process influent and effluent points move, but the actual mechanical connections do not

The solid adsorbent is in fixed, non-moving beds

The liquid feed flows counter-currently relative to the solid

More than 130 process units based on Sorbex Technology licensed worldwide

UOP 5614D-4

Extension of Previous UOP Experience in Naphtha Separation

Liquid phase extraction technology widely used to recover n-paraffins

Gasoline Molex process (C5 to C6) in light naphtha isomerization applications for octane improvement

– 15 licensed units

Kerosene Molex process (C10 to C13) for detergent applications. Heavy Molex process (C14 to C18 ) for other surfactant applications

– 35 licensed units

MaxEne process (C6 to C11) bridges the carbon range between Gasoline and Kerosene Molex

UOP 5614D-5

Contents



MaxEne Case Studies


UOP 5614D-6

Average 2010 Steam Cracker Feedstock Slates

Other than in N America and the ME, most steam crackercapacity is from naphtha -- presents an opportunity to refiners

Source: CMAI 2011 World Ethylene Cost Study

UOP 5614D-7

Contents



MaxEne Case Studies


UOP 5614D-8

Case Study 1: MaxEne Process Integration Integration with a Catalytic Reformer

Goal

Maximize Catalytic Reformer profitability when market demand requires less gasoline production

Produce high quality petrochemical naphtha for domestic or export sales

Basis for integration

Feed is a full range naphtha (FRN). FRN rate kept constant.

MaxEne unit, catalytic reformer and steam cracker yields based on feed composition

Feed, major products, and by-products included

W. Europe price-set assumed with reformate price based on octane value

Catalytic Reformer originally designed for 102 RONC but currently running at 96 RONC based on market need

Why was MaxEne considered?

Flexibility to increase reformate yield and/or octane

Minimize changes to catalytic reformer

Increase value of export naphtha

UOP 5614D-9

Existing Refinery Complex

855kMTA

545 kMTA

Yields, kMTA

C2 = 316

C3= 162

478

96 RONC

795 kMTA

Cracker

NHTNHT

*328 kMTA

Petrochemical Facility

873kMTA

3.22 Wt-% H2 Yield

27.5 kMTA

* Purchased naphtha from other refiner

UOP 5614D-10

93.0 Wt-% C5+ Yield

Full rangenaphtha

1400kMTA

CatalyticReformer

873kMTA

Refinery Complex with MaxEneConstant Full Range Naphtha

Normals

Non-normals

52 kMTA / 82 RONC(light gasoline to

blending)

Catalyticreformer

207 kMTA

584 kMTA

*192 kMTA

681 kMTA

667 kMTA

3.68 Wt-% H2 Yield

24.5 kmta

• Can run catalytic reformer at higher severity with higher quality feedstock

• DeC6 on MaxEne raffinate to remove Bz pre-cursors from reformer feed

UOP 5614D-11

Full rangenaphtha

531kMTA136 kMTA

NHTNHT

Cracker



Yields, kMTA

C2 = 337C3= 171

508

104 RONC

607 kMTA

91.0 Wt-%

C5+ Yield

CatalyticReformer

MaxEneUnit

474 kMTA

1400kMTA

The MaxEne Process EffectCase Study #1 - Refinery Balance

Existing with MaxEne

kMTA kMTA

Full Range Naphtha 1400 1400

Export Naphtha 545 681

n-paraffin Wt-% 42 62

Reformer Feed 855 667

Light Gasoline 0 52

Reformer Gasoline 795 607

RONC 96 104

Hydrogen 28 25

Tail Gas 11 12

LPG 22 24

MaxEne minimizes financial impact of lower reformate production via:

Production of Light gasoline with 82 RONC

Production of 104 RONC Reformate (within existing unit constraints of WAIT, Heater Duty and CCR Size)

Production of Higher Quality (higher % n-paraffin) Petrochemical Naphtha ExportUOP 5614D-12

The MaxEne Process EffectCase Study #1 - Refinery GM Comparison

0

200

400

600

800

1000

1200

1400

Feedstock Products Feedstock Products

$M

/yr

Feedstock Export Naphtha Reformate Light Gasoline

Hydrogen LPG Tail Gas

$176M $199M

Existing With MaxEne

• MaxEne resulted in $23M/yr incremental gross margin increase

• GM increase supports capital investment for MaxEne with simple payback periods < 3 years

• Export Naphtha value increase of $30/MT assumed based on sharing benefit with Ethylene Cracker

UOP 5614D-13

Existing w/MaxEne Existing w/MaxEne

KMTA KMTA $M/yr $M/yr

Feed 872 872 654 674

H2 11 9 12 10

Fuel Gas 138 107 36 27

C2= 316 337 462 493

C3= 162 171 243 256

C4’s 95 87 89 81

pygas 150 163 135 148

Total 872 872 324 341

GM Increase - 17

The MaxEne Process EffectCase Study #1 - Steam Cracker Balance

v

+7%

+6%

Increased paraffin content to cracker results in $17M/yr additional GM with $30/MT

premium on refiner export naphtha price for 500 kmta cracker (ethylene+propylene).

Pay MaxEne

refiner 4%

premium for

high quality

PC Naphtha

Feedstock to

get 5% GM

increase

UOP 5614D-14

MaxEne Process Integration Case Study #2Integration with a Catalytic Reformer

Goal

Maximize yields of catalytic reformate (and hydrogen)

Produce high quality petrochemical naphtha for domestic or export sales

Basis for integration

Feed is a full range naphtha (FRN). FRN rate allowed to increase.

MaxEne unit, catalytic reformer and steam cracker yields based on feed composition

Feed, major products, and by-products included

W. Europe price-set assumed with reformate price based on octane value

Feed rate to catalytic reformer kept constant and increased.

Catalytic Reformer originally designed for 102 RONC and running at nameplate conditions

Why was MaxEne considered?

Increase reformate and hydrogen yield

Minimize changes to catalytic reformer

Increase value of export naphtha

UOP 5614D-15

Existing Refinery Complex

855kMTA

545 kMTA

Yields, kMTA

C2 = 316C3= 162

478

102 RONC

772 kMTA

Cracker

NHTNHT

*328 kMTA


873kMTA

3.75 Wt-% H2 Yield

32 kMTA


UOP 5614D-16

90.4 Wt-% C5+ Yield

Full rangenaphtha

1400kMTA

CatalyticReformer

Refinery Complex with MaxEneConstant Reformer Feedrate

Normals

Non-normals


blending)

Catalyticreformer

265 kMTA

748 kMTA

0 kMTA

872 kMTA

855 kMTA

3.46 Wt-% H2 Yield

30 kMTA

• Additional FRN required to keep reformer full

• DeC6 on MaxEne raffinate to remove Bz pre-cursors from reformer feed UOP 5614D-17

Full rangenaphtha

1794kMTA

174kMTA

Cracker


Yields, kMTA

C2 = 347C3= 175

522

102 RONC

789 kMTA

92.4 Wt-%

C5+ Yield

CatalyticReformer

MaxEneUnit

NHTNHT

607 kMTA

681 kMTA

Refinery Complex with MaxEneConstant Reformer Feedrate

Non-normals


blending)

Catalyticreformer

748 kMTA

0 kMTA

872 kMTA

950 kMTA

3.46 Wt-% H2 Yield

33 kMTA

UOP 5614D-18

Full rangenaphtha

1794kMTA

174kMTA

Cracker


Yields, kMTA

C2 = 347C3= 175

522

102 RONC

878 kMTA

92.4 Wt-%

C5+ Yield

CatalyticReformer

MaxEne process allows reformer to run at 11% over

existing production rate

95 kMTA

NHTNHT

MaxEneUnit

Normals265 kMTA

The MaxEne Process EffectCase Study #2 - Refinery Balance

Existing with MaxEne Cases

kMTA kMTA kMTA

Full Range Naphtha 1400 1794 1794

CCR Range Naphtha 95

Export Naphtha 545 872 872

Reformer Feed 855 855 950

Light Gasoline 0 67 67

Reformer Gasoline 772 789 878

Hydrogen 32 30 33

Tail Gas 17 12 13

LPG 34 24 26

Richer feed allowsreformer to run at higher

capacity while still staying within CCR

regenerator capacity,Rx WAIT and heater duty

MaxEne enables:

Production of Light gasoline with 82 RONC

Increase in C5+ gasoline yield at constant octane

Higher quality (higher % paraffin) Petrochemical Naphtha Export that can command premium pricing…

UOP 5614D-19

The MaxEne Process EffectCase Study #2 - Refinery GM Comparison

0

200

400

600

800

1000

1200

1400

1600

1800

Feedstock Products Feedstock Products Feedstock Products

$M

/yr

Feedstock Export Naphtha Reformate Light Gasoline

Hydrogen LPG Tail Gas

$208M

$247M$271M

Existing w/MaxEne w/MaxEne w/Max Reformer

MaxEne resulted in $39-63M/yr incremental gross margin increase

GM increase supports capital investment for MaxEne with simple payback periods < 2 years

Export Naphtha value increase of $30/MT assumed based on sharing benefit with Ethylene Cracker UOP 5614D-20

Existing w/MaxEne Existing w/MaxEne

KMTA KMTA $M/yr $M/yr

Feed 872 872 654 680

H2 11 8 12 9

Fuel Gas 138 103 36 27

C2= 316 347 462 507

C3= 162 175 243 262

C4’s 95 83 89 78

pygas 150 156 135 141

Total 872 872 324 344

GM Increase - 20

The MaxEne Process EffectCase Study #2 - Steam Cracker Balance

v

+10%

+8%

Increased paraffin content to cracker results in $20M/yr additional GM with $30/MT

premium on naphtha price for 500 kmta cracker (ethylene+propylene).

Pay MaxEne

refiner 2%

premium for

high quality

PC Naphtha

Feedstock to

get 10% GM

increase

UOP 5614D-21

Contents



MaxEne Case Studies


UOP 5614D-22

MaxEne Commercialization Status

First unit to come on-stream in Asia in 2012

Refinery-Petrochemical Integration Application

– Licensee is refinery and cracker operator

MaxEne feedrate is 1.2 MMTA (1200 kMTA)

UOP 5614D-23

Ma

xE

ne

fee

dra

te

1.2

MM

TA

Ma

xE

ne

fee

dra

te

1.2

MM

TA

In Conclusion

European and Asian refiners will need outlet for naphtha as diesel continues to be transportation fuel of choice.

Over half of the world’s ethylene comes from cracking naphtha

MaxEne can help refiners face the increasing shift towards diesel by …

– Maximizing existing catalytic reforming assets

– Producing a premium petrochemical naphtha feedstock for sales to petrochemical producers

MaxEne is an extension of well-proven, reliable commercial Sorbex technology used in aromatics, refining and detergents applications.

First commercial unit start-up in 2012 in Asia

UOP 5614D-24

UOP 5614D-25

enhance naphtha value and gasoline reformer performance

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