Refining-Petrochemical

Synergies & Opportunities

Christian Dupraz

1
 Agenda

• Refining & Petrochemical (R&P) synergies

Facts & figures
• Axens portfolio for R&P integration :
• Refinery & Steam Cracker
• Refinery & ParamaX Suite for Aromatics
• Around (R)FCC: PetroRiserSM, FlexEneTM,
Olicrack
• Olefins upgrading and purification
• APU: new way for BTX production
• Conclusion

OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 2
 Agenda

• Refining & Petrochemical (R&P) synergies

Facts & figures
• Axens portfolio for R&P integration :
• Refinery & Steam Cracker
• Refinery & ParamaX Suite for Aromatics
• Around (R)FCC: PetroRiserSM, FlexEneTM,
Olicrack
• Olefins upgrading and purification
• APU: new way for BTX production
• Conclusion

OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 3
 Market Analysis

World demand, index Olefins & Aromatics feedstock

sources
900 Avg
Mt
Growth Polymers Methanol
800 rate To Olefins
1997-07 500 Renewables
700 Ethane

600 Feedstock from

400 oil refining (LPG,
(LPG,
500 Naphtha, …)
4.7% GDP 82 %
400 300
300
3.9% 85 %
200 Crude oil 200

100 86 %
1.5% 100
0
1980 1990 2000 2010 2020 2030
1980 2005 2030
Alternative routes
routes to
to polymers
polymers not
not fast
fast
Polymers demand growing much enough to feed petchem
petchem growth
growth
quicker than crude oil production
Source: Total Petrochemicals
OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 4
 Refining & Petrochemical Synergies

• Taking out total profit from low value crude oil to

high value refined/petrochemical products
• Enhanced cost competitiveness
• Maximized margin by flow exchanges
• Economy of scale
• Optimized CAPEX/OPEX
• Increased flexibilities towards
• Crude price volatility
• Refined/ petrochemical market evolution
• Financial resistance to cyclic market
• Environmental benefits

OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 5
 R&P Flow Exchanges

Main Refining Units Exchanged flows Petrochemical

Products
Concerned Units
Refinery Off Gases
FCC C3/C4
Naphtha SR or cracked
Reforming Middle Distillates
CCR VGO
Hydrocracker bleed
Polyethylene
FCC Steam
CDU Hydrogen Polypropylene
C4 Cracker …
VDU
Hydrocracker
Reformate
Raffin. Pygas
Heavy Naphtha from Polystyrene
RFCC Maxi C3= FCC
Aromatics
Complex Polyethylene
Raffinate
ParamaX terephthalate
…
OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 6
 R&P Integration
Key Issues for Scheme Selection

• Geographical location and

targeted markets (local vs export)
• Flexibility window for feedstocks and
products
• Investment constraints

OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 7
 Agenda

• Refining & Petrochemical (R&P) synergies

Facts & figures
• Axens portfolio for R&P integration :
• Refinery & Steam Cracker
• Refinery & ParamaX Suite for Aromatics
• Around (R)FCC: PetroRiserSM, FlexEneTM,
Olicrack
• Olefins upgrading and purification
• APU: new way for BTX production
• Conclusion

OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 8
 Case Study 1
Feasibility Study

SITE LOCATION EVALUATION Unit Local Export

Market
LPG Kbd 2.2 -
MARKET STUDY / MARKET ANALYSIS Gasoline Kbd 4.8 -

Jet A1 Kbd 0.52 0.052

CRUDE SELECTION Lighting Kbd 0.1 0
MASS BALANCE MODELS Kerosene
PROCESS SCHEME OPTIMISATION
Diesel Kbd 12.5 Max
RISK STUDY & HSFO Kbd Min Min
ENVIRONMENTAL IMPACT PE Kt/y 300
ASSESSMENT PP Kt/y 300
PVC Kt/y 120
COST ESTIMATION (UP TO CLASS IV)

FINANCIAL ANALYSIS &

PROJECT RISK ASSESSMENT Minimized Investment
OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 9
 Case Study 1
Refinery + Steam Cracker
LN Gasoline
NHT Isom.
FG NaCI + HCI PVC
Tol PVC
Benzene Comonomer
Naphtha BT Extraction
SHU PE
FRAC PE
C2/C3/C4
Raffinate C2 = C2

HN PP PP
SHU C3
CDU Kero WN C3 = FRAC
Blend
Steam to SMR
HDS Kero Cracker C4= C4
GO Kero & GO Jet THU LPG
GO C4 to SMR
Diesel Pygas
FRN
AR HDT C7-
GO Pygas
HD1-HD2
VGO HCK Kero PyOil
VDU
HCK Bleed
C5 C8+

HN + LN GO SR
VR VBU GO
Fuel Oil
VBU VBU Res
OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 10
 Case Study 1
Overall Mass Balance
PURCHASES Kt/y Kbd wt%
Crude Blend 26 3538 75 95%
Hexene 27 0.5 1%
Sodium Chloride 138 4%
Hydrochloric acid 8 0%
Total 3711 100%
SALES Kt/y Kbd wt%
LPG 68 1.3 2%
Mogas 91 65 1.7 2%
Mogas 95 129 3.3 4%
Jet A1 29 0.7 1%
Automotive Diesel Oil 1592 35.1 53%
Heavy Fuel Oil 396 7.4 13%
Sulphur 19 1%
Polyethylene 300 10%
Polypropylene 213 7%
23%
PVC 120 4%
Benzene 59 1.1 2%
Total 2990 100%
OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 11
 Agenda

• Refining & Petrochemical (R&P) synergies

Facts & figures
• Axens portfolio for R&P integration :
• Refinery & Steam Cracker
• Refinery & ParamaX Suite for Aromatics
• Around (R)FCC: PetroRiserSM, FlexEneTM,
Olicrack
• Olefins upgrading and purification
• APU: new way for BTX production
• Conclusion

OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 12
 Case Study 2
Refinery with High C3= FCC + ParamaX
SR Naphtha Aromatic Complex Benzene
Toluene
ParamaX
Paraxylene
CDU Naphtha Naphtha

Kero

Diesel
Hydro
cracker
VDU
VGO Bleed
High Propylene
C3= FCC

HCGO
Delayed LPG
Coker
Coke

OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 13
 Aromatics Complex Blocks Functions
ParamaX Suite

OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 14
 Agenda

• Refining & Petrochemical (R&P) synergies

Facts & figures
• Axens portfolio for R&P integration :
• Refinery & steam Cracker
• Refinery & ParamaX Suite for Aromatics
• Around (R)FCC: PetroRiserSM, FlexEneTM,
Olicrack
• Olefins upgrading and purification
• APU: new way for BTX production
• Conclusion

OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 15
 Case Study 3
Refinery + ParamaX + High C3= FCC + Steam Cracker
Naphtha SR
Heavy LPG
LPG Naphtha Aromatic Benzene
Naphtha Complex
Paraxylene
HDT & ParamaX
CDU Kero Splitter
Raffinate HDT Pygas
150 000 Diesel
bpsd Kero Pygas
KERO Steam Pygas
Ethylene
HDT Cracker &
LPG Propylene Petro FCC
Naphtha
VGO
VDU MID C5 Recycle HDT
Distillate
HDT Light C2 C4 recycle
Naphtha LPG Naph C3
C4 Butadiene
+Kero.
Heavy Ethylene Butadiene
Delayed Naph. Extrac.
HCC High Propylene
Coker LCGO C3=
UCO FCC Naphtha
HCGO
C4 HDT
Coke Diesel
LPG
OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 16
 Axens Technologies Around FCC (1)
2008 Production Resid to Propylene Technology Suite
~ 74 Million tons (Mt)
8%

34%
58%
720-740°C 550°C
C/O 8
590°C
C/O 12
From Refineries (FCC)
From Steam crackers
On purpose production 660°C
• Metathesis
• Olefins cracking
• MeOH to propylene
• C3 dehydrogenation

Main Riser PetroRiser

Source: Nexant Oct. 08 + CEH SRI July. 09 R2R Unit Resid LCN
OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 17
 Axens Technologies Around FCC (2)

FlexEneTM
Oligomerisation
C4 olefins + 15 ~ 20 %
Propylene
Selective cracking
LPG ex FCC

OlicrackTM Steam Cracker

C4 Cut
C5 Cut
FCC or C6 Cut Ethylene
Resid FCC
Up to + 50% R2R Olicrack
Propylene
Propylene Coker
C3=/C2= ratio > 3- 4
Alternative fuel
units

OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 18
 Agenda

• Refining & Petrochemical (R&P) synergies

Facts & figures
• Axens portfolio for R&P integration :
• Refinery & steam Cracker
• Refinery & ParamaX Suite for Aromatics
• Around (R)FCC: PetroRiserSM, FlexEneTM,
Olicrack
• Olefins upgrading and purification
• APU: new way for BTX production
• Conclusion

OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 19
 Axens Technologies for
Olefins Upgrading
1-Hexene
Ethylene
Oligomerization
Oligomerization
MAPD Dimerization
Dimerization α-Select/ α-Hexol Lin. - Olefins
MAPD Purification
Purification AlphaButol α-Select/ α-Hexol
C3 = Selective
Selective AlphaButol
Hydrogenation
Hydrogenation
Multibed
Multibed Propylene
Maximum Butadiene Butadiene
C4 C4 Acetylenes
C4 Acetylenes
Selective
Butadiene 1-Butene
Selective
Hydrogenation Extraction
Hydrogenation Isobutane
Maximum Butenes Isobutylene
Max B=1
Max B=1 Super-
Super-
Butadiene
Butadiene CC44 2-Butenes Dimerization
Selective Etherification
Etherification
Hydrogenation
Hydrogenation Fractionation
Fractionation Dimerization Octenes
Selective Dimersol
Hydrogenation
Hydrogenation Catacol
Catacol Dimersol
Steam Cracker

n-Butane
Max B=2
B=2 IB=Purification
IB= Purification
Max Hydration Dehydro. MEK
Hydrogenation
Hydrogenation Isopure
Isopure
MTBE, ETBE
Skeletal
Skeletal Oligomerization
Oligomerization
Isomerization
Isomerization Selectopol Olefins
Olefins Solvents
Iso-5
Iso-5 C5= Selectopol Hydrogenation
C4/C5 Polynaphtha Hydrogenation
CC44/C
/C55 Polynaphtha
CC55Etherification
Etherification
TAME, TAEE
Olefins
Olefins Catacol
Hydrogenation
Catacol
Hydrogenation
C2 Advanced Benzene
Advanced
LPG Pygas
Pygas
Upgrading
Upgrading
Toluene
APU
APU C8 Aromatics
C5 to Aro. Complex
C6-C10 C6-C8 Extraction
Extraction
Sulfolane
Sulfolane
C5-C10 Pygas
Pygas C6-C10 Pygas Morphylane
Selective
Pygas Morphylane
Pygas Selective Hydrodesulfurization
Hydrodesulfurization C9-C10
Hydrogenation
Hydrogenation
GHU1
GHU2
GHU2 Sulfur
Sulfur To Motor
GHU1 Gasoline Pool
Removal
Removal
Removal of OATS
OATS
Arsenic & Mercury Condensates
RAM II
OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 20
 Olefins Purification

Axens’ high performance adsorbents

AxSorb & AxTrap

Typical contaminants
AxSorb 531
• CO2
• H2O AxSorb 980
• Other oxygenates Products
AxSorb 970
• Sulfurs compounds • Feedstock Olefin
• NH3, amine AxSorb 911 upgrading units
• Arsine • Polymer grade ethylene
• Phosphine AxTrap 191 • Polymer grade propylene
• Mercury
•…
OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 21
 Agenda

• Refining & Petrochemical (R&P) synergies

Facts & figures
• Axens portfolio for R&P integration :
• Refinery & steam Cracker
• Refinery & ParamaX Suite for Aromatics
• Around (R)FCC: PetroRiserSM, FlexEneTM,
Olicrack
• Olefins upgrading and purification
• APU: new way for BTX production
• Conclusion

OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 22
 Advanced Pygas Upgrading (APU)

 New technology developed by SK, Korea

 Concept validated by industrial trial

• SK Refinery

 Commercial agreement signed in July 2005

 Axens selected as exclusive licensor for its

strong position in
• Pygas hydrogenation
• Aromatics production

OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 23
 APU Main Reactions

• Hydrocracking of paraffins

• Ring opening on naphthenes

• Hydrodealkylation of heavy
aromatics

OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 24
 APU Main Benefits

• Cracking of non aromatics

• high purity BTX left, recovered by distillation
• High quality C2-C4 for co-cracking produced
• Maximization of ethylene & propylene yields

• Hydrodealkylation of Heavy Aromatics

• Conversion of heavy pygas fractions, C9-C10
• Additional production of BTX
• Mixed xylenes quality improved

OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 25
 APU Integration into Cracker

Hydrogen
Fuel Gas (FG)
Ethylene
Steam Propylene
Cracker Butadiene
C4 Olefins
recycle to steam cracker furnaces
C6 – C10
C5s FG + FG +
FG H2S LPG
C5+ (Pygas)

1st Stage C6+ 2nd Stage BTX

APU
Hydro. Hydro.
H2
H2 H2

C11+ (opt.)
OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 26
 Agenda

• Refining & Petrochemical (R&P) synergies

Facts & figures
• Axens portfolio for R&P integration :
• Refinery & steam Cracker
• Refinery & ParamaX Suite for Aromatics
• Around (R)FCC: PetroRiserSM, FlexEneTM,
Olicrack
• Olefins upgrading and purification
• APU: new way for BTX production
• Conclusion

OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 27
 Conclusion

Integrating Refining & Petrochemical presents

synergies realizable with Axens’ portfolio :
• Full range of technologies from residue
conversion to olefins / aromatics maximization
• Full range of products : catalysts &
absorbents
• Full range of associated services : tech
service, consulting…

OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010 28
 Refining-Petrochemical
Synergies & Opportunities

29