Enhance Naphtha Value and Gasoline Reformer Performance Using UOPs MaxEneTM Process

Mark Turowicz UOP IPL, A Honeywell Company

1st IndianOil Petrochemical Conclave March 16, 2012 Gurgaon, India

2011 UOP LLC. All rights reserved.
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Contents

MaxEne Technology Introduction Market Drivers for MaxEne Projects MaxEne Case Studies MaxEne Commercial Experience

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Refining-Petrochemical Integration
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)
Full Range Naphtha

Naphtha Cracker

Typical Integrated Complex

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
Full Range Naphtha

Catalytic Reformer

Naphtha Cracker

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

MaxEne Unit
Catalytic Reformer

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

Adsorptive separation
Adsorbent Chamber Rotary Valve

Extract Column
n-Paraffins feed to steam cracker

Based on SorbexTM Technology The adsorbent has greater affinity for n-paraffins

Desorbent
Feed

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 countercurrently relative to the solid

Raffinate Column

Pumparound pump

Naphtha

Feed to reformer

More than 130 process units based on Sorbex Technology licensed worldwide
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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
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Contents

MaxEne Technology Introduction Market Drivers for MaxEne Projects MaxEne Case Studies MaxEne Commercial Experience

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Average 2010 Steam Cracker Feedstock Slates

Source: CMAI 2011 World Ethylene Cost Study

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

MaxEne Technology Introduction Market Drivers for MaxEne Projects MaxEne Case Studies MaxEne Commercial Experience

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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
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Existing Refinery Complex

* Purchased naphtha from other refiner

*328 kMTA 873 kMTA

Yields, kMTA

545 kMTA

Cracker

C2 = C3=

316 162 478

Petrochemical Facility 1400 kMTA Full range naphtha

3.22 Wt-% H2 Yield 27.5 kMTA 93.0 Wt-% C5+ Yield NHT 855 kMTA
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Catalytic Reformer

96 RONC 795 kMTA

Refinery Complex with MaxEne Constant Full Range Naphtha

* Purchased naphtha from other refiner

*192 kMTA
474 kMTA 681 kMTA 873 kMTA

Yields, kMTA

Cracker

C2 = C3=

207 kMTA Normals 1400 kMTA Full range naphtha

337 171 508

Petrochemical Facility

MaxEne Unit

52 kMTA / 82 RONC
(light gasoline to blending)

NHT

Non-normals 584 kMTA 531 kMTA 136 kMTA

3.68 Wt-% H2 Yield 24.5 kmta

104 RONC 607 kMTA

Can run catalytic reformer at higher severity with higher quality feedstock DeC6 on MaxEne raffinate to remove Bz pre-cursors from reformer feed

Catalytic Catalytic Reformer reformer

667 kMTA

91.0 Wt-% C5+ Yield

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The MaxEne Process Effect

Case Study #1 - Refinery Balance

Existing kMTA 1400 545 42 855 0 795 96 28 11 22 with MaxEne kMTA 1400 681 62 667 52 607 104 25 12 24

Full Range Naphtha Export Naphtha n-paraffin Wt-% Reformer Feed Light Gasoline Reformer Gasoline RONC Hydrogen Tail Gas LPG

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 Export
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The MaxEne Process Effect

1400 1200 1000

Case Study #1 - Refinery GM Comparison

Existing With MaxEne

$176M

$199M

$M/yr

800 600 400 200 0

Feedstock Feedstock Hydrogen

Products Export Naphtha LPG

Feedstock Reformate Tail Gas

Products Light Gasoline

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 UOP 5614D-13 with Ethylene Cracker

The MaxEne Process Effect Case Study #1 - Steam Cracker Balance

Existing w/MaxEne Existing w/MaxEne
$M/yr $M/yr KMTA KMTA

Feed H2

872 11

872 9 107 337 171 87 163 872

v

654 12
+7% +6%

674 10 27 493 256 81 148 341 17

Pay MaxEne refiner 4% premium for high quality PC Naphtha Feedstock to get 5% GM increase

Fuel Gas 138 C2= 316 C3= C4s pygas Total 162 95 150 872

36 462 243 89 135 324 -

GM Increase

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). UOP 5614D-14

MaxEne Process Integration Case Study #2 Integration 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
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Existing Refinery Complex

* Purchased naphtha from other refiner

*328 kMTA 873 kMTA

Yields, kMTA

545 kMTA

Cracker

C2 = C3=

316 162 478

Petrochemical Facility 1400 kMTA Full range naphtha

3.75 Wt-% H2 Yield 32 kMTA 90.4 Wt-% C5+ Yield NHT 855 kMTA
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Catalytic Reformer

102 RONC 772 kMTA

Refinery Complex with MaxEne

Constant Reformer Feedrate
0 kMTA 607 kMTA 265 kMTA Normals 1794 kMTA Full range naphtha 872 kMTA Yields, kMTA

Cracker

C2 = C3=

347 175 522

MaxEne Unit

Petrochemical Facility 67 kMTA / 82 RONC

(light gasoline to blending)

174 kMTA

Non-normals 748 kMTA NHT 681 kMTA

3.46 Wt-% H2 Yield 30 kMTA

102 RONC 789 kMTA

Additional FRN required to keep reformer full DeC6 on MaxEne raffinate to remove Bz pre-cursors from reformer feed

Catalytic Catalytic Reformer reformer

855 kMTA

92.4 Wt-% C5+ Yield

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Refinery Complex with MaxEne

Constant Reformer Feedrate
0 kMTA 872 kMTA 265 kMTA Normals 1794 kMTA Full range naphtha Yields, kMTA

Cracker

C2 = C3=

347 175 522

MaxEne Unit

Petrochemical Facility 67 kMTA / 82 RONC

(light gasoline to blending)

174 kMTA

Non-normals 748 kMTA NHT 95 kMTA

3.46 Wt-% H2 Yield 33 kMTA

102 RONC 878 kMTA

MaxEne process allows reformer to run at 11% over existing production rate

Catalytic Catalytic Reformer reformer

950 kMTA

92.4 Wt-% C5+ Yield

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The MaxEne Process Effect Case Study #2 - Refinery Balance

Existing with MaxEne Cases kMTA kMTA kMTA Full Range Naphtha 1400 1794 1794 CCR Range Naphtha 95 Richer feed allows Export Naphtha 545 872 872 reformer to run at higher capacity while still Reformer Feed 855 855 950 staying within CCR regenerator capacity, Light Gasoline 0 67 67 Rx WAIT and heater duty Reformer Gasoline 772 789 878 Hydrogen 32 30 33 Tail Gas 17 12 13 LPG 34 24 26
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
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The MaxEne Process Effect Case Study #2 - Refinery GM Comparison

1800 1600 1400 1200

Existing

w/MaxEne

w/MaxEne w/Max Reformer $271M

$247M $208M

$M/yr

1000 800 600 400 200 0

Feedstock Feedstock Hydrogen

Products

Feedstock

Products Reformate Tail Gas

Feedstock

Products

Export Naphtha LPG

Light Gasoline

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 UOP 5614D-20 with Ethylene Cracker

The MaxEne Process Effect Case Study #2 - Steam Cracker Balance

Existing w/MaxEne Existing w/MaxEne
$M/yr $M/yr KMTA KMTA

Feed H2

872 11

872 8 103 347 175 83 156 872

v

654 12 36 +10% 462

+8%

680 9 27 507 262 78 141 344 20

Pay MaxEne refiner 2% premium for high quality PC Naphtha Feedstock to get 10% GM increase

Fuel Gas 138 C2= 316 C3= C4s pygas Total 162 95 150 872

243 89 135 324 -

GM Increase

Increased paraffin content to cracker results in $20M/yr additional GM with $30/MT premium on naphtha price for 500 kmta cracker (ethylene+propylene).UOP 5614D-21

Contents

MaxEne Technology Introduction Market Drivers for MaxEne Projects MaxEne Case Studies MaxEne Commercial Experience

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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)

MaxEne feedrate 1.2 MMTA

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In Conclusion
European and Asian refiners will need outlet for naphtha as diesel continues to be transportation fuel of choice. Over half of the worlds 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

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