1914 - 2014 A Century of Innovation in the Oil and Gas Industry

© 2014 UOP LLC. All rights reserved. UOP 6510-1

Alternative Feedstocks for the Production of Aromatics

Tim Foley UOP LLC, A Honeywell Company

IHS Petrochemical Technology Seminar March 27-28, 2014 Houston, Texas

Aromatics - Feedstock & Product Diversity

Rearrange

Separate

Purify

LPG

Naphtha

High Octane Fuel Blend

Benzene for Derivatives

High Purity Para-Xylene

C

C

C

C

C C

C

C

UOP 6510-2

DeHydroCycloDimerization (DHCD)

Light

Paraffins Olefins Oligomers Naphthenes Aromatics

Light Ends

Hydrogen

LPG to Aromatics

Feed

Propane/Butane Intermediates /By-products Products

UOP 6510-3

UOP CyclarTM Process: Cost Effective Aromatics from LPG

Originally developed by UOP and British Petroleum

Conversion of LPG to mixed aromatics

– LPG from field, pipeline or refinery by-product

– Typical feed is from 25% - 75% Propane, balance Butane

– Product - LPG spread between $500-700/MT

– Significant amount of by-product Hydrogen can be recovered by PSA

Continuous Catalyst Regeneration (CCR™) system maintains steady state operation over catalyst life

– Removes carbon deposition and re-conditions the catalyst continuously for constant activity

Economics improve as C3/C4 availability increases and cost declines

UOP 6510-4

UOP Cyclar Process

Pilot Plant development began in the 1980s

Demonstration Unit commissioned in 1990

– 1,000 BPSD mixed LPG

First Commercial Unit – 1999 Start Up

– Saudi Arabia

– Mixed C3/C4 Feed

– ~1,300 kMTA feed

– Mixed xylenes fed to a UOP Aromatics Complex to produce para-Xylene and Benzene

– Operated until 2013

Continuous process development over the 14 years of operation

UOP 6510-5

Representative Cyclar Process Yield

C 3 /C 4 Feed 75/25 Wt-%

0

5

10

15

20

25

30

35

40

Wt-

% Y

ield

Wt % Yield

C3 C4

Aromatics Products

Higher C4 content in feed shifts yields slightly to more toluene and heavier aromatic products

H2 Fuel Gas Benzene Toluene A8 A9+

UOP 6510-6

UOP Cyclar Process Flow Diagram

Reactors

Regenerator

Fresh LPG Feed

Fired Heaters

Hydrogen Light Ends

C6+

Aromatic

Light Ends

Stripper

Over 250 CCR Units Operating

(PlatformingTM, OleflexTM,

Cyclar Units)

Since 1971

H H H H

Gas Recovery

C F E S

E P

UOP 6510-7

Cyclar Process Based Aromatics Production

Cyclar Process for production for gasoline blending

– May include benzene management technology – UOP BenSat™ Process (benzene saturation)

Cyclar Process for the production of benzene and mixed xylenes

– TatorayTM Process: Toluene Benzene + Xylenes

Cyclar Process for the production of benzene and p-Xylene

– Tatoray Process: Toluene Benzene + Xylenes

– ParexTM Process: para-xylene Separation/Purification

– IsomarTM Process: o- and m-xylene para-xylene

Cyclar process based flow schemes enable many different product slates

UOP 6510-8

Cyclar Configuration: Gasoline Blending

Effective management of benzene in the gasoline pool

Cyclohexane

Gasoline Pool

~ 110 RONC

~84 RONC

Benzene Saturation

Heavies

Bz Column

Cyclar

Process

H2

Propane / Butane

Rerun Column

Cyclar Process

A6 BenSat Process

Aromatics

~ 108 RONC

UOP 6510-9

Cyclar Process Based Aromatics Production

Cyclar Process for production for gasoline blending

– May include benzene management technology – UOP BenSat™ Process (benzene saturation)

Cyclar Process for the production of benzene and mixed xylenes

– TatorayTM Process: Toluene Benzene + Xylenes

Cyclar Process for the production of benzene and p-Xylene

– Tatoray Process: Toluene Benzene + Xylenes

– ParexTM Process: para-xylene Separation/Purification

– IsomarTM Process: o- and m-xylene para-xylene

Cyclar process based flow schemes enable many different product slates

UOP 6510-10

Maximize Benzene and Xylene Production

Conversion of toluene & A9’s to benzene and mixed xylenes by transalkylation and disproportionation

Major Tatoray Reactions

Disproportionation

Transalkylation

Toluene Benzene Xylenes

Toluene C9 Aromatics Xylenes

2

C C

C

+

C

C

C

C C

C

+ 2

Tatoray Process

UOP 6510-11

Increased Benzene + Mixed Xylenes

Heavies

Benzene

Bz Column

Tol Column

Cyclar

Process

H2

Propane / Butane

Xyl Column

HA Column

A7 A8

A9

Tatoray Process

Cyclar Process

Extraction technology is not required for high purity benzene

Mixed Xylenes

UOP 6510-12

1139

835 878

652 695

0

200

400

600

800

1,000

1,200

Naphtha $500/T $500/T $400/T $400/T

$/M

T B

z +

Mix

ed

Xy Capital Charges

Fixed COP

Cat & Chems

Utilities

Net Feedstock

CCOP

NCOP

Aromatics Cost of Production – LPG v Naphtha Benzene plus Mixed Xylenes

Basis Assumed: @$967/T w/ H2 export no H2 export w/ H2 export no H2 export

LPG at $600/MT is an economically competitive alternative feedstock

1088

745 791

608 563

US price set: Benzene = $1,300/MT , Mixed Xylene = $1140/ mT

LPG LPG LPG LPG

$685 /MT LPG equivalent

UOP 6510-13

Platforming Based

Cyclar Based

Cyclar Process Based Aromatics Production

Cyclar Process for production for gasoline blending

– May include benzene management technology – UOP BenSat™ Process (benzene saturation)

Cyclar Process for the production of benzene and mixed xylenes

– TatorayTM Process: Toluene Benzene + Xylenes

Cyclar Process for the production of benzene and p-Xylene

– Tatoray Process: Toluene Benzene + Xylenes

– ParexTM Process: para-xylene Separation/Purification

– IsomarTM Process: o- and m-xylene para-xylene

Cyclar process based flow schemes enable many different product slates

UOP 6510-14

Maximum para-Xylene and Benzene

H2

Mixed Xylenes efficiently converted to higher value para-Xylene

Heavies

Benzene

Bz Column

Tol Column

Cyclar

Process

Propane / Butane

Xyl Column

HA Column

A7 A8

A9

Light Ends

High Purity

para-Xylene

Parex Process

Isomar Process

Tatoray Process

Cyclar Process

DeC7

Heavies

Benzene

Bz Column

Tol Column

Cyclar

Process

H2

Propane / Butane

Xyl Column

HA Column

A7 A8

A9

Tatoray Process

Cyclar Process

Mixed Xylenes

Mixed Xylenes

UOP 6510-15

1252

893 936

709 752

0

200

400

600

800

1,000

1,200

1,400

Naphtha $500/T $500/T $400/T $400/T

$/M

T B

z +

p-X

Capital Charges

Fixed COP

Cat & Chems

Utilities

Net Feedstock

CCOP

NCOP

Aromatics Cost of Production – LPG v Naphtha Benzene plus p-Xylene

Basis Assumed: @$967/T w/ H2 export no H2 export w/ H2 export no H2 export

LPG at $600/MT is an economically competitive alternative feedstock

1146

771 817

632 587

US price set : Benzene = $1,300/MT , p-Xylene = $1455/ mT

LPG LPG LPG LPG

$695 /MT LPG equivalent

Platforming Based

Cyclar Based

UOP 6510-16

Summary

Cost advantaged LPG can be economically converted to a mixed aromatics product for:

• High octane gasoline blending with the benzene management as necessary

• Conversion to high-purity benzene and mixed xylenes

‒ Further processing to benzene derivatives

• Conversion to benzene and para-xylene

‒ Further processing to downstream petrochemicals

UOP 6510-17

UOP 6510-18

THANK YOU!