ABU DHABI NATIONAL OIL COMPANYADNOC REFINING

CRUDE TO CHEMICALSDIRECT CRACKING FOR LIGHT OLEFINS FROM CRUDE OIL (LOCO)

SPEAKER: DR. GNANA PRAGASAM SINGARAVEL

TABLE OF CONTENTA

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▪ Introduction

▪ Refining strategy

▪ Crude to chemicals

▪ Key players

▪ Feedstock drives

▪ Problem definition

▪ Case study

▪ Summary

INTRODUCTIONA

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G R O W T H A N D D E M A N D

Ke

rose

ne

Ga

solin

e

Die

se

l

Be

nze

ne

Bu

ten

e

Eth

yle

ne

Pro

pyle

ne

Pa

raxyle

ne

0

1

2

3

4

5

6

7

8

Gro

wth

, %

Fuels

2.1 CAGR

Chemicals

5.6 CAGR

Sources: OPEC 2016, IEA 2016, IHS 2016, Platts 2016, and

TCGR 2016

An objective assessment and detailed

technological analysis of the activities directed

towards Crude to chemicals.

The CAGR for chemicals is higher than Fuels

Numerous independent technology developers

like UOP/Honeywell, Axens, CB&I and other

majors like SABIC are working towards

combinations of technologies

REFINING STRATEGYA

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4 S t e a m c r a c k i n g a n d C o n t r o l l e d v a p o r i z a t i o n

Steam cracking

Packing

Catalyst

Vaporization / mild

catalytic cracking

First zone

Second zone

Steam

Whole

Crude OilOlefins plant

Preheater

REFINING STRATEGYA

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Steam cracking

Lig

ht

ole

fin

s,

BT

EX

Catalytic cracking

HY

D/D

AO

DIST

Pyro

lysis

oil

Atmospheric

residue

Light stream

P r e - t r e a t m e n t , S t e a m c r a c k i n g , C a t a l y t i c C r a c k i n g o f h e a v y f r a c t i o n

REFINING STRATEGYA

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Steam cracking

Catalytic pyrolysis

process

Cru

de

oil

DIST

AR, VGO, VR

Hydrodesulfurisation

BTEX

Fuel oil

Diesel

Aromatics

Light olefins,

BD, LPG

Light olefins

S t e a m C r a c k i n g , b o t t o m u p g r a d a t i o n a n d p e t r o c h e m i s t r y

CRUDE TO CHEMICALS –CONVENTIONAL VS NEW CONFIGURATION

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Crude to chemicals

Traditional

CRUDE TO CHEMICALSA

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PROPYLENE DEMAND

9

▪ Polypropylene (PP) industry consumes about 70% of

all propylene produced

▪ Traditional propylene production methods, new on-

purpose technologies have penetrated the market;

among them are propane dehydrogenation (PDH),

methanol to olefins (MTO), methanol to propylene

(MTP) and isobutylene to propylene

▪ China will introduce considerable on-purpose

propylene capacity to become self-sufficient in

propylene supply

▪ Overall propylene market is expected to post good

growth rates with Asia Pacific being the leader

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MIDDLE EAST- FEEDSTOCK DRIVES NOT THE MARKET

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C1 / C2

based

feedstock

projects

Mixed

feedstock C1

/ C2 / C3 / C4

/ LN based

projects

Projects with

Speciality /

differentiated

products

Refinery /

petrochemical

integrated

naphtha

based (non-

discounted)

projects

Direct Oil to Chemicals Downstream Industry Developments

Key Objectives

Monetise gas, Diversify local Economics, Downstream Industry and Job Creation

KEY PLAYERSA

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N E W T E C H N O L O G I E S

▪ ExxonMobil has been reported to be cracking crude oil at its

Singapore complex since January 2014.

▪ Saudi Aramco announced an operational demo plant (TC2C)

▪ SABIC suggested a “Crude Oil to Chemicals” project for Yanbu

(KSA)

▪ Aramco and SABIC announced a JV in 2016.

▪ Siluria’s OCM technology for ethylene from natural gas.

PROBLEM DEFINITIONA

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▪ Fluid catalytic cracking (FCC/RFCC) has proven high flexibility in feedstock and product slate, especially for

chemicals feedstocks.

▪ Crude oil cracking in a FCC/RFCC process may appear as an ideal candidate to fulfill chemical producer's needs

which usually run on vacuum gas oil (VGO) and vacuum residue (VR) and atmospheric residue (AR).

▪ All the technologies developed to enhance olefin yield in FCC/RFCC are of high interest for converting crude to

chemicals. Such a disruptive technology may probably be based on a conversion unit which can handle the heavy

fractions of the crude oil, converting it partially to light olefins and reducing the amount of heavy products to a

minimum.

CASE STUDY-FEEDSTOCKA

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Crude Oil Atmospheric Residue

Murban Upper Zakum Murban Upper Zakum

Density at 15OC ASTM D4052 g/cm3 0.8232 0.8539 0.9268 0.9612

Specific Gravity at 60/60 OC Calculation 0.8236 0.8544

Sulphur, Total ASTM D2622 wt% 0.778 1.95 1.87 3.26

Total Nitrogen ASTM D5762 wppm 438 890 1300 1400

Concarbon Residue (CCR) ASTM D4530 wt% 1.43 5.07 4.37 9.89

Nickel IP 433 wppm 2 12 5 14

Vanadium IP 433 wppm 2 13 8 20

Iron AAS wppm <1 1 <2 3

Boiling point cuts

IBP Mass % 58.0 - 257 328

50% Mass % 286.8 336.8 475 485

90% Mass % 528.8 598.4 629 666

95% Mass % 593.4 659.0 669 707

Upper Zakum crude is heavier than Murban in terms of density, CCR, Sulfur etc.,

CASE STUDY- CATALYST & CONDITIONSA

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Properties Ecat

TSA (m2/gm) 183

ABD (gm/cc) 0.76

APS (µm) 78

UCS (Å) 24.32

RE2O3 (wt%) 2.61

Ni (ppm) 4000

V (ppm) 4300

Total (Ni+V) (ppm) 8300

Experimental conditions Value

Temperature, oC 550

Catalyst to oil ratio (CTO) 4-8

Injection time, s 1

Injection quantity, g 3

Catalyst quantity, g 12-24

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TESTING UNIT-SHORT CONTACT TIME RISER TEST (SCTRT)

EFFECT OF CATALYST TO OIL RATIO ON CONVERSION

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▪ Conversion increases with increase of catalyst

to oil ratio irrespective of feed and temperature.

UZC showed lower conversion than MBC due

to feed quality.

▪ At higher CTO and temperature, the delta

conversion increases for UZC whereas MBC

showed nearly zero delta conversion

PRODUCT DISTRIBUTION FOR DIFFERENT CRUDES AND MIXTURES

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0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

UZC Feed UZC Product MBC Feed MBC Product UZC + MBCfeed

UZC + MBCProduct

Pro

du

ct

yie

lds

Conversion Coke C1-C4 P C2-C4 O Gasoline LCO BTM

EXPERIMENTAL CONDITIONS: TEMP., 550 OC and CTO,8

▪ The product distribution for UZC and MBC crudes

showed light olefins and paraffins and reduction in

middle distillate and heavier compounds.

▪ Despite feedstock differences, UZC and MBC

crudes are similar in conversion and product yield.

LIGHT OLEFINS CONTENT FROM DIFFERENT CRUDES

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0

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15

20

25

30

MBC-RAW UZC-RAW MBC/UZC-RAW MBC-RAW-OA UZC-RAW-OA MBC-AR UZC-AR

Lig

ht

ole

fin

s (

C2

-C4

O),

wt%

MBC-RAW UZC-RAW MBC/UZC-RAW MBC-RAW-OA UZC-RAW-OA MBC-AR UZC-AR

EXPERIMENTAL CONDITIONS: TEMP., 550OC AND CTO,8

▪ Light olefins production from MBC is higher than

UZC and mixture of MBC and UZC.

▪ Atmospheric residue of MBC produces highest

light olefins than UZC.

▪ Addition of Olefin additive from 10 wt% to higher

level produces equal amount of light olefins from

both crude oils

SUMMARYA

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▪ The use of crude oil as a feedstock to produce olefins and other petrochemicals is attractive economically

where naphtha cracking is predominant.

▪ A central part of such complex could be a catalytic conversion unit such as an FCC/RFCC like process

optimized for light olefins.

▪ The technology already existing in FCC field to boost light olefins production could be extended to process

the whole crude oil fraction, propelling the direct petrochemicals production in the 30–50% yield range,

which is far beyond the current levels in refinery.

▪ An important issue in the near future that may impact an olefins oriented catalytic cracker to process feed-

stocks with diverse compositions require additional research to obtain processes and catalysts.

REFERENCESA

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▪ Corma 2017 ; Crude to Chemicals: Light Olefins from Crude Oil (Catal. Sci. Technol., 2017, 7,12-46)

▪ CB&I, 2017 ;Crude to Chemicals: Opportunities and Challenges of an Industry Game-Changer, MERTC,

Bahrain IEA, 2016

▪ IHS, 2016

▪ OPEC, 2016

▪ Platts, 2016

▪ TCGR, 2017

ADNOC REFINING

THANK YOU