Enhance Naphtha Value and Gasoline Reformer Performance ...
Transcript of 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
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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
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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
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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
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
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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
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
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Full rangenaphtha
531kMTA136 kMTA
NHTNHT
Cracker
Petrochemical Facility
* Purchased naphtha from other refiner
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
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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
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Existing Refinery Complex
855kMTA
545 kMTA
Yields, kMTA
C2 = 316C3= 162
478
102 RONC
772 kMTA
Cracker
NHTNHT
*328 kMTA
Petrochemical Facility
873kMTA
3.75 Wt-% H2 Yield
32 kMTA
* Purchased naphtha from other refiner
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90.4 Wt-% C5+ Yield
Full rangenaphtha
1400kMTA
CatalyticReformer
Refinery Complex with MaxEneConstant Reformer Feedrate
Normals
Non-normals
67 kMTA / 82 RONC(light gasoline to
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
Petrochemical Facility
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
67 kMTA / 82 RONC(light gasoline to
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
Petrochemical Facility
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
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Contents
MaxEne Technology Introduction
Market Drivers for MaxEne Projects
MaxEne Case Studies
MaxEne Commercial Experience
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)
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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
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