valero energy Texas City Refinery Tour – November 13, 2007
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Transcript of valero energy Texas City Refinery Tour – November 13, 2007
1
Texas City Refinery Tour November 13, 2007
2
Basics of RefiningDesulfurizationHydrocrackingTexas City Refinery OperationsQ&APlant TourConcluding Remarks
Agenda
3
Jonathan StuartVice President
Regional Refinery Operations
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Crude Oil Characteristics
Crudes are classified and priced by density and sulfur contentCrude density is commonly measured by API gravity• API gravity provides a relative measure of crude oil density • The higher the API number, the lighter the crude
−
Light crudes are easier to process −
Heavy crudes are more difficult to process
Crude sulfur content is measured as a percentage• Less than 0.7% sulfur content = sweet• Greater than 0.7% sulfur content = sour• High sulfur crudes require additional processing to meet regulatory specs
Acid content is measured by Total Acid Number (TAN)• Acidic crudes highly corrosive to refinery equipment• High acid crudes are those with TAN greater than 0.7
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Crude Oil Basics
Majority of global reserves are sourMost quoted benchmark prices are light sweet crudes
• WTI (West Texas Intermediate), Western Hemisphere• Brent (North Sea Crude), Europe
Historical trend shows global crude supply becoming heavier and more sour
Estimated Quality of Reserves (2006)
13%
20%
66%
2%
High Acid(Sweet)
Source: Oil & Gas Journal, Company Information
Light/MediumSour
HeavySour
Sweet
SWEE
T
SU
LFU
R C
ON
TEN
T
S
OU
R
HEAVY API GRAVITY LIGHT
Crude Quality by Types
Source: Industry reportsNOTE: Red line represents the average crude quality by decade (actual and projected)
Arab Heavy
Arab Medium
Arab Light
Alaskan North Slope
Iran Heavy
DubaiMars
TapisWTIBrent
Bonny LightCabinda
Napo
Cold Lake
WCSMaya
Ameriven-Hamaca
M-100 (resid)
1980
19902000
2010
Urals
Cerro Negro
0.0%
0.5%
1.0%
1.5%
2.0%
2.5%
3.0%
3.5%
4.0%
15 20 25 30 35 40 45 50
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What’s in a Barrel of Crude Oil?
50%
26%
21%
3%
63%
22%
14%1%
33%
34%
30%
3%> 34 API Gravity
< 0.7 % Sulfur
35% Demand
Most Expensive
24 – 34 API Gravity
> 0.7 % Sulfur
50% Demand
Less Expensive
< 24 API Gravity
> 0.7 % Sulfur
15% Demand
Least Expensive
Refineries upgrade crude oil to higher value products
2005 U.S. Production
8% Propane/Butane
50%
GasolineRFGConventionalCARBPremium
33% DistillateJet FuelDieselHeating Oil
Heavy Fuel Oil & Other
10%
Source: EIA Refiner Production
Refinery Gases7%
Light Sweet Crude(e.g. WTI, Brent, Saharan
Blend)
Medium Sour Crude(e.g. Mars, Arab Light,Arab Medium, Urals)
Heavy Sour Crude(e.g. Maya, Cerro Negro, Cold
Lake, Western Canadian Select)
Crude Types Characteristics Yields
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Basic Refining Concepts
DistillationTower
(CrudeUnit)
Propane, Butane and lighter
• Refinery fuel gas • Propane• NGLs
< 90°F
Straight Run Gasoline (low
octane)• Gasoline (high octane)
90–220°F
Naphtha • Gasoline (high octane)• Jet fuel
220–315°F
Kerosene• Kerosene • Jet fuel• Diesel • Fuel oil
315–450°F
Light Gas Oil• Gasoline (high octane)• Diesel• Fuel oil
450–650°F
Heavy Gas Oil650–800°F
Residual Fuel Oil/Asphalt
800+°F
Furnace
VacuumUnit
More
• Gasoline (high octane)• Diesel• Fuel oil
• Gasoline (high octane)• Diesel• Fuel oil• Lube stocks
Intermediates Final Products
processing
More
processing
More
processing
More
processing
More
processing
More
processing
Crude oil
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Hydroskimming/Topping Refinery
LightSweetCrude
100% Total Yield
Heavy Fuel Oil & Other
30%GasolineRFGConventionalCARBPremium
Simple, low upgrading capability refineries run sweet crude
Propane/Butane
Hydrogen
Crude Unit
Vacuum Unit
Reformer
Propane/Butane
High Octane Gasoline
Heavy Fuel Oil
LS Diesel/Heating Oil
Distillate Desulfurizer
HS Diesel/Heating Oil
HS Kerosene/Jet Fuel
Gas Oil
4%
32%
34% DistillateJet FuelDieselHeating Oil
Dis
tilla
tion
Tow
er
Low Octane Gasoline and Naphtha
LS Kerosene/Jet Fuel
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Crude and Vacuum Towers
Crude Atmospheric Tower Vacuum Tower Reformer
Heater
Reactor
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Medium Conversion: Catalytic Cracking
Moderate upgrading capability refineries tend to run more sour crudes while achieving increased higher value product yields and volume gain
Hydrogen
Light Cycle Oil (LCO)
Crude Unit
Vacuum Unit
Reformer
Alkylation Unit
Propane/Butane
High Octane Gasoline
Heavy Fuel Oil
FCC Gasoline
Alkylate
Distillate Desulfurizer
HS Diesel/Heating Oil
HS Kerosene/Jet Fuel
Gas OilFluid Catalytic Cracker (FCC)
104% Total Yield
Heavy Fuel Oil & Other24%
Dis
tilla
tion
Tow
er
Propane/Butane8%
27% DistillateJet FuelDieselHeating Oil
45%GasolineRFGConventionalCARBPremium
LightSour
Crude
Low Octane Gasoline and Naphtha
LS Kerosene/Jet Fuel
LS Diesel/Heating Oil
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High Conversion: Coking/Resid Destruction
Complex refineries can run heavier and more sour crudes while achieving the highest light product yields and volume gain
108% Total Yield
Heavy Fuel Oil & Other15%
Propane/Butane7%
28% DistillateJet FuelDieselHeating Oil
58%GasolineRFGConventionalCARBPremium
Hydrogen
LCO
Reformer
Medium Gas Oil
Propane/Butane
Heavy Fuel Oil
FCC Gasoline
Alky Gasoline
Hydrogen Plant
Coke
Gas
DelayedCoker
Fluid Catalytic Cracker (FCC)
Alkylation Unit
DistillateDesulfurizer
Crude Unit
Vacuum Unit
Light Gas Oil Hydrocrackate Gasoline
Ultra Low Sulfur Jet/Diesel
Hydrocracker
Medium/ Heavy Sour
Crude Dis
tilla
tion
Tow
er Low Octane Gasoline and Naphtha
HS Kerosene/Jet Fuel
HS Diesel/Heating Oil
LS Kerosene/Jet Fuel
LS Diesel/Heating Oil
High Octane Gasoline
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FCC and Hydrocracker ReactorsReactor
RegeneratorMain Column
Hydrocracker ReactorsFluidized Catalytic Cracker
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CokersDelayed Coker
Superstructure holds the drill and drill stem while the coke is forming in the drum Fluid Coker - Benicia
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Conversion Economics
Need conversion capacity to capitalize on sour crude discounts• Hydroskim – Breakeven or moderate margins; High resid yield
−
When margins are positive – increase crude runs−
When margins are negative – decrease crude runs• Cracking – Better margins; Lower resid yield• Coking – Best margins; Lowest resid yield
−
Maximize heavy crudes
U.S. Gulf Coast Refinery Margins
(10)
(5)
0
5
10
15
20
25
30
Jan-00 Jan-01 Jan-02 Jan-03 Jan-04 Jan-05 Jan-06 Jan-07
U S
$ /
B b
l
Arab Medium Hydroskimming LLS Cracking Maya Coking
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Desulfurization Basics
High SulfurLight
Products(HC-S)
Desulfurization Unit
Sulfur Plant• Agricultural• Pharmaceutical
Desulfurized Light Products
ElementalSulfur
HC-S
HC-SSHC-S
SS
Catalyst
HC-SS
HC-S
S
HC
H2S S
HC-S
H2
Hydrogen UnitH2
H2H2
H2
H2H2
H2
H2H2
H2
LEGENDHC : HydrocarbonH2 : HydrogenS : Sulfur
LEGENDHC : HydrocarbonH2 : HydrogenS : Sulfur
1000 or less PSI;700 F or less
ObjectiveRemove sulfur from light products (gasoline or diesel) to meet air quality requirements for clean burning fuels
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Hydrocracking Basics
LEGENDHC : HydrocarbonH2 : HydrogenS : Sulfur
LEGENDHC : HydrocarbonH2 : HydrogenS : Sulfur
ObjectiveValue added upgrading of high sulfur distillates to low sulfur gasoline and ultra low sulfur jet/diesel to meet air quality requirements for clean burning fuels
High SulfurDistillate(HC-S)
Hydrocracking Unit
HC-S
HC-S
HC-S
Catalysts
HC-S
HC-S
Desulfurized Hydrocrackate GasolineHC
Sulfur Plant• Agricultural• Pharmaceutical
ElementalSulfur
SS
SSS
H2S S
HC-S
H2
H2H2
H2
Desulfurized Ultra Low Sulfur Jet/DieselHC
H2
H2 H2
H2
H2H2
1300+ PSI;725 to 780 F
H2
Hydrogen UnitH2
H2H2
H2
H2H2
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Michael HarrisonVice President and General Manager
Texas City Refinery
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Valero Texas City Refinery
Acquired by Valero in 1997 via purchase of Basis Petroleum from Solomon, Inc.
Located along Houston’s Deep Water Ship Channel at the Port of Texas City
Began operations in 1908. Supported World Wars I and II
Throughput capacity of 245,000 barrels per day of crude and other feedstocks
Produces gasoline, jet fuel, diesel,
LPG, sulfur and chemical feedstocks
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Valero Texas City Refinery
Staffed by over 500 full-time employees and 300 continuing service contractors
Recognized as an “OSHA VPP Star Site”
Received VPP “Star Among Stars Status in 2003
Received VPP “Spirit Award” in 2004
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Texas City Products and Feedstock Slate
Product BPD %Gasoline 94,000 40
Ultra Low Sulfur Diesel 50,000 21
Jet Fuel 36,000 15
Diesel Intermediates 26,000 11
Low Sulfur VGO 15,000 6
Propylene 11,000 4
Propane 3,000 1
Petroleum Coke(tons/day)
4,000 <1
Sulfur (tons/day) 800 <1
Total Liquid Products 235,000
Crude S % / API BPD %Arab Medium / Kuwait 2.7 / 30.7 106,000 46
Maya 3.5 / 21.1 90,000 39
Green Canyon 2.2 / 30.4 14,000 6
High Sulfur VGO 5.0 / 12.2 7,000 3
Residual Oil 6.3 / 4.2 7,000 3
Gasoline Components 6,000 3
Total 230,000 100
Typical Product Slate Typical Feedstock Slate
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Over $900 MM invested in capital improvements and $300 MM for turnaround maintenance at Texas City since Valero’s acquisition
• Delayed Coker Unit – 45 MBPD Capacity−
Started up in 2003
• Gasoline Desulfurization Unit – 48 MBPD Capacity−
Started up in 2003
• LPG Recovery Unit – 35 MM SCF/D Capacity−
Started up in 2004
• Steam Boilers (3)−
Started up in 2005 and 2006
• Electrical Substation−
Operational in 2006
• Administrative Office and Central Control Center−
Occupied May 2005
• Major plant turnaround just completed ($80 MM Turnaround Maintenance and $70 MM Capital Improvements).
Texas City Capital Investments
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Appendix
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Texas City Refinery Flow Diagram
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Major Refining Processes – Crude Processing
Definition• Separating crude oil into different hydrocarbon groups • The most common means is through distillation
Process• Desalting – Prior to distillation, crude oil is often desalted to remove
corrosive salts as well as metals and other suspended solids.• Atmospheric Distillation – Used to separate the desalted crude into specific
hydrocarbon groups (straight run gasoline, naphtha, light gas oil, etc.) or fractions.
• Vacuum Distillation – Heavy crude residue (“bottoms”) from the atmospheric column is further separated using a lower–pressure distillation process. Means to lower the boiling points of the fractions and permit separation at lower temperatures, without decomposition and excessive coke formation.
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Major Refining Processes – Cracking
Definition• “Cracking” or breaking down large, heavy hydrocarbon molecules into
smaller hydrocarbon molecules thru application of heat (thermal) or through the use of catalysts
Process• Coking – Thermal non–catalytic cracking process that converts low value oils to
higher value gasoline, gas oils and marketable coke. Residual fuel oil from vacuum distillation column is typical feedstock.
• Visbreaking – Thermal non–catalytic process used to convert large hydrocarbon molecules in heavy feedstocks to lighter products such as fuel gas, gasoline, naphtha and gas oil. Produces sufficient middle distillates to reduce the viscosity of the heavy feed.
• Catalytic Cracking – A central process in refining where heavy gas oil range feeds are subjected to heat in the presence of catalyst and large molecules crack into smaller molecules in the gasoline and surrounding ranges.
• Catalytic Hydrocracking – Like cracking, used to produce blending stocks for gasoline and other fuels from heavy feedstocks. Introduction of hydrogen in addition to a catalyst allows the cracking reaction to proceed at lower temperatures than in catalytic cracking, although pressures are much higher.
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Major Refining Processes – Combination
Definition• Linking two or more hydrocarbon molecules together to form a large
molecule (e.g. converting gases to liquids) or rearranging to improve the quality of the molecule
Process• Alkylation – Important process to upgrade light olefins to high–value
gasoline components. Used to combine small molecules into large molecules to produce a higher octane product for blending with gasoline.
• Catalytic Reforming – The process whereby naphthas are changed chemically to increase their octane numbers. Octane numbers are measures of whether a gasoline will knock in an engine. The higher the octane number, the more resistance to pre or self–ignition.
• Polymerization – Process that combines smaller molecules to produce high octane blending stock.
• Isomerization – Process used to produce compounds with high octane for blending into the gasoline pool. Also used to produce isobutene, an important feedstock for alkylation.
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Major Refining Processes – Treating
Definition• Processing of petroleum products to remove some of the sulfur, nitrogen,
heavy metals, and other impuritiesProcess• Catalytic Hydrotreating, Hydroprocessing, sulfur/metals removal – Used to
remove impurities (e.g. sulfur, nitrogen, oxygen and halides) from petroleum fractions. Hydrotreating further “upgrades” heavy feeds by converting olefins and diolefins to parafins, which reduces gum formation in fuels. Hydroprocessing also cracks heavier products to lighter, more saleable products.
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List of Refining AcronymsAGO – Atmospheric Gas OilATB – Atmospheric Tower BottomsB–B – Butane–Butylene FractionBBLS – BarrelsBPD – Barrels Per DayBTX – Benzene, Toluene, XyleneCARB – California Air Resource BoardCCR – Continuous Catalytic RegeneratorDAO – De–Asphalted OilDCS – Distributed Control SystemsDHT – Diesel HydrotreaterDSU – Desulfurization Unit EPA – Environmental Protection AgencyESP – Electrostatic PrecipitatorFCC – Fluid Catalytic CrackerGDU – Gasoline Desulfurization UnitGHT – Gasoline HydrotreaterGOHT – Gas Oil HydrotreaterGPM – Gallon Per MinuteHAGO – Heavy Atmospheric Gas OilHCU – Hydrocracker UnitHDS – HydrodesulfurizationHDT – HydrotreatingHGO – Heavy Gas OilHOC – Heavy Oil Cracker (FCC)H2 – HydrogenH2S – Hydrogen SulfideHF – Hydroflouric (adic)HVGO – Heavy Vacuum Gas OilkV – Kilovolt
kVA – Kilovolt AmpLCO – Light Cycle OilLGO – Light Gas OilLPG – Liquefied Petroleum GasLSD – Low Sulfur DieselLSR – Light Straight Run (Gasoline)MON – Motor Octane NumberMTBE – Methyl Tertiary–Butyl EtherMW – MegawattNGL – Natural Gas LiquidsNOX – Nitrogen OxidesP–P – Propane–PropylenePSI – Pounds per Square InchRBOB – Reformulated Blendstock for Oxygen Blending RDS – Resid DesulfurizationRFG – Reformulated GasolineRON – Research Octane NumberRVP – Reid Vapor PressureSMR – Steam Methane Reformer (Hydrogen Plant)SOX – Sulfur OxidesSRU – Sulfur Recovery UnitTAME – Tertiary Amyl Methyl EtherTAN – Total Acid NumberULSD – Ultra–low Sulfur DieselVGO – Vacuum Gas OilVOC – Volatile Organic CompoundVPP – Voluntary Protection ProgramVTB – Vacuum Tower BottomsWTI – West Texas IntermediateWWTP – Waste Water Treatment Plant
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Safe Harbor Statement
Statements contained in this presentation that state the Company's or management's expectations or predictions of the future are forward–looking statements intended to be covered by the safe harbor provisions of the Securities Act of 1933 and the Securities Exchange Act of 1934. The words "believe," "expect," "should," "estimates," and other similar expressions identify forward–looking statements. It is important to note that actual results could differ materially from those projected in such forward– looking statements. For more information concerning factors that could cause actual results to differ from those expressed or forecasted, see Valero’s annual reports on Form 10-K and quarterly reports on Form 10-Q, filed with the Securities and Exchange Commission, and available on Valero’s website at www.valero.com.