Maximize Conversion and Flexibility The UOP UniflexTM Process

Robert Haizmann UOP LLC

6th Russia & CIS BBTC Conference April 13-14, 2011 Moscow, Russia
2011 UOP LLC. All rights reserved.

Maximize Conversion and Flexibility With the UOP Uniflex Process

Market Factors Technology Summary Capital Savings Through Integration

Product Demand, Specifications, and Prices are Changing

Incremental Fuel Demand 2010-2020
8.0 6.0 4.0 2.0 0.0 Gasoline -2.0 Diesel Kerosene /Jet Residue Fuel Oil Sulfur, Wt% max MM BPD

Bunker Fuel Oil Sulfur Specifications

5.0 4.0

3.0

2.0

Global Global Delayed ECA

1.0

Source: Purvin & Gertz, 2010 GPMO

0.0

2005

2010

2015

2020

2025

2030

NW European Product Differentials to Brent,

Forecast in Constant 2010 $/Bbl
40 30 20 10 0 -10 -20 -30 2000

Diesel Price Premium over Coke

Coke Diesel

800 Product Value ($/MT)

Euro Unleaded Diesel EN590 RFO, 1%S RFO, 3.5%S

600 400 200 0

2005

2010

2015

2020

20 (2000)

40 (2004)

60 (2009)

80 (Future)

Source: Purvin & Gertz, 2010 GPMO

Crude Price, $/bbl (year)

Common goal: Maximize residue conversion to distillates

UOPs Heavy Oil Upgrading Processes

Naphtha Naphtha Hydrotreating & Reforming Distillate Hydrotreating FCC or Hydrocracking
Transportation Fuels: Gasoline, Jet Fuel, Diesel

Distillates Distillation

Crude Oil

Vacuum Gas Oil

Vacuum Residue

Residue Conversion

UOP Solutions for Residue Conversion UOP Solutions

UOPUOP RCD UOP/FWUSA FWUSA SYDECTM TM RCD UOP/FWUSA FWUSA SYDECUOP/FWUSA UOP/FWUSAUOP UNIFLEX UnionfiningTM TM Solvent Unionfining Solvent Delayed Coking Visbreaking Delayed Coking Visbreaking Process Process Process Deasphalting Deasphalting Process Process

Residues: Heavy Fuel Oil, Pitch, Coke

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UOP Uniflex Process

Reactor Makeup Hydrogen Gasoline Diesel VGO

Vacuum Residue Catalyst

Pitch

Typical Yields
105 85 Volume% of Feed 65 45 25
VGO Naphtha Distillate Distillate Naphtha

Slurry hydrocracking technology High conversion to desired products Contains elements of proven processes
CANMET Hydrocracking Process UOP UnionfiningTM and UOP UnicrackingTM Processes

5 -15 -35
Coke (wt.%)

VGO Pitch (wt.%)

Uniflex Process has >25% yield advantage over Delayed Coking

Delayed Coking Uniflex Process

Uniflex Process
Extensive Commercial Experience

25 years R&D 15 years commercial operation Variety of feedstocks High conversion 97%+ availability
Commercial Performance
85%
100 80 Yield, vol % 60 40 20 0 -20
Naphtha Distillate VGO Pitch

Petro-Canada Montreal Unit

90%

94% Conversion

Many UOP improvements in the last 5 years

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Uniflex Process
Proven Flowscheme with Improvements
Makeup H2 Hot Separator Uniflex Reactor Recycle Gas Heater Hot Flash Drum Stripper/ Product Fractionator HVGO Recycle Fractionator Heater Cold Separator Recycle H2 Flash Gas C4-

Cold Flash Drum

Naphtha Diesel Vacuum Fractionator LVGO

Vacuum Residue Feed Feed Heater Catalyst

Pitch

Large Unit Capacities Capital Cost Savings Through Process Integration

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Uniflex Process
HVGO Recycle Improves Yields and Quality
100 80
Wt.% of Feed

Delayed Coking

Uniflex

Uniflex + HVGO Recycle

Increased Naphtha & Distillate Yields

60 40 20 0 -20 -40
Pitch/Coke 524+ Naphtha C5-204C Gasoil 343-524C Fuel Gas + LPG

Lighter VGO, easier to process

Distillate 204-343C

Maximum naphtha and diesel yield from vacuum residue VGO conversion without a separate Mild Hydrocracking Unit
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Base Case:
Uniflex Process Compared to Other VR Conversion Processes
SDA

Uniflex Process Benefits:

High liquid yields on vacuum residue feed, especially distillates Minimum residue by-products Significantly increases margins
Vol.% of Feed

110 90 70 50 30 10 -10 -30 -50

Delayed Coking

EBED HC

Uniflex Process

Residue Conversion Yields

SDA

Delayed Coking

EBED HC 60%

Uniflex Process

SDA

90

Delayed Coking

EBED HC

Uniflex Process

Upgrading Margins
With Hydrocracking
Vol.% of Feed

80 70 60 50 40 30

Distillate Yield
(After Hydrocracking)

Arab Light Vacuum Residue

Uniflex Process Integrated with

UOP/FW Solvent Deasphalting & Unicracking Process
Vacuum Gas Oil Unicracking Naphtha and Distillate

Vacuum Residue

UOP/FWUSA Solvent Deasphalting Process SDA Pitch

DAO

UOP Unicracking Process Uniflex VGO

Unicracking UCO (to FCC) Uniflex Naphtha and Distillate To New or Existing HDT

UOP Uniflex Process

Uniflex Pitch

Maximum Distillate Production

- 95% Vacuum Residue Conversion with Uniflex and SDA - 99+% VGO conversion with Unicracking Process

Low Capital Cost Upgrading Complex

- Low capital cost SDA - Small, moderate reactor pressure Uniflex Process Unit
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Integrated Case:
Solvent Deasphalting/Uniflex/Unicracking Processes
SDA/Uniflex/Unicracking Benefits:
Very high vacuum residue conversion Maximum distillate yields on vacuum residue feed Highest margins Capital cost reduced Increased operating flexibility
Delayed Coking SDA + Coking Uniflex Process SDA + Uniflex
Vol.% of Feed 110 90 70 50 30 10 -10 -30 -50
Residue, wt% DAO VGO Distillate Naphtha

Delayed Coking

SDA + Coking

Uniflex Process

SDA + Uniflex

Delayed Coking

SDA + Coking

Uniflex Process

SDA + Uniflex

Upgrading Margins
With Hydrocracking

Distillate Yield
(After Hydrocracking)

Arab Light Vacuum Residue

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UOP/FWUSA SDA Process

Commercial Experience

UOP/FWUSA Combined Experience

Over 70 units licensed (500 to 50000 BPD) Proven scale-up between pilot plant and commercial operations

Recent Selection in 6 Projects

All units won in competitive bidding Utilizing features from both UOP and FW technologies

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UOP Unicracking Process

Commercial Experience

Proven Experience
>60% of the Worlds Licensed Hydrocracking Units 195 Licensed Units in 40 Countries >100 Operating Units 54 Licenses Since 2000 Experience with all flow scheme options and DAO processing

Experience IS the difference

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Uniflex Process Integrated with

Existing Delayed Coking Unit
Uniflex Process

Products

HCGO

Vacuum Residue Feed

Pitch

Delayed Coking

Products Coke

Increased Naphtha and Distillate yield Heavy Coker Gas Oil converted in Uniflex Uniflex Pitch converted in Coker Debottleneck Coker and Coker Heavy Gas Oil Hydrotreater
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Integration of Hydroprocessing Units

Naphtha Naphtha Hydrotreating Distillate Hydrotreating
Transportation Fuels: Gasoline, Jet Fuel, Diesel

Distillates Distillation

Crude Oil

Vacuum Gas Oil

Hydrocracking

Vacuum Residue

UOP Uniflex Process

Residues: Heavy Fuel Oil, Pitch, Coke
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Integration Drivers Capital Cost Reduction and Energy Efficiency

Slurry Hydrocracking and Hydroprocessing

Issues that impact optimal degree of integration

Economics
Capital cost savings Utilities savings

Design and operating flexibility

Operating pressures and relative flowrates of units Future changes in crudes and product slate Catalyst performance in HC and HDT Timing of catalyst and inspection turn-arounds Start-up, shut-down, emergency procedures

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Full Process Integration Challenges

Straight Run Diesel and VGO

Features
Slurry HC Rx Hydroprocessing Rx
Recycle Gas

Combines slurry hydrocracking and Hydroprocessing in one hydrogen gas loop Requires both sour and sweet fractionation systems products fractionated twice Slurry HC and Hydroprocessing sections require same high reactor pressure

Challenges
Vacuum Residue

Moderate effect on overall capital and operating costs H2S and NH3 depress catalytic activity and selectivity Diesel yield loss via cracking

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Selective Integration Benefits

UOP offers many integration options to meet refiners varied requirements Examples
Common H2 recovery and compression systems for make-up gas and off-gas Parallel recycle gas systems Uniflex products integrated directly to UOP Unicracking and UOP Distillate Unionfining

Benefits
>10% capital savings for Uniflex, Unicracking, Distillate Unionfining Heavy Oils Complex Performance optimized of each unit
Reduced contamination in catalytic process units Unicracking: >99% VGO conversion Distillate Unionfining - Maximum diesel yield, quality and cycle length at minimum reactor pressure

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UOP Uniflex Process Will Meet Your Future Transportation Fuel Requirements
Ideal Process for Maximizing Transportation Fuels from Vacuum Residue Unique Solutions for Maximizing Distillate Extensive Commercial Operations Background UOP Development Program Assures Future Units Success Optimization and Integration Solutions will Maximize Benefits for your Refinery

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