Towards a Zero Gasoline Production Refinery

European Refining Technology Conference 12-14 November 2012, Vienna Blasis Stamateris

2012 Foster Wheeler. All rights reserved.

Background
European gasoline-based refineries are facing profitability challenges
European gasoline market declining whilst demand for middle distillates remains strong Natural market for surplus of European gasoline declining

Increasing interest in world-scale integrated aromatics and petrochemical projects in Middle East, India, Asia and Latin America
Capital investments in excess of US $10 billion for grassroots refinery and petrochemical projects Economies of scale required to deliver investment returns

Synergies and new technologies enable integration opportunities

Ability to share infrastructure, utilities and related services Potential to maximise value of hydrocarbon streams Hydrogen balance management

Key to success is to define and execute the right project

2012 Foster Wheeler. All rights reserved.

Agenda

Drivers for refinery/petrochemical integration Building blocks:

Petrochemicals production Aromatics production Handling of C4s Ways to vary C3=/C2= ratio, aromatics, distillates

Putting it all together: refinery configurations Conclusions

2012 Foster Wheeler. All rights reserved.

The Drivers for Refinery/Petrochemicals Integration

2012 Foster Wheeler. All rights reserved.

Refinery/Petrochemical Integration drivers

MARKET ISSUES Strong demand for petrochemicals, aromatics and transportation fuels Prices favour petrochemicals & aromatics at the expense of transportation fuels Impact on economics of consumers PROJECT ECONOMICS SECURITY OF SUPPLY Oil reserves and products away from consumer centres Import reduction / development of domestic sources Diversification of energy sources: fossil fuel-based, renewables, others High crude oil and product prices increases opportunity to increase project viability Reduce influence of market fluctuations of crude & refined product prices on revenues Save investments through sharing process facilities-economies of scale Save on operating costs: transportation

Drivers

ENVIRONMENTAL IMPACT Public desire / pressure for green fuels, power, biodegradable products, reduce GHE / support agricultural industry Legislation affects competitiveness of oil industry
2012 Foster Wheeler. All rights reserved.

The Building Blocks

2012 Foster Wheeler. All rights reserved.

Refinery and Petrochemical Interface

Integration Options
PE, EO, EG PP, PO, EG C3=, C4= C3, C4 Naphtha Gasoline Jet/Kero C2

Steam Cracker

C2=, C3= C4= Pyrolysis Gas

Petchems (olefins)

Acetic/Acrylic acid

Polyols VAM, PVC C4== EBSM ABS, SBR Cumene, Phenol Polycarbonate Polyurethane

Refinery
Gasoil

Naphtha Reformer

Complex Pet Chems

Fuel Oil

Benzene Toluene

Coke

Aromatics

Xylenes Heavy Aromatics

Petchems (aromatics)

PTA, PET Fibre, Film Bottles

Gasification

Synthesis Gas

Hydrogen, steam, power Ammonia, Methanol Olefins Gas-to-Liquids

2012 Foster Wheeler. All rights reserved.

Refinery & Petrochemicals Integration Opportunities

Steam cracker opportunities
Naphtha/steam cracking gives a far wider range of products than gas cracking and makes sense when integrated with refineries Surplus hydrogen to refinery for hydrotreating Common gas recovery section (FCC light ends to cracker complex) allows rationalisation of investments with minor impact reliability Processing of mixed C4 streams => several routes

2012 Foster Wheeler. All rights reserved.

Refinery/Petrochemicals Integration Opportunities

FCC opportunities
No longer just a gasoline machine: increasingly used for olefins and even aromatics, especially high severity FCC (hydrotreated feed) and recycle (C4s, light cat naphtha, oligomers) cracking Propylene yields of 10-20 wt% on feed, recovery of ethylene viable FCC heavy naphtha can contain 55-75% aromatics Needs more severe hydrotreating due to high olefins, sulphur, nitrogen

Aromatics raffinate stream is a perfect steam cracker feedstock: light material, low in aromatics, high in paraffins Recover aromatics from pygas

2012 Foster Wheeler. All rights reserved.

Steam Cracker Feed Options

Yields for steam cracker feeds vs. FCC and CCR for petrochemicals

ethylene
C2 C3

propylene

nC4 iC4 LN

butenes

AGO FCC CCR

BTX

10

20

30

40

50

60

70

80

90
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2012 Foster Wheeler. All rights reserved.

Aromatics Integration Opportunities

Typical Aromatics Content [wt%]

Pyrolysis gasoline %wt BTX in product stream Benzene Toluene C8 aromatics (incl xylenes)

CCR reformate

Petrochemical FCC naphtha

85 56 19 9-11

56-80 7-10 19-28 30-42

59 6 22 31

2012 Foster Wheeler. All rights reserved.

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Refinery Petrochemicals Integration Opportunities

Configuration of Aromatics plant
Mid/Hvy Naphtha
lt. refte C5 Raffinate

naphtha / gasoline

extract. benzene
mixed med.aroms refte C6/C7 Bnz/ C7 + Tol splitter Tol column

HT CCR
isom C7 react C6

refte splitter

toluene
C7

isom.
C8 +

LE Benzene mixed X

mixed X

hvy. refte C8 +

purify
C8 + Xyl column C9 +

p-xylene react
LE

reformate stabiliser

Raffinate HCN

Xylene Loop

C9-C10-C11 C6 Heavy Aromatics

FCC

HT

LLE

2012 Foster Wheeler. All rights reserved.

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C4s: Handling options

Typical Compositions
Steam Cracker C4s wt % Butadiene C4 olefins C4 paraffins Total 40 50 45 50 5 10 100

FCC C4s wt % <1 65 75 25 35 100

2012 Foster Wheeler. All rights reserved.

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C4s: Handling options

Selective hydrogenation (1)
C4s / Naphtha recycle to FCC: Oligomerisation vs. direct recycle of C4s/LCN. Simplicity vs. selectivity Steam cracker feed / LPG Butadiene MTBE Decomposition
Raffinate-2

Mixed C4s Raffinate-1

Mixed C4s from refinery and petrochemicals

Butadiene extraction

Total hydrogenation

Isobutylene

Butene-1 fractionation

Butene-1 : Comonomer for Polyethylene production Metathesis feed

Butene-2 fractionation
(1) Butadiene saturation

2012 Foster Wheeler. All rights reserved.

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Putting it all together: Refinery Configurations

2012 Foster Wheeler. All rights reserved.

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Refinery Petrochemicals Integration Opportunities

Foster Wheeler has studied a wide range of refinery configurations for the production of petrochemicals/aromatics/transportation fuels. Cases presented feature: Crude processing : 15 MM KTPA about 300,000 bpd GCC type crudes around 28 API Capacities/product slates can be adjusted to process heavier crudes (17-22 API) Look at ways to vary product slate (C3=/C2= ratio, aromatics, distillates) and effect of handling of C4s with minimum investments

2012 Foster Wheeler. All rights reserved.

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Refinery Configurations: ARDS + RFCC

LPG
SR Naphtha

LPG Naphtha HDT & Splitter LN HN

Aromatics Complex
Raffinate

Benzene Paraxylene

CDU 150 000 bpsd

Kero

HDT Pygas + FCCN

Diesel

Kero HDT

Kero

Steam Cracker

Pygas Propylene Ethylene HHN C5 Recycle

export

Atm Res Naph

Middle Diesel Distillate HDT C2 C3 Diesel

Pygas & Naphtha HDT

C4 recycle C4 Ethylene Propylene

ARDS

C4 HDT

FCC
HDT Res

Naphtha LCO

C4 SALES

2012 Foster Wheeler. All rights reserved.

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Refinery Configurations: ARDS + RFCC

Product Slate
Product C4s Gasoline Jet Fuel Diesel Fuel Oil Ethylene Propylene paraXylene Benzene Unit KTA KBPD KBPD KBPD KBPD KTA KTA KTA KTA Base 1,151 0 15.6 128.8 7.2 1,123 1,100 1,600 490 With OCU [Metathesis] 974 0 15.6 128.8 7.2 907 1,558 1,587 501

Findings

OCU increases C3= production by 40% at the expense of C2= Capacity of ARDS /RFCC: 121/108 KBD manageable Potential for production high purity butylenes and/or more C2=/C3=/Distillates through C4s oligomerisation + cracking
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Refinery Configurations: HCU + VRDS + RFCC

LPG
SR Naphtha

LPG Naphtha HDT & Splitter LN HN

Aromatics Complex
Raffinate

Benzene Paraxylene

CDU 150 000 bpsd

Diesel

Kero

HDT Pygas + FCCN

Kero HDT

Kero

Steam Cracker

Pygas Propylene Ethylene HHN C5 Recycle

export

VDU
LVGO

Middle Diesel Distillate HDT LPG Naph HCK Kero + Diesel Naph

Pygas & Naphtha HDT

C2 C3

C4 recycle C4 Ethylene

HVGO Vac Res

VRDS

Diesel HDT Res

C4 HDT

FCC

Propylene Naphtha LCO

To Fuel Oil

C4 SALES
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2012 Foster Wheeler. All rights reserved.

Refinery Configurations: HCU + VRDS + RFCC

Product Slate
Product C4s Gasoline Jet Fuel Diesel Fuel Oil Ethylene Propylene paraXylene Benzene Unit KTA KBPD KBPD KBPD KBPD KTA KTA KTA KTA Base 1,151 0 15.6 128.8 7.2 1,123 1,100 1,600 490 With HCU 792 0 23.5 147.3 6.1 1,081 838 1,573 509

Findings

HCU brings significant increase middle distillates production C3= production decreases due to reduced RFCC capacity Capacity of HCU/VRDS/RFCC: 55/82/65 KBD manageable Potential for production of high purity butylenes or change C2=/C3=/distillates through C4s oligomerisation + cracking
2012 Foster Wheeler. All rights reserved.

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Refinery Configurations: HCU + SDA/Delayed Coker + FCC

Naphtha SR LPG LPG HN LN Raffinate Kero HDT Pygas + FCCN Pygas Propylene Ethylene HHN C5 Recycle C2 C3 C4 recycle C4 Ethylene
export

CDU 150 000 bpsd

Kero Diesel

Naphtha HDT & Splitter

Kero HDT

Aromatic Complex

Benzene Paraxylene

Steam Cracker

LVGO

VDU
HVGO

Middle Diesel Distillate HDT

Pygas & Naphtha HDT

Naphtha

HCK

HN LPG Kero + Diesel Diesel HT FEED

C4 HDT

SDA+ Coker
Coke

LCGO DAO HCGO

VGO HT

FCC

Propylene Naphtha C4 SALES

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SDA + Delayed Coking

SDA selectively separates residue components into those suitable for:
Catalytic conversion (DAO) Thermal conversion (Pitch) DAO lift can be adjusted

SDA + Coking
Vacuum Residue Solvent Deasphalting Pitch Delayed Coking Coker Light Products DAO To VGO HT + FCC HCGO

Delayed coking
Low pressure, low recycle design Highest liquid yields

HCGO + DAO acceptable FCC feed Synergy FCC slurry and DCU SDA + coking overall capital cost similar to higher capacity coking
Coke

2012 Foster Wheeler. All rights reserved.

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The PetroPowerTM Solution: Coke Disposal Option

Coker Products Residues SYDECSM Delayed Coking

PetroPowerTM
Circulating Fluidized Bed (CFB) Boiler Power Steam

Coke

Minimizes energy costs and increases margins

2012 Foster Wheeler. All rights reserved.

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Refinery Configurations: HCU + SDA/Delayed Coker + FCC

Product C4s Gasoline Jet Fuel Diesel Fuel Oil Ethylene Propylene paraXylene Benzene Coke Unit KTA KBPD KBPD KBPD KBPD KTA KTA KTA KTA KTA Base 1,151 0 15.6 128.8 7.2 1,123 1,100 1,600 490 With SDA + Delayed Coker 690 0 27.4 145 2.4 1,044 766 1,562 508 385

Product Slate

Findings

HCU + SDA / delayed coker boost middle distillates production C3= production decreases due to reduced FCC capacity Fuel oil production is reduced Potential for production of high purity butylenes or change C2=/C3=/distillates through C4s oligomerisation + cracking
2012 Foster Wheeler. All rights reserved.

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Conclusions

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Conclusions
Integrated refining products, aromatics and petrochemical complexes offer opportunities for
Adding value to refinery streams, Synergies between streams, Rationalising investments which impact positively economics

Refinery configuration can be tailor-made to suit processing objectives

Variations to C3=/C2= ratio, middle distillates production, aromatics

Handling C4s is the key issue The Zero Gasoline Production Refinery is a practical and viable reality
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2012 Foster Wheeler. All rights reserved.

www.fwc.com Refining@fwc.com

2012 Foster Wheeler. All rights reserved.