Technology Selection & Project

Execution – A Case in Point

IRPC - Upstream Project for Hygiene & Value Added Products

Wittaya Heawararak (IRPC)

Mai Do (Axens)
Agenda
 IRPC Introduction
 Upstream Project for Hygiene & Value Added
Products (UHV)
• Technology Selection
• Project Execution
 UHV in Operation - Focus on Hyvahl™ Unit
 Conclusion

Axens Asia Seminar 2018, Bangkok 2

Agenda
 IRPC Introduction
 Upstream Project for Hygiene & Value Added
Products (UHV)
• Technology Selection
• Project Execution
 UHV in Operation - Focus on Hyvahl™ Unit
 Conclusion

Axens Asia Seminar 2018, Bangkok 3

Leading Integrated Petrochemical Complex in Asia by 2020

Revenue Growth of 5% 1st Quartile ROIC in Petroleum Member of DJSI

EBITDA Growth of 10% and Petrochemical Industry Emerging Markets
BIG STRONG LONG Universe

Incremental Margin and

•
•
Operational Efficiency Improvement
Asset Utilization Enhancement
Margin Improvement Organization Health
• Capability Building
G Power of Growth
• Product and Service Improvement • Owner mindset & Performance
• Capacity and Products Expansion Orientation
• Cultural Changes D Power of Digital
Other Projects Completion • Operational Excellence Capacity Before After
P
• Commercial Excellence
Capacity Before After • Procurement & HR Propylene
412 KTA 732 KTA Power of People
Excellence (UHV)
CHP I
• Electricity 108 MW 328 MW Fully Integrated PP
• Steam 200 T/hr 620 T/hr Benefit +135 MUSD 2020
Capacity Before After
PRP 312 KTA 412 KTA ROIC 14%
EBSM 200 KTA 260 KTA PP
475 KTA 775 KTA
(PPE-PPC)
2018
2016
2014

2010

CONFIDENTIAL AND PROPRIETARY

Any use of this material without specific permission of IRPC is strictly prohibited 4
Agenda
 IRPC Introduction
 UHV Project
• Technology Selection
• Project Execution
 UHV in Operation - Focus on Hyvahl™ Unit
 Conclusion

Axens Asia Seminar 2018, Bangkok 5

Upstream Project for Hygiene & Value Added
Products (UHV)

Objectives
 Enhance refinery competitiveness &
margin by strong integration refining &
petrochemical
 Create future opportunities with wider
crude flexibility
 Get rid of low value heavy fuel oil
while maximizing petchem production
 Preserve environnement and make
efficient ressources utilizations

Courtesy IRPC website

Axens Asia Seminar 2018, Bangkok 6
Owner, PMC and Licensors

Note:
 “Shaw Stone & Webster” is now known as “Technip Stone & Webster Process
Technologies” after Technip acquired Shaw in 2012
 As of 2013, Tecnimont KT is known as KT, Kinetics Technology

Axens Asia Seminar 2018, Bangkok 7

UHV Project
Technology Selection & Optimization
 In 2011, Axens in partnership  During licensor bidding,
with TechnipFMC got involved Axens/TechnipFMC proposed a
in UHV project at licensor scheme that allowed producing
selection step 320 KTA of propylene & 73 KTA
of Ethylene

Preliminary blockflow

Axens Asia Seminar 2018, Bangkok 8

 UHV Project
Integrated Scheme towards Maximum Petchem

LPG
External C4
Sulfrex PRU Propylene
(324 KTA)
Propane

Residue
Hyvahl™ DCC

C4 raf Steam
Polynaphtha Cracker
Hydrogene

LN

Prime-G+ HN Aromatics

Hydrogene
Off gas Ethylene
ERU (73 KTA)

Axens Asia Seminar 2018, Bangkok 9

UHV - Resid DCC Unit
 Two-Riser System for the best
propylene selectivity
• Main Riser (fresh feed)
• Light HC Riser (Mixed C4 recycle,
external C4’s, Oligomer, LCN recycle
and wild naphtha)

 Lower Reactor Outlet

Temperature (ROT) for lower
dry gas and coke
 FlexEneTM Integration to
enhance secondary cracking of
C4s and naphtha to propylene

Axens Asia Seminar 2018, Bangkok 10

FlexEne™: Integration of Proven Technologies:
Polynaphtha™& FCC
Fuel Gas
Propylene
Product LPG
Recovery Gasoline
Distillate
Fuel Oil
Extension to C5 / C6 cuts
with PolyFuel™ C4 cut C4 Raffinate

Gasoline Gasoline
Polynaphtha™ Motor
Recycle Distillate Oligomerization Distillate Fuels

Recycle Selected Oligomers to Recover Oligomers as Gasoline

FCC Riser to Maximize Propylene
or or Distillate to optimize G/D ratio

FCC Feed
VGO/Resid

Axens Asia Seminar 2018, Bangkok 11

UHV Project
Maximizing Petchem Production
 Heave
Product Yield on High Value Products from
Residue [NOM DE Residue
CATÉGORI
E]
LN C[POURCEN
4 S  Polymer grade propylene
6%
TAGE]
 Polymer grade ethylene
HCN
Propylene
18%
22%  Highly aromatic heavy naphtha
( > 60 % aromatics)
 Premium quality feed for
export/steam cracker (C3, C4
raffinates…)
Propane
3%
 2/3 of the residue are transformed
Gas + LCO Ethylene
+ CLO + 5% and used in petrochemicals
Coke
34%

Axens Asia Seminar 2018, Bangkok 12

 UHV Project
Seamless Basic Engineering Execution
Integrated team
 Axens/Technip PDP was executed by a fully
integrated team to ensure that a quality
package consistent with IRPC objectives is
delivered on schedule
 Seamless Axens/Technip Team to provide to
IRPC a Single Point of Contact and
Responsibility
PDP Team
 Detailed project plan & Coordination Sulfrex PRU
procedure for an efficient communication
CV
Hyvahl DCC
 Rigorous project control
• Identify critical path Polyna
phtha
• Foresee ressources according to project
Axens (Paris)
baseline progress curve Prime G+
• Closed monitoring of actual progress versus TechnipFMC
(Houston)
baseline ERU

Axens Asia Seminar 2018, Bangkok 13

 UHV Project Execution
Milestones & Axens Involvement
 Basic Engineering work on schedule gave headstart for EPC
work T0 for
Prime G+

KOM of all units LLI Final

PFD PID PBooks package
except Prime G+ PFD PG+

Week 1 Week 6 Week 9 Week 12 Week 40

Week 17-19 Week 28

Licensor Commissioning
Process Design Follow –up with EPC Start-up
selection
Training

Feb July April Dec Dec

2011 2011 2012 2014 2016
PGTR
& PAC
FEED/EPC phase

Axens Asia Seminar 2018, Bangkok 14

 UHV Project Execution
Milestones & Axens Involvement
 Basic Engineering work on schedule gave headstart for EPC
work T0 for
Prime G+

KOM of all units LLI Final

PFD PID PBooks package
except Prime G+ PFD PG+

Week 1 Week 6 Week 9 Week 12 Week 40

Week 17-19 Week 28

1875 mandays
in Axens office

Licensor Commissioning
Process Design Follow –up with EPC Start-up
selection
Training

Feb July April Dec Dec

2011 2011 2012 2014 2016
PGTR
& PAC
FEED/EPC phase
Technology transfer all along the Project Execution

Axens Asia Seminar 2018, Bangkok 15

Training of IRPC Personnel

 Class room (2014 - Rayong)

• Applied theory
• Exercise & Practice

 On-site training (2014 - Korea)

• Observe similar units in operation
• Share operation experience

 Start-up Training (2016 - Rayong)

• Start- up & transition operations
• Trouble shooting

Axens Asia Seminar 2018, Bangkok 16

Agenda
 IRPC Introduction
 Upstream Project for Hygiene & Value Added
Products (UHV)
• Technology Selection
• Project Execution
 UHV in Operation - Focus on Hyvahl™ Unit
 Conclusion

Axens Asia Seminar 2018, Bangkok 17

 Unit Follow-up: A Close Look at the Hyvahl™ unit

HyvahlTM prepares the feed to the RDCC unit

H2 Catalyst
Metals & CCR Replacement
(24 months) LPG
Removal Improved
Propylene FCC Yields

AR HyvahlTM RDCC Low Sulfur

Gasoline Gasoline

LCO Decreased
Main Target: Metals Removal: LCO &
Reduced RFCC Catalyst Slurry Yield
HDS/HDA/HDN Consumption Slurry

 Hyvahl™ feed impurities is directly subject to refinery daily operations:

• Change in Crude Diet
• Crude Tank Management
• Desalter Operation
• Slop Management

Axens Asia Seminar 2018, Bangkok 18

Agenda
 IRPC Introduction
 UHV Project
• Technology Selection
• Project Execution
 UHV in Operation - Focus on Hyvahl™ Unit
 Conclusion

Axens Asia Seminar 2018, Bangkok 19

Lesson Learnt
 Upgrading fuel oil to petrochemicals is the pathway to
increase refinery competitiveness

 Selecting the right technologies is key to:

• Economics of a conversion project
• Facing real life variation versus design basis

 Project Execution for a complex

• Single Point of contact and seamless integration between units are key to
save time & money

 As a partner, Axens provides supports and transfer the know-

how during all phases of your project

Axens Asia Seminar 2018, Bangkok 20

Thank you! And see you on Axens’ Blog
axens.net/blog

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