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A Chevron and CB&I Joint Venture
© 2017 Chevron Lummus Global. All Rights Reserved. Company Confidential
Maximum Value Addition through
Flexible Upgrading of Crude to
Transportation Fuels and Petrochemicals
Ujjal Mukherjee
Vice President, Technology
Chevron Lummus Global
ERTC-GPS Summit
Athens, Greece
November 2017
2 © 2017 Chevron Lummus Global. All Rights Reserved. A World of Solutions
2
Changing Refined Product Landscape
0.5-1% growth in refined products
Gasoline demand remains flat
Pressure on Gasoline likely from Electric Cars and Hybrids within the next decade
Jet and Diesel demand growth modest
IMO sulfur specs for bunker fuel to be implemented 2020 → very significant high sulfur fuel oil reduction
Recent Industry Trends – Refined Products
Source: IEA
3 © 2017 Chevron Lummus Global. All Rights Reserved. A World of Solutions
3
Oil prices volatile (~ $45-55/Bbl)
Multiple supply sources make oil prices unpredictable:
OPEC initiatives to manage supply
Resiliency of US tight oil
Crude volatility +/- 100%
Polymer volatility +/- 40%
Recent Industry Trends – Oil and Petrochemicals
Greater petrochemical price
stability drives advantage to
monetize crude by conversion to
petrochemical products
Propylene to Ethylene Price Ratios vary widely by region (0.7-1.2)
Olefin Production Margin vary widely based on feedstock source and by region
Refineries provide an excellent route to naphtha and other feedstocks for crackers from cheap crude
4 © 2017 Chevron Lummus Global. All Rights Reserved.
On-Purpose Production of Petrochemicals
Naphtha
Ethylene
Propylene
Butadiene Butylenes
Olefins Plant Refinery
Gas Plant Ethylene Plant Natural Gas
Ethane Ethylene
Benzene
Propane Butane
5 © 2017 Chevron Lummus Global. All Rights Reserved.
Change in Mindset in Crude to Chemicals
Crude
Transportation
Fuels
Chemicals Crude
Chemicals
Transportation Fuels (Optional)
Fixed Qty
in KTA
Fixed
Barrels
Traditional
Crude to Chemicals
6 © 2017 Chevron Lummus Global. All Rights Reserved.
Crude Cracking via Heavy Oil Processing Scheme
(HOPS)
Direct crude cracking can be achieved using Heavy Oil Processing Scheme (HOPS)
Lummus patented the HOPS
4 units were designed and commissioned
Elimination of CDU and/or VDU with multi-stage HOPS
Lowest investment solution
Careful adjustment of temperature profile and steam addition to minimize fouling
Dilution
Steam
Naphtha Cut
Storage Naphtha
Heaters
Dilution
Steam Residue
VGO Cut
VGO
Heaters
Dilution
Steam
AGO Cut
Storage
AGO
Heaters
Crude
Number of HOPS stages dependent on crude gravity
7 © 2017 Chevron Lummus Global. All Rights Reserved.
0
100
200
300
400
500
600
700
800
900
0 20 40 60 80 100
TB
P T
em
pera
ture
, C
°
Vol% Distilled
Condensate
Pen.Lt.Crude 5%
Arab Light 20%
Arab HVY 30+%
What are the Challenges?
Typically the heaviest material (residue) must be removed before cracking
Residue
Crude residue
fraction much
larger
8 © 2017 Chevron Lummus Global. All Rights Reserved.
Summary of Direct Crude Cracking
CB&I HOPS technology successfully employed for
condensates and extra light crudes – niche application
Potential large volume of residue to be sold for heavier
crudes
For most crudes an intermediate step is essential with
molecular management to maximize production of
desired petrochemicals
Miracle of hydrogen addition
9 © 2017 Chevron Lummus Global. All Rights Reserved.
The Miracle of Hydrogen Addition
>2.0 MM MTA of Ethylene can be produced from 140,000 – 200,000 BPSD
of AL Crude depending on flowscheme
Hydrocracking of Residue and Distillates provides the most efficient route to feeding the Ethylene Cracker in terms of Feed Flexibility AND Conversion Yield
0% 5% 10% 15% 20% 25% 30% 35%
Raw VGO ᷉ 18 wt%
Hydrocracked VGO ˜ 32 wt%
Ethylene Yield / wt%
10 © 2017 Chevron Lummus Global. All Rights Reserved.
What should we do?
Should we convert crude completely
to chemicals or should the
configuration be able to produce
transportation fuels as well – on
demand?
11 © 2017 Chevron Lummus Global. All Rights Reserved.
Adding Hydrogen – Residue and
Distillate Hydrocracking
Reformate
Atm
. Tow
er
Vac. Tow
er
ISOCRACKING
DelayedCoking
CatalyticReforming
AromaticsProduction
Anode Grade Coke
Benzene
LC-FINING
EthyleneCrackerComplex
Paraxylene
Ethylene
Propylene
Butadiene
Hydrogen
Lt. Naphtha, C2, LPG
Crude
UCO
Lt. Naphtha, C2, LPG
Fuels as
Required
Versatile Hydrocracking Process that
partially or totally converts gas oils to
maximum naphtha or distillates –
Hydrogen addition and molecular
transformation
12 © 2017 Chevron Lummus Global. All Rights Reserved.
Enhancing Margin with Hydrocracking
and Ethylene Complex
Naptha, C2, LPG
Kero/Diesel
LCGO/HCGO
VGO
UCO
Atm
. Tow
er
Vac. Tow
er
ISOCRACKING
DelayedCoking
Anode Coke toAluminum Smelter
LC-FINING
EthyleneCrackerComplex
Ethylene
Propylene
ButadieneHydrogen
Naphtha, C2, LPG
Crude
Benzene
Mixed Xylenes
MTBE
Diesel
UCO
Lt. Py. Oil
Hvy. Py. Oil
13 © 2017 Chevron Lummus Global. All Rights Reserved.
Enhancing Margin with Hydrocracking
and Ethylene Complex
Naptha, C2, LPG
Kero/Diesel
Hydrogen
VGO
Pitch
Atm
. Tow
er
Vac. Tow
er
ISOCRACKING
E-Gas
LC-MAX
EthyleneCrackerComplex
Olefins Recovery; Olefins Conversion Technology;
Butadiene Extraction Unit;MTBE Unit; C4 Selective Hydro+Butene-1 Recov.;
Pyrolysis Gasoline Treatment;Aromatics Extraction;
Disproportionation
Ethylene
Propylene
Butadiene
Py. Oil
Hydrogen
Naphtha, C2, LPG
Crude
Power
Benzene
MTBE
Mixed XylenesTotal
Conversion to Naphtha Mode
14 © 2017 Chevron Lummus Global. All Rights Reserved.
Complete Crude Conversion …
Naptha, C2, LPG
Hydrogen
Hydrogen
Atm
. Tow
er
Vac. Tow
er ISOCRACKING
LC-SLURRY
Ethylene
Propylene
Benzene
Light Py. Oil
Naphtha, C2, LPG
Crude
Ultra Low Sulfur Fuel Oil
EthyleneCrackerComplex
Olefins Recovery
Butadiene Extraction Unit
MTBE Unit
C4 Selective Hydro+Butene-1 Recov.
DPG 1 and 2
Aromatics Extraction
Disproportionation
Butadiene
MTBE
Mixed Xylenes
Heavy Py. Oil
15 © 2017 Chevron Lummus Global. All Rights Reserved.
Light to Moderately Heavy Crudes with
Large Gasoline and Propylene Demands
HCO
Atm
. Tow
er
RFCC
ARDS
Ethylene Cracker
Complex
C2/LPG/Naphtha
High SulfurFuelOil
HDT
Crude
Diesel
LCO
Benzene
Ethylene
Propylene
Butadiene
Mixed Xylenes/
p-Xylene
Gasoline
16 © 2017 Chevron Lummus Global. All Rights Reserved.
Analysis of Crude to Chemicals Complexes
Some Case Studies
Minimum
Investment; No
Resid Upgrader;
No Fuels; Sell
HSFO
LC-FINING; No
Fuels; Sell LSFO
LC-FINING With
Fuels; Sell LSFO
LC-FINING With
Fuels; Sell LSFO -
Two Train Cracker
LC-FINING +
Delayed Coking;
No Fuels;
Produce Anode
Coke
LC-Slurry With
Fuels; Produce
ULSFO
Crude (Arab Light), BPD 195,000 162,000 227,000 400,000 137,689 246,515
Ethylene, KTA 2,000 2,000 2,000 4,000 2,000 2,000
Propylene, KTA 1,480 1,493 1,469 2,805 1,481 1,489
Butadiene, KTA 357 358 347 774 373 326
Euro VI Diesel, BPD 0 0 74,500 94,265 0 106,000
Fuel Oil, BPD 54,000 25,000 20,000 36,935 0 8,500
Anode Coke, KTA 0 0 0 0 194 0
H2 Required, MMSCFD 167 251 379 665 282 417
% Required H2 from Cracker 39 26 18 22 24 16
Natural Gas Required, KTA 596 777 1,011 1,872 794 992
Chemical Yield on Crude, % 58 70 49 57 83 45
Total Project Cost, MM$ 6,954 7,995 8,910 14,173 8,492 9,285
%IRR 14.6 22.4 24.4 33.0 21.4 25.0
Notes
1. 3%S HSFO 1%S LSFO 1%S LSFO 1%S LSFO Anode Coke 0.1%S ULSFO
2.
3.
4.
5.
All cases includes Hydrocracker + Olefins Conversion Technology
All cases produces MTBE, Butene-1, Benzene, Xylenes
3% HSFO priced at $21/Bbl less than crude
%IRR based on 70 / 30 debt / equity ratio
17 © 2017 Chevron Lummus Global. All Rights Reserved.
Features of Most Projects
Different Mindset : Petrochemicals are measured in KTA of product;
refineries in barrels of feed. PC unit feedstocks require precise quality; fuels
are more forgiving.
Require high on-stream factor in refining technologies to match
Petrochemicals on-stream factor.
Flexibility in Crude and Product Slate because crude and product pricing
and product demand can shift dramatically. Balance between Light and
Heavy Crudes to take opportunity of low cost crudes without excessive
CAPEX.
High Residue Conversion a necessity.
RDS-RFCC attractive when gasoline/propylene market is good
Residue Hydrocracking offers maximum conversion and crude flexibility.
Hydrocracking provides the best mix of petrochemical feedstock AND
transportation fuels.
World Scale Steam Cracker with adequately sized refinery provides
highest margins on Crude Conversion and Maximum Flexibility.
18 © 2017 Chevron Lummus Global. All Rights Reserved.
Thank You!
18 Courtesy – GS Caltex