Maximize Conversion and Flexibility

The UOP UniflexTM Process

Maximize Conversion and Flexibility

The UOP UniflexTM ProcessRobert Haizmann

UOP LLC

Robert Haizmann

UOP LLC

© 2011 UOP LLC. All rights reserved.

6th Russia & CIS BBTC Conference April 13-14, 2011Moscow, Russia

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Maximize Conversion and Flexibility With the UOP Uniflex Process

Market Factors

Technology Summary

Capital Savings Through Integration

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Product Demand, Specifications, and Prices are ChangingIncremental Fuel Demand 2010-2020

Source: Purvin & Gertz, 2010 GPMO

Common goal: Maximize residue conversion to distillatesCommon goal: Maximize residue conversion to distillates

-2.0

0.0

2.0

4.0

6.0

8.0

Gasoline Diesel Kerosene/Jet Residue

Fuel Oil

MM

BPD

Bunker Fuel Oil Sulfur Specifications

0.0

1.0

2.0

3.0

4.0

5.0

2005 2010 2015 2020 2025 2030

Sulfu

r, W

t% m

ax

GlobalGlobal DelayedECA

NW European Product Differentials to Brent, Forecast in Constant 2010 $/Bbl

Source: Purvin & Gertz, 2010 GPMO

-30

-20

-10

0

10

20

30

40

2000 2005 2010 2015 2020

Euro UnleadedDiesel EN590RFO, 1%SRFO, 3.5%S

Diesel Price Premium over Coke

0

200

400

600

800

20 (2000) 40 (2004) 60 (2009) 80 (Future)

Crude Price, $/bbl (year)

Prod

uct V

alue

($/M

T)

CokeDiesel

4

TransportationFuels:

Gasoline, Jet Fuel, Diesel

Dist

illatio

nNaphtha

Crude Oil

VacuumResidue

VacuumGas Oil

Distillates

Residues:Heavy Fuel Oil, Pitch,

Coke

NaphthaHydrotreating & Reforming

FCC orHydrocracking

DistillateHydrotreating

UOP’s Heavy Oil Upgrading Processes

ResidueConversion

UOP/FWUSASolvent

DeasphaltingFWUSA SYDECTMDelayed Coking

ProcessUOP/FWUSAVisbreaking

UOP RCDUnionfiningTM

Process

UOP SolutionsUOP/FWUSA

SolventDeasphalting

FWUSA SYDECTM

Delayed CokingProcess

UOP/FWUSAVisbreaking

UOP RCDUnionfiningTM

Process

UOP Solutions for Residue ConversionUOP UNIFLEXUOP UNIFLEX

ProcessProcess

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UOP Uniflex Process

VacuumResidue

Catalyst

Gasoline

Diesel

VGO

MakeupHydrogen

Pitch

ReactorSlurry hydrocracking technologyHigh conversion to desired productsContains elements of proven processes

–CANMET Hydrocracking Process

–UOP UnionfiningTM and UOP UnicrackingTM Processes

•• Uniflex Process has >25% yield Uniflex Process has >25% yield advantage over Delayed Cokingadvantage over Delayed Coking

-35

-15

5

25

45

65

85

105

Delayed Coking Uniflex Process

Volu

me%

of F

eed

VGOVGO

DistillateDistillate

Naphtha

Naphtha

Coke(wt.%)

Pitch(wt.%)Pitch(wt.%)

Typical Yields

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Uniflex Process Extensive Commercial ExperienceExtensive Commercial Experience

Petro-Canada Montreal Unit25 years R&D15 years commercial

operation Variety of feedstocks High conversion 97%+ availability

Many UOP improvements in the last 5 yearsMany UOP improvements in the last 5 years-20

0

20

40

60

80

100

Yiel

d, v

ol %

Naphtha

Distillate

VGO

Pitch

85% 94%90%Commercial Performance

Conversion

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Uniflex Process Proven Flowscheme with ImprovementsProven Flowscheme with Improvements

UniflexReactor

Vacuum Residue Feed

HotSeparator

Stripper/Product

Fractionator

Catalyst

Recycle H2

Naphtha

Diesel

C4 -

MakeupH2

Pitch

LVGO

Cold Separator

HVGO Recycle

Flash Gas

HotFlashDrum

ColdFlashDrum

VacuumFractionator

FeedHeater

RecycleGas

Heater

FractionatorHeater

Large Unit CapacitiesLarge Unit Capacities

Capital Cost Savings Through Process IntegrationCapital Cost Savings Through Process Integration

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-40

-20

0

20

40

60

80

100W

t.% o

f Fee

d

Pitch/Coke 524+ Gasoil 343-524°C Distillate 204-343°CNaphtha C5-204°C Fuel Gas + LPG

Uniflex Process Uniflex Process HVGO Recycle Improves Yields and QualityHVGO Recycle Improves Yields and Quality

IncreasedNaphtha &Distillate

Yields

Lighter VGO, easier

to process

Delayed Coking

Uniflex Uniflex + HVGO Recycle

Maximum naphtha and diesel yield from vacuum residueMaximum naphtha and diesel yield from vacuum residue

VGO conversion without a separate Mild Hydrocracking UnitVGO conversion without a separate Mild Hydrocracking Unit

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-50

-30

-10

10

30

50

70

90

110

Vol.%

of F

eed

DelayedCoking

UniflexProcessSDA EBED

HC

Base Case: Uniflex Process Compared to Other VR Conversion ProcessesUniflex Process Compared to Other VR Conversion Processes

Uniflex Process Benefits:

High liquid yields on vacuum residue feed, especially distillates

Minimum residue by-products

Significantly increases margins

Residue Conversion Yields

30

40

50

60

70

80

90

Vol.%

of F

eed

Distillate Yield(After Hydrocracking)

DelayedCoking

UniflexProcessSDA EBED

HC

Upgrading MarginsWith Hydrocracking

DelayedCoking

UniflexProcessSDA EBED

HC 60%

Arab Light Vacuum Residue

10

SDAPitch

Uniflex Pitch

Uniflex Naphtha and Distillate

To New or Existing HDT

Unicracking UCO (to FCC)

DAO

Vacuum Gas Oil

Uniflex VGO

Uniflex Process Integrated with UOP/FW Solvent Deasphalting & Unicracking ProcessUOP/FW Solvent Deasphalting & Unicracking Process

UOPUniflexProcess

UOP/FWUSASolvent

DeasphaltingProcess

Vacuum Residue UOPUnicracking

Process

Unicracking Naphtha and Distillate

Maximum Distillate Production Maximum Distillate Production -- 95% Vacuum Residue Conversion with Uniflex and SDA95% Vacuum Residue Conversion with Uniflex and SDA-- 99+% VGO conversion with Unicracking Process99+% VGO conversion with Unicracking Process

Low Capital Cost Upgrading ComplexLow Capital Cost Upgrading Complex-- Low capital cost SDALow capital cost SDA-- Small, moderate reactor pressure Uniflex Process UnitSmall, moderate reactor pressure Uniflex Process Unit

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Integrated Case: Solvent Deasphalting/Uniflex/Unicracking ProcessesSolvent Deasphalting/Uniflex/Unicracking Processes

-50

-30

-10

10

30

50

70

90

110

Vol.%

of F

eed

Residue, wt% DAO VGO Distillate Naphtha

SDA +Uniflex

DelayedCoking

SDA +Coking

UniflexProcessSDA/Uniflex/Unicracking Benefits:

Very high vacuum residue conversion

Maximum distillate yields on vacuum residue feed

Highest margins

Capital cost reduced

Increased operating flexibility

Distillate Yield(After Hydrocracking)

SDA +Uniflex

DelayedCoking

SDA +Coking

UniflexProcess

Upgrading MarginsWith Hydrocracking

SDA +Uniflex

DelayedCoking

SDA +Coking

UniflexProcess

Arab Light Vacuum Residue

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UOP/FWUSA SDA Process Commercial ExperienceCommercial 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 ExperienceCommercial Experience

Proven Experience

– >60% of the World’s 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 differenceExperience IS the difference

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Coke

Uniflex Process Integrated with Existing Delayed Coking UnitExisting Delayed Coking Unit

Increased Naphtha and Distillate yieldIncreased Naphtha and Distillate yield

Heavy Coker Gas Oil converted in UniflexHeavy Coker Gas Oil converted in Uniflex

Uniflex Pitch converted in CokerUniflex Pitch converted in Coker

Debottleneck Coker and Coker Heavy Gas Oil Debottleneck Coker and Coker Heavy Gas Oil HydrotreaterHydrotreater

Vacuum Residue

Feed

Delayed Coking

ProductsUniflexProcess

Pitch Products

HCGO

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TransportationFuels:

Gasoline, Jet Fuel, Diesel

Dist

illatio

nNaphtha

Crude Oil

VacuumResidue

VacuumGas Oil

Distillates

Residues:Heavy Fuel Oil, Pitch,

Coke

NaphthaHydrotreating

Hydrocracking

DistillateHydrotreating

Integration of Hydroprocessing Units

UOP UniflexProcess

Integration Drivers Integration Drivers --Capital Cost Reduction and Energy EfficiencyCapital Cost Reduction and Energy Efficiency

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Slurry Hydrocracking and Hydroprocessing Issues that impact optimal degree of integrationIssues 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

Features

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

Moderate effect on overall capital and operating costs

H2 S and NH3 depress catalytic activity and selectivity

Diesel yield loss via cracking

Straight Run Diesel and VGO

VacuumResidue

Slurry HCRx

HydroprocessingRx

RecycleGas

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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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