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Global Refining and Petrochemical Congress
17th -18th July, 2019
Refinery Pivot Points in a Refinery –
Petrochemical Integrated Complex
Rajesh Samarth
Vice President- Business Development
LUMMUS TECHNOLOGY 2
Challenges Facing Refiners
Reduced Growth in Fuel Demand
►Extended Fuel Mileage
►Enhanced Electric Vehicles
►Environmental Headwinds
► Total Transport: Oil,
Biofuels, Gas, Other
CAGR
2.8%
1.1%
GDP vs Total Transport
LUMMUS TECHNOLOGY 3
Drivers of Rapid Petrochemicals Growth
Africa / Middle EastAsia Pacific
Latin America
Europe
North America
Global Middle Class Growth
2030
5.3 Billion People
0.4
0.3
0.7
0.3
1.4 3.4
0.50.7
0.3
0.3
0
50
100
150
200
250
300
350
400
1990 2000 2010 2020 2030 2040 2050
Index =
100
Relative Olefins and Aromatics Demand vs GDP
Relative
Olefins and
Aromatics
GDP
McDermott: Profit Pivot Points
From 2016 to 2040, 40%
chemicals sector growth
Quality of Life Improvement
Rising Prosperity
Development of Middle Class
Petrochemical growth exceeds
GDP growth
Emerging Markets
unprecedented Growth
2015
3 Billion People
LUMMUS TECHNOLOGY 4
Synergies of Refinery / Petrochemical Integration
► Recent Trend: Greater Integration not just Co-location
► Position Petrochemicals Plants near:
►Low-cost feedstock
►Lower Transportation Costs for Feedstocks
►Fuel Sources
►Existing Infrastructure
►Downstream Markets: PE / PP / PET
► Petrochemicals Provide High Value Outlet for Refiners
Complimentary Units
Refinery
H2
Naphtha
Py-Oil
Petrochemicals
LUMMUS TECHNOLOGY 5
McDermott Technology – One Stop Shop
❑ Leading Technology Licensor
❑ Refining
❑ Petrochemical
❑ Gas Processing
❑ Coal Gasification Technologies
❑ 120+ Licensed Technologies
❑ 3000+ Patents, Applications, Trademarks
❑ Industry Leading Ethylene Technology
❑ Joint Venture
❑ Chevron: Major Oil Company
❑ McDermott: A Premier EPC Company
❑ 100+ Hydroprocessing Plants Designed
Worldwide
❑ Active R&D Programs, Pilot Plant in
Richmond, CA and Pasadena, TX
Lummus TechnologyChevron Lummus Global (CLG)
LUMMUS TECHNOLOGY 6
Traditional Refinery
Atm
Tower
Crude
Vac
Tower
DHT
LPG
NHTCCR
Naphtha
Jet, Diesel
Resid
VGO
HT
Delayed
Coker
FCC
VGO
Hydro
CrackPropylene
Gasoline
Cycle Oil
IsomGasoline
H2
Gasoline
Oil Conversion
90% Fuels
10% Chemicals Coke
Jet, Diesel
Bottoms
Aromatics
LUMMUS TECHNOLOGY 7
Traditional Petrochemicals
Gas Feed
Steam
Cracker
Hydrogen
Fuel Gas
Ethylene
Ethane
Gas Crackers
PGO/PFO
Pygas
LPG
Liquid Feed
Steam
Cracker
Hydrogen
Fuel Gas
Ethylene
Propylene
Butadiene
BTX
PGO/PFO
Naphtha
AGO
VGO
Mixed C4s
Pygas
HVGO
Liquid Crackers
LPG
LUMMUS TECHNOLOGY 8
Feed Flexible Petrochemical Complex
Mixed Feed Steam Crackers
Provide Ultimate Flexibility
Multiple Feeds and Products
Larger Capacity
Hydrogen
Fuel Gas
Ethylene
Propylene
Butadiene
BTX
PGO/PFO
Naphtha
AGO
VGO
Mixed C4s
Pygas
HVGO*
Ethane
Mixed Feed Crackers
LPG
*Hydrocracked
Vacuum Gas Oil
Mixed
Feed Steam
Cracker Unit
LUMMUS TECHNOLOGY 9
Integrated Refinery and Petrochemicals Unit
Atm
TowerCrude
LPG
Jet
Diesel
Resid
ISO
CRACKER
Naphtha
Mixed
Feed
Steam
Cracker
Unit
Naphtha
Ethylene
Propylene
Mixed C4s
HVGO
C5+ Pygas
Hydrogen
Vac
Tower
VGO
Dow
nstr
eam
Petr
ochem
icals
Units
Diesel BTX
Hydro
processing
ULSFO
Py-OilLC-Fining / LC-
Max / LC-Slurry
LUMMUS TECHNOLOGY 10
Profit Pivot Points for an Integrated Complex
• Optimize Cracker Feeds
• Balance Hydrogen Consumption to Optimize Production of Chemicals
• HVGO Excellent Lubes or Cracker Feedstock
Hydroprocessing
• Feed Flexibility
• Cracking Severity Determined by Propylene to Ethylene (P/E) Ratio
Mixed Feed Steam Cracker
• Monetize valuable Co-products such as Butadiene, Paraxylene, BTX
• Olefins Conversion Technology maximizes C2-C3-C4 Product flexibility
Co-Product Selectivity
LUMMUS TECHNOLOGY 11
Hydroprocessing Pivot Point
Miracle of Hydrogen Addition
Effectively prepares Feed to
Mixed Feed Steam Cracker
in terms of Feed Flexibility,
Conversion, and Yield
Jet
Diesel
ISO
CRACKER
LC-Fining / LC-
Max / LC-Slurry
VGO
Hydroprocessing
Resid
H2
H2
LPG
Naphtha
Diesel
HVGO
ULSFO
LUMMUS TECHNOLOGY 12
Upgrading the Bottom of the Barrel
Catalyst and Reactor
configurations determine
range of conversion
Outlet for Py-Oil
upgrading from Steam
Cracker
LUMMUS TECHNOLOGY 13
Mixed Feed Steam Cracker
Liquid
Heaters
Process Features
SRT ® Pyrolysis Furnace Module
High Yield
Long Run Length
Optimized CAPEX / OPEX
Low Pressure Design vs Conventional Plants
Multi Component Refrigeration
Reduced Compressor Casings and Equipment Count
Gasoline
and Heavies
Removal
Gas
Heaters
CompressionRecovery &
Purification
LUMMUS TECHNOLOGY 14
Mixed Feed Steam Cracker Profit Pivot Points
0
50
100
Wt.
%
Feed Flexibility Typical Pyrolysis Yields(High Value Chemicals)
Ethylene Propylene Butadiene BTX
*P/E Ratio defined as
Propylene / Ethylene Ratio
Cracking Severity
Cracking Severity High Low
P/E Ratio 0.45 0.65
Energy / kg Ethylene Base + 16%
Feed Rate Base + 14%
Ethylene Production Base Base
Propylene Production Base + 46%
LUMMUS TECHNOLOGY 15
Co-Product Profit Pivot Point
Steam
Cracker
UnitSat’d C4s
Hydrogen
Fuel Gas
Ethylene
Propylene
Mixed C4s
C5-C8 Pygas Pygas
HT
Total Hydro
Sat’d C5-C8
NaphthaSat’d C4s
PP Unit
PE UnitPolyethylene
Polypropylene
LUMMUS TECHNOLOGY 16
Co-Product Profit Pivot Point C4 Train (Optimized)
Steam
Cracker
Unit
Butadiene
Extraction
MTBE / HP IB
Unit
1,3-Butadiene
Butene-1
i-Butane to Alky
MTBE
Butene-1
Raff-1
Raff-2
Raff-3
EthylenePropylene
Mixed
C4s
n-Butane
Raff-3 to Alky
C5s
Olefins
Conversion
Technology
IsobutyleneMethanol
LUMMUS TECHNOLOGY 17
Co-Product Profit Pivot Point Pygas (Optimized)
Steam
Cracker Unit
Stage 1 Pygas
Hydrotreating
C5s to Cracker
C5+
Pygas
Stage 2 Pygas
Hydrotreating
Pygas
BTX
Paraxylene
Benzene
Paraxylene
Propylene Aromatics
Styrene
C6-C8
to OCT
Ethylene
Cumene
LUMMUS TECHNOLOGY 18
Profit Pivot Points: Putting it all together
Co-
Product
Block
Mixed
Feed
Steam
Cracker
Unit
Atm
Tower
Arab
Light
Crude
LPG
Jet
Diesel
Resid
ISO
CRACKER
Naphtha
Ethylene
Propylene
Mixed
C4s
HVGO
C5+
Pygas
Hydrogen
Vac
Tower
VGO
Diesel
PGO
Hydro
processing
Naphtha
Py-Oil
ULSFOLC-Fining / LC-
Slurry
Benzene
Xylenes
Butene-1
Butadiene
LUMMUS TECHNOLOGY 19
Case Study – Refinery / Petrochemicals Integration
Case 1 2 3 4 5
Reside Upgrading No LC-FINING LC-FINING LC-FINING LC-SLURRY
Fuels Production No No Yes Yes Yes
Fuel Oil Type 3% HSFO 1% LSFO 1% LSFO 1% LSFO 0.1% ULSFO
Additional Processing
Crude (Arab Light), BPD 195,000 162,000 227,000 400,000 246,515
Ethylene, KTA 2,000 2,000 2,000 4,000 2,000
Propylene, KTA 1,480 1,493 1,469 2,805 1,489
Butadiene, KTA 357 357 347 774 326
Euro VI Diesel, BPD 0 0 74,500 94,265 106,000
Fuel Oil, BPD 54,000 25,000 20,000 36,935 8,500
Anode Coke, KTA
Chemical Yield on Crude, % 58% 70% 49% 57% 45%
% IRR Base +7.8% +9.8% +18.4% +10.4%Notes
1. All cases includes Hydrocracker + Olefins Conversion Technology
2. All cases produce MTBE, Butene-1, Benzene, Xylenes
3. 3% HSFO priced at $21/Bbl less than crude
LUMMUS TECHNOLOGY 20
Crude to Chemicals: A Disruptive Technology
Source: Saudi Aramco Presentation
At Baker Hughes (GE) 2018
Annual Meeting, Mr. Abdulaziz Al-Judaimi
LUMMUS TECHNOLOGY 21
Conclusion
Focus on integration of refinery and
Petrochemicals Units
Rapid Petrochemicals Demand Provides
Opportunities for Refiners to shift to
Chemicals
Profit Pivot Points will allow producers to
pivot to meet changing market demands:
Hydrocracker
Mixed Feed Steam Cracker
Co-Product Management
Source: EIA and Global Data
Technology solutions exist
to upgrade refined products
to valuable petrochemicals
LUMMUS TECHNOLOGY
Contact
Rajesh Samarth
Vice President- Business Development
22
Contact Information:
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