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Page 1: geoscan.nrcan.gc.ca · with the UOP Uniflex™ Process Dan Gillis UOP LLC 2009 Canadian Refining and Upgrading Conference September 14-16 th, ... Best Practices from CANMET Hydrocracking

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Page 2: geoscan.nrcan.gc.ca · with the UOP Uniflex™ Process Dan Gillis UOP LLC 2009 Canadian Refining and Upgrading Conference September 14-16 th, ... Best Practices from CANMET Hydrocracking

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Page 3: geoscan.nrcan.gc.ca · with the UOP Uniflex™ Process Dan Gillis UOP LLC 2009 Canadian Refining and Upgrading Conference September 14-16 th, ... Best Practices from CANMET Hydrocracking

Breaking Throughthe Bitumen Upgrading Barrierswith the UOP Uniflex™ Process

Breaking Throughthe Bitumen Upgrading Barrierswith the UOP Uniflex™ Process

Dan GillisUOP LLC

Dan GillisUOP LLC

2009 Canadian Refining and Upgrading ConferenceSeptember 14-16th, 2009Edmonton, Alberta

© 2009 UOP LLC. All rights reserved. UOP 5228-01

Page 4: geoscan.nrcan.gc.ca · with the UOP Uniflex™ Process Dan Gillis UOP LLC 2009 Canadian Refining and Upgrading Conference September 14-16 th, ... Best Practices from CANMET Hydrocracking

Bitumen Upgrading Challenges

Product Yields and Qualities

Byproduct Disposal

Expansion of Existing Assets

Return on Investment

Project Financing

UOP 5228-02

Page 5: geoscan.nrcan.gc.ca · with the UOP Uniflex™ Process Dan Gillis UOP LLC 2009 Canadian Refining and Upgrading Conference September 14-16 th, ... Best Practices from CANMET Hydrocracking

Source: 2008 FACTS Global Energy

Strong Incentive for High Conversion Technologies

UOP 5228-03

0

20

40

60

80

100

120

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

Crude Price, $/bbl (year)

Pro

du

ct

Va

lue

($

/bb

l)

Coke $/bbl (FOEB) Diesel

Page 6: geoscan.nrcan.gc.ca · with the UOP Uniflex™ Process Dan Gillis UOP LLC 2009 Canadian Refining and Upgrading Conference September 14-16 th, ... Best Practices from CANMET Hydrocracking

High Conversion Technology Barriers

Technical Issues

Commercialization Status

Costs

Technology Support

Risk Management

UOP 5228-04

Page 7: geoscan.nrcan.gc.ca · with the UOP Uniflex™ Process Dan Gillis UOP LLC 2009 Canadian Refining and Upgrading Conference September 14-16 th, ... Best Practices from CANMET Hydrocracking

UOP Uniflex Process

Contains elements of proven processes

– Commercialized CANMET Hydrocracking Process

– UOP UnionfiningTM andUnicrackingTM Processes

Up flow high temperature and pressure reactor

Hydrogen and proprietary dispersed phase catalyst added to the feed

Results in high conversion to desired products

UniflexProcessReactor

VacuumResidue(100%)

Gasoline (20-25%)

Fuel Gas (5%)

Diesel (45-50%)

ProductFractionation

Pitch (<10%)

Vacuum Gas Oil (20-30%)

Hydrogen

Catalyst

-40

-20

0

20

40

60

80

100

Delayed Coking Uniflex Process at

90% Conversion

Vo

lum

e%

of

Fe

ed

VGOVGO VGOVGO

DistillateDistillate

DistillateDistillate

NaphthaNaphtha

NaphthaNaphtha

Coke(wt.%)Coke(wt.%)

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

Uniflex Process has a26 vol% yield advantage!

UOP 5228-05

Page 8: geoscan.nrcan.gc.ca · with the UOP Uniflex™ Process Dan Gillis UOP LLC 2009 Canadian Refining and Upgrading Conference September 14-16 th, ... Best Practices from CANMET Hydrocracking

CANMET Hydrocracking Process Background

Petro-Canada Montreal Unit

15 years of operation

Achieved 95% conversion

Processed many vacuum residues

Also processed VGO, Visbroken Vacuum Residue, FCC Slurry Oil

Long term operational learning curve

97%+ availability

-20

0

20

40

60

80

100

Vo

l.%

of

Feed

85% 94%90%

PitchPitch

VGOVGO

DistillateDistillate

VGOVGO

PitchPitch

DistillateDistillate

NaphthaNaphthaNaphthaNaphtha

VGOVGO

PitchPitch

DistillateDistillate

NaphthaNaphtha

Cold Lake Vacuum Residue Wt.% Conversion

High Conversion Commercial Verification

Supported by 25 years of R&D

Technology owned by Natural Resources Canada

Commercially proven high conversion on a wide range of feedstocks

UOP acquired exclusive licensing rights in 2007

UOP 5228-06

Page 9: geoscan.nrcan.gc.ca · with the UOP Uniflex™ Process Dan Gillis UOP LLC 2009 Canadian Refining and Upgrading Conference September 14-16 th, ... Best Practices from CANMET Hydrocracking

Product Yields Drive Economic Advantages

Uniflex Process focus is on medium to high conversion

65

75

85

95

105

DC only 80 85 90 95

Uniflex Process Conversion, wt %

Liq

uid

Yie

lds,

vo

l % Yields

10

15

20

25

30

35

DC only 80 85 90 95

Uniflex Process Conversion , wt. %

Ma

rgin

, $

/bb

l V

R

Margins Track Yields

0%

20%

40%

60%

80%

100%

120%

140%

Re

lati

ve

To

tal

Pro

jec

t C

os

ts

Delayed Coking Uniflex Process

ResidueConversion

ResidueConversion

ResidueConversion

ResidueConversion

OtherISBLOtherISBLOther

ISBLOtherISBL

OSBLOSBLOSBLOSBL

Owner’s CostOwner’s Cost

Owner’s CostOwner’s CostContingencyContingency

ContingencyContingency

Similar Project Capital Costs

UOP 5228-07

0

5

10

15

20

40 60 80

Crude Price, $/bbl

$/b

bl

Vacu

um

Resid

ue

Margin Advantage Sensitive to Prices

with high process reliability!

Page 10: geoscan.nrcan.gc.ca · with the UOP Uniflex™ Process Dan Gillis UOP LLC 2009 Canadian Refining and Upgrading Conference September 14-16 th, ... Best Practices from CANMET Hydrocracking

Best Practices from CANMET Experiences

Advanced Pilot Plants

New Catalysts

Flow Scheme and Equipment Improvements

Pitch Product Options

UOP is Advancing the Technology

UOP 5228-08

Feed

Catalyst

Naphtha

Diesel

C4-

FlashGas

HVGO

LVGO

MakeupH2

HVGO RecyclePitch

RecycleGas

Page 11: geoscan.nrcan.gc.ca · with the UOP Uniflex™ Process Dan Gillis UOP LLC 2009 Canadian Refining and Upgrading Conference September 14-16 th, ... Best Practices from CANMET Hydrocracking

Alberta Energy Research InstituteHydrocarbon Upgrading Program

Alberta Energy Research Institute (AERI)

– Energy technology arm of the Alberta Government

– Partners with industry to develop technologies of strategic importance

Hydrocarbon Upgrading Demonstration Program (HUPD)

– Phase 1: Screened over 100 technologies for upgrading bitumen

– Phase 2: UOP Uniflex Process was selected for further development and demonstration

– AERI providing financial support

AERI support is helping to enable technology advances

UOP 5228-09

Page 12: geoscan.nrcan.gc.ca · with the UOP Uniflex™ Process Dan Gillis UOP LLC 2009 Canadian Refining and Upgrading Conference September 14-16 th, ... Best Practices from CANMET Hydrocracking

Petro-Canada Montreal Unit Yields

0

10

20

30

40

50

60

80 85 90 95 100

Vacuum Residue Conversion, wt%

Pro

du

ct

Yie

lds,

vo

l%

Naphtha

VGO

Diesel

UOP 5228-10

Page 13: geoscan.nrcan.gc.ca · with the UOP Uniflex™ Process Dan Gillis UOP LLC 2009 Canadian Refining and Upgrading Conference September 14-16 th, ... Best Practices from CANMET Hydrocracking

0

10

20

30

40

50

60

80 85 90 95 100

Vacuum Residue Conversion, wt%

Pro

du

ct

Yie

lds, vo

l%

Naphtha

VGO

Diesel

UOP Pilot Plant Yields MatchPetro-Canada Montreal Unit Yields

UOP 5228-11

Page 14: geoscan.nrcan.gc.ca · with the UOP Uniflex™ Process Dan Gillis UOP LLC 2009 Canadian Refining and Upgrading Conference September 14-16 th, ... Best Practices from CANMET Hydrocracking

UOP Uniflex Process Basic Flow Scheme

HVGO

UniflexReactor

Feed

HotSeparator

Stripper/Product

Fractionator

Catalyst

RecycleH2

Naphtha

Diesel

C4-

MakeupH2

Pitch

LVGO

Cold Separator

Flash Gas

HotFlashDrum

ColdFlashDrum

VacuumFractionator

FeedHeater

RecycleGas

Heater

FractionatorHeater

Key Equipment designed to assure Product Stability and avoid Equipment Fouling UOP 5228-12

Page 15: geoscan.nrcan.gc.ca · with the UOP Uniflex™ Process Dan Gillis UOP LLC 2009 Canadian Refining and Upgrading Conference September 14-16 th, ... Best Practices from CANMET Hydrocracking

UOP Uniflex Process with Heavy Vacuum Gas Oil Recycle

HVGO

UniflexReactor

Feed

HotSeparator

Stripper/Product

Fractionator

Catalyst

RecycleH2

Naphtha

Diesel

C4-

MakeupH2

Pitch

LVGO

Cold Separator

HVGO Recycle

Flash Gas

HotFlashDrum

ColdFlashDrum

VacuumFractionator

FeedHeater

RecycleGas

Heater

FractionatorHeater

UOP 5228-13

Page 16: geoscan.nrcan.gc.ca · with the UOP Uniflex™ Process Dan Gillis UOP LLC 2009 Canadian Refining and Upgrading Conference September 14-16 th, ... Best Practices from CANMET Hydrocracking

boiling point

pola

rity

saturates

mono-aromatics

di-aromatics

poly-aromaticstri-aromatics

GCxGC/FIDPoly-aromatics ideal for reducing mesophase by

improving asphaltene solubility

UOP 5228-14

UOP Uniflex ProcessHeavy Vacuum Gas Oil

Page 17: geoscan.nrcan.gc.ca · with the UOP Uniflex™ Process Dan Gillis UOP LLC 2009 Canadian Refining and Upgrading Conference September 14-16 th, ... Best Practices from CANMET Hydrocracking

pola

rity

boiling point

saturates

mono-aromatics

di-aromatics

tri-aromatics

poly-aromatics

UOP Uniflex ProcessVacuum Gas Oil Product

atics

OriginalHVGO Area

Significant improvement in VGO quality to downstream FCC and Hydrocracking

GCxGC/FID

UOP 5228-15

Page 18: geoscan.nrcan.gc.ca · with the UOP Uniflex™ Process Dan Gillis UOP LLC 2009 Canadian Refining and Upgrading Conference September 14-16 th, ... Best Practices from CANMET Hydrocracking

End uses include:– Cement kilns

– Fluidized bed boilers

– Conventional boilers

– Gasification

– Delayed coking

– Solvent deasphalting

Can be handled in:

– Liquid form for nearby uses

– Solidified for transportation to distant markets

Feed

PitchCatalyst

Pitch Product Utilization

UOP can assist customers for all applications

UOP 5228-16

Page 19: geoscan.nrcan.gc.ca · with the UOP Uniflex™ Process Dan Gillis UOP LLC 2009 Canadian Refining and Upgrading Conference September 14-16 th, ... Best Practices from CANMET Hydrocracking

UOP Uniflex ProcessCreates Additional Opportunities

Heavier Crude Processing

FCC Slurry Oil Conversion

Hydroprocessing Integration

Synergies with other Residue Processes

– Solvent Deasphalting

– Delayed Coking

– Residue Hydrotreating

UOP 5228-17

Page 20: geoscan.nrcan.gc.ca · with the UOP Uniflex™ Process Dan Gillis UOP LLC 2009 Canadian Refining and Upgrading Conference September 14-16 th, ... Best Practices from CANMET Hydrocracking

UOP Uniflex Process + Integrated Hydrotreating Options

Integration can reduce Costs

Benefits are Project Specific

UOP 5228-18

Several integration options are possible

Best flow scheme depends on product objectives

Project specific issues need to be considered

Page 21: geoscan.nrcan.gc.ca · with the UOP Uniflex™ Process Dan Gillis UOP LLC 2009 Canadian Refining and Upgrading Conference September 14-16 th, ... Best Practices from CANMET Hydrocracking

Fractionation Approach has Implications

0

5

10

15

20

25

30

70 75 80 85 90 95 100

Uniflex Process Conversion

Pit

ch

Yie

ld

ConventionalFractionation

*NCUT Pilot Plant

Solvent Extraction Potential

Heavy Solvent

Light Solvent

Specialized Fractionation

Equipment

Pitch Yield versus Conversion*

Feed

AdvancedSeparationSystems

Products

Pitch

UniflexProcess

Residue

Recycle

Product Separation Approach Impacts Profitability and

Process Reliability

Yields are impacted by both process conversion and fractionation approach

Maximizing conversion and product recovery can lead to equipment reliability issues

Uniflex Process has addressed these issues with:

– Flow scheme and equipment designs that manage product stability and fouling issues

– Advanced separation systems to maximize product recoveries

UOP 5228-19

Page 22: geoscan.nrcan.gc.ca · with the UOP Uniflex™ Process Dan Gillis UOP LLC 2009 Canadian Refining and Upgrading Conference September 14-16 th, ... Best Practices from CANMET Hydrocracking

Uniflex Process Integration with Coking

Conventional residue byproduct

Yields much less sensitive to Uniflex Process conversion

High margins even at low Uniflex Process conversion

65

75

85

95

105

DC only 80 85 90 95

Uniflex Process Conversion, wt %

Liq

uid

Yie

lds,

vo

l %

Yields

10

15

20

25

30

35

DC only 80 85 90 95

Uniflex Conversion , wt. %

Ma

rgin

, $

/bb

l V

R

Margins

Very high margins can be sustained based on combining proven technologies

UOP 5228-20

Feed

Coking

Products

Coke

UniflexProcess

Pitch

HCGO Recycle

Page 23: geoscan.nrcan.gc.ca · with the UOP Uniflex™ Process Dan Gillis UOP LLC 2009 Canadian Refining and Upgrading Conference September 14-16 th, ... Best Practices from CANMET Hydrocracking

UOP Uniflex Process Breaks Throughthe High Conversion Selection Barriers

Best Practices from CANMET Hydrocracking

Continuous Development facilitated by AERI

High Conversion and Upgrading Margins

Design assures High Reliability

Meets Investors Expectations

UOP Uniflex Process Will Maximize Your Upgrader’s Profitability

UOP Uniflex Process Will Maximize Your Upgrader’s Profitability

UOP 5228-21

Page 24: geoscan.nrcan.gc.ca · with the UOP Uniflex™ Process Dan Gillis UOP LLC 2009 Canadian Refining and Upgrading Conference September 14-16 th, ... Best Practices from CANMET Hydrocracking

UOP 5228-22