Maximize Conversion and Flexibility

(1)

Maximize Conversion

and Flexibility

The UOP Uniflex

TM

Process

Maximize Conversion

and Flexibility

The UOP Uniflex

TM

Process

Robert Haizmann

UOP LLC

Robert Haizmann

UOP LLC

6th _{Russia & CIS BBTC Conference}

April 13-14, 2011 Moscow, Russia

(2)

2

Maximize Conversion and Flexibility

With the UOP Uniflex Process



Market Factors



Technology Summary

(3)

Product Demand, Specifications,

and Prices are Changing

Incremental Fuel Demand 2010-2020

Source: Purvin & Gertz, 2010 GPMO

Common 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

Sulfur, Wt%

max

Global

Global Delayed ECA

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 Unleaded Diesel EN590 RFO, 1%S RFO, 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)

Product V a lu e ($/MT) Coke Diesel

(4)

4

Transportation

Fuels:

Gasoline,

Jet Fuel, Diesel

Distillation

Naphtha

Crude

Oil

Vacuum

Residue

Vacuum

Gas Oil

Distillates

Residues:

Heavy Fuel

Oil, Pitch,

Coke

Naphtha

Hydrotreating

& Reforming

FCC or

Hydrocracking

Distillate

Hydrotreating

UOP’s Heavy Oil Upgrading Processes

Residue

Conversion

UOP/FWUSA Solvent Deasphalting

FWUSA SYDECTM

Delayed Coking Process UOP/FWUSA Visbreaking UOP RCD UnionfiningTM Process

UOP Solutions

UOP/FWUSA Solvent Deasphalting

FWUSA SYDECTM Delayed Coking Process UOP/FWUSA Visbreaking UOP RCD UnionfiningTM Process

UOP Solutions for Residue Conversion

UOP UNIFLEX

Process

(5)

UOP Uniflex Process

Vacuum Residue Catalyst Gasoline Diesel VGO Makeup Hydrogen Pitch Reactor



Slurry hydrocracking

technology



High conversion to desired

products



Contains elements of proven

processes

–

CANMET Hydrocracking

Process

–

UOP Unionfining

TM

_{and UOP}

Unicracking

TM

_Processes

•

• Uniflex Process has >25% yield

Uniflex Process has >25% yield

advantage over Delayed Coking

-35 -15 5 25 45 65 85 105

De laye d Coking Unifle x Proce ss

V o lu me % o f Fe e d VGO VGO Distillate Distillate Naphtha Naphtha Coke (wt.%) Pitch (wt.%) Pitch (wt.%)

Typical Yields

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6

Uniflex Process

Extensive Commercial Experience

Petro-Canada Montreal Unit



25 years R&D



15 years commercial

operation



Variety of feedstocks



High conversion



97%+ availability

Many UOP improvements in the last 5 years

-20 0 20 40 60 80 100

Y

ie

ld

, v

o

l %

Naphtha Distillate VGO Pitch

85% 90% 94%

Commercial Performance

Conversion

(7)

Uniflex Process

Proven Flowscheme with Improvements

Uniflex Reactor

Vacuum Residue Feed

Hot Separator

Stripper/ Product Fractionator

Catalyst

Recycle H₂

Naphtha Diesel C₄

-Makeup H₂

Pitch LVGO

Cold Separator

HVGO Recycle

Flash Gas

Hot Flash Drum

Cold Flash Drum

Vacuum Fractionator

Feed Heater Recycle

Gas Heater

Fractionator Heater



Large Unit Capacities



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8

-40

-20

0

20

40

60

80

100

Wt

.%

of

Fe

e

d

Pitch/Coke 524+ Gasoil 343-524°C Distillate 204-343°C

Naphtha C5-204°C Fuel Gas + LPG

Uniflex Process

HVGO Recycle Improves Yields and Quality

Increased Naphtha &

Distillate Yields

Lighter VGO, easier to process

Delayed

Coking

Uniflex

Uniflex +

HVGO Recycle



Maximum naphtha and diesel yield from vacuum residue



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9 -50 -30 -10 10 30 50 70 90 110 Vol .% of Fe e d Delayed Coking Uniflex Process SDA EBED HC

Base Case:

Uniflex 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 V o l.% o f F e e d Distillate Yield (After Hydrocracking) Delayed Coking Uniflex Process SDA EBED HC Upgrading Margins With Hydrocracking Delayed Coking Uniflex Process SDA EBED HC 60%

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10

SDA Pitch

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 Process

UOP Uniflex Process UOP/FWUSA

Solvent Deasphalting

Process

Vacuum Residue _UOP

Unicracking Process

Unicracking Naphtha and Distillate



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 Complex

-- Low capital cost SDALow capital cost SDA

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11

Integrated Case:

Solvent Deasphalting/Uniflex/Unicracking Processes

-50 -30 -10 10 30 50 70 90 110 V ol .% of Fe e d

Residue, wt% DAO VGO Distillate Naphtha

SDA + Uniflex Delayed Coking SDA + Coking Uniflex Process

SDA/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 Delayed Coking SDA + Coking Uniflex Process

Upgrading Margins

With Hydrocracking SDA + Uniflex Delayed Coking SDA + Coking Uniflex Process

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12

UOP/FWUSA SDA Process

Commercial 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

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UOP Unicracking Process

Commercial 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 difference

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14

Coke

Uniflex Process Integrated with

Existing Delayed Coking Unit



Increased Naphtha and Distillate yield



Heavy Coker Gas Oil converted in Uniflex



Uniflex Pitch converted in Coker



Debottleneck Coker and Coker Heavy Gas Oil

Hydrotreater

Vacuum

Residue Feed

Delayed Coking

Products Uniflex

Process

Pitch

Products

(15)

Transportation

Fuels:

Gasoline,

Jet Fuel, Diesel

Distillation

Naphtha

Crude

Oil

Vacuum

Residue

Vacuum

Gas Oil

Distillates

Residues:

Heavy Fuel

Oil, Pitch,

Coke

Naphtha

Hydrotreating

Hydrocracking

Distillate

Hydrotreating

Integration of Hydroprocessing Units

UOP Uniflex

Process

Integration Drivers

-

-Capital Cost Reduction and Energy Efficiency

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16

Slurry Hydrocracking and Hydroprocessing

Issues 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

 H₂S and NH₃depress catalytic activity and selectivity

 Diesel yield loss via cracking

Straight Run Diesel and VGO

Vacuum Residue

Slurry HC

Rx

Hydroprocessing

Rx

Recycle Gas

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18

Selective Integration Benefits



UOP offers many integration options to meet refiners varied

requirements



Examples

–

Common H

₂

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