UOP’s Modular Solutions Implementation for Refiners€¦ · • Revamp of Crude Unit, DHT, NHT, Gas Con, LPG Merox, and CCR Platforming Unit • Addition of a new 14,000 B/D Modular

© 2018 UOP LLC. A Honeywell Company All rights reserved.

UOP’s Modular Solutions Implementation for RefinersMike Trivunovic

February 20, 2018UOP 8080E-0

Honeywell UOP ME-TECH SeminarDubai, UAE

UOP Offers Complete Solutions for Refineries and Petrochemical Plants

1

Simplify Process Technology Implementation with UOP’s Comprehensive Solutions

• Complete Technology Package– Planning and Consulting Studies– Basic Engineering Design– Engineering Services– Advanced Process Control & Monitoring– Catalysts & Adsorbents– Key Mechanical Equipment– Modular Solutions– Installation support– Inspection Services

• UOP has been delivering Refining Modular Solutions for over 30 years

Modular Process Unit Delivery:UOP Technology Transfer Through Modularization

2

UOP Schedule A Detailed Design 3-D Model Shop Fabrication

Efficient Site Work Installation and Commissioning Completed Process Unit

Seamless Technology Transfer From Basic Design to Start-up

Example above is a 19 month delivery for a modular Penex in Pakistan~ 3 months required to install 20 modules

Benefits of UOP’s Modular Approach

Modular Approach Reduces Cost, Schedule, and Risk

3

• UOP Fixed Price• Superior quality via

shop fabrication & UOP inspection

• Effective labor• Avoid cost overruns

and change orders• Earlier start-up

• UOP basic/ detailed design, fabrication, & site services

• Parallel path design, procurement, fabrication & site

• Extensive UOP MOD experience

• Fewer disruptions to operations

• Less site construction & congestion

• Improved safety and security

• Less waste & material loss

Lower Cost ShorterSchedule

SmootherSite Works

UOP Continues to Expand Modular Offerings and Delivery More Value

4

• CCR Regenerator• Merox™ Treating• Chlorsorb™ Unit• Recovery Plus™ system• Recovery Max™ system

• UOP Modular Refinery• PetroPlexTM is UOP’s new

Integrated Naphtha Complex

CD

U

Sat Gas

NHTIsom

Plat

DHT

Pro

duct

s Ta

nkag

e

Merox

Merox

OSBL (utilities, controls etc)

PSA HPU

UOP Modular Refinery

• Platforming™

• Isomerization• Hydrotreating

• Iso-Alky™

• CDU• Olefins Reduction

Continuous Innovations in UOP’s Modular Portfolio

Project Development Model – Refinery Project5

Significant Incremental Revenue from Early Start-Up

5

0.5 0.5 1.0 2.5 0.5

0.5 2.0 0.75 0.25

Tech. Selection

Basic Design FEED Detailed Engineering, Procurement,

and Construction Start Up

Tech. Selection

Basic & Detailed EngineeringModule Fabrication Ship & Install Start

Up

K/O FID S/U

S/UFID

>4.5 Years “Traditional Stick Build Approach”

<3 Years “Modular Approach”

Refinery Capacity EnhancementIncluding a New Modular Penex Isomerization Unit

6

UOP 8080E-6

Refinery Capacity Enhancement

Multiple Units Revamped for 20% Capacity Increase and Meet Clean Fuel Requirements

7

LPG MEROX

Sour Gas

Visbreaker

Naphtha

Gasoline(Euro III)

Amine

SRD

Diesel MaxCat/Frac/Thermal

Sections

Asphalt Air Blowing

At Res

CDU

VDU

CrudeOil

Gases

Naphtha

SulfurRecovery

LPGGas-Con

DHDS

NAPHTHA GASES

Gases

NHT

F.OBlending

Kero Diesel

Kerosene

Vac Residue

SR Diesel

H2HSD

GasesNaphtha RFO

VIS. BTM

VAC RESIDUE

D-MX RESIDUE

Stab. Naphtha

Gases

Platformer CCR

HVGO HVGOLVGO

Sulfur

LPG

Fuel GasFuel Gas

IsomerateLPG

HOBC

JP-1-8

Kero

HSD(Euro III)

Furnace Oil

Asphalt

LDO

LVGOLVGO

500 MTPD

Isomerization

GasesH2

Reformate

H-Naphtha

H2

HSD/LDOBlending

JP-1/JP-8Blending

GasolineBlending

H2S

H2

< 10% Increase

< 10-20% Increase

20%-30% Increase

New

Kero Merox

Objective: Increase Capacity and Improve Product Quality Within Shortest Schedule

• Schedule – Pressure to implement Euro III standards quickly

• FEED work not completed– Revamp study not completed– Design basis not defined– Basic Engineering for Isomerization Unit

not available

• Size and complexity of revamp project implementation for refinery team

• Overall schedule for Isomerization unit underestimated

• Disruption to existing units and unit down-time• Restrictive plot space availability

13 8

• Increased crude processing capacity– 100,000 BPSD to 120,000 BPSD– Reduce reliance on fuel imports

• Process additional indigenous crudes/condensates feed compositions:

– Light, low in sulfur– Low in Conradson carbon

• Improve final product specifications– Euro II to Euro III

• Optimize feed blend and flow scheme • Debottleneck downstream process units• Minimize modifications and overall Capex

Refiner Problem

Production Needs (Revamp Obj’s) Project Implementation Challenges

Case Study: Refinery Capacity EnhancementNew Modular Isomerization Unit


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UOP’s Approach for Project Implementation

Phase 1 - Optimization and Configuration Study• Define technically feasible /economically optimum flow scheme by:

– Maximizing process units which are adequate as-is– Minimizing process units requiring revamp– Identify New Unit(s)- e.g.- Isomerization

• Provide a fixed-price proposal for new modular isom unit

Result: Parallel execution scheme to achieve shortest schedule

Phase 2 –Parallel Path Execution• Issue process studies for revamped units• Supply new Modular Isom Unit

– Basic engineering, detailed design & procurement activities overlapped for optimal schedule

• Work proceeded in parallel for modular isomerization unit

UOP Solution


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• Revamp of Crude Unit, DHT, NHT, Gas Con, LPG Merox, and CCR Platforming Unit

• Addition of a new 14,000 B/D Modular Penex™ Process Unit• I-82 Penex Catalyst• New PSA unit for increased H2

• Supply of DCS/DRCS and PSA control system as integrated package

UOP’s Revamp Solution

Refinery Benefits• ~ 20% increase in total refinery throughput• Higher utilization of lower value naphtha into high octane gasoline• Upgrade from Euro 2 to Euro 3 gasoline product specs• Fast track execution meeting mandated timeline

– Schedule: 88 months, FCA fabrication shop – 9 Months faster than traditional stick build approach, earlier revenue!

Project KO

Month 0

Design Complete

11

Ship 1st Modules

18

Final Shipment

20

M C

26

UOP 8080E-10

UOP Solution

LPG

HeavyFuel Oil

UOP Modular Merox™ Unit Implementation11

UOP 8080E-11

Fuel Gas Extraction

*

LPGExtraction

LSR GasolineSweetening

KeroseneJet Fuel

Sweetening

LPGExtraction

FCCGasoline

Sweetening

Isom

Platforming™Unit

AlkylationInAlk

Cat. Con.

Fuel Gas

Gasoline

KeroseneJet Fuel

Diesel

ATM CrudeTower

VacuumTower

*

*

*

*

*

*

**

UOP Modular Equipment Offering Available*

SaturateGas. Con.

*

NaphthaHDS

*

DieselHDS

*

FCC

Case Study: 5,000 B/D Kerosene Jet Fuel SweeteningModular Merox™ Unit Implementation

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Objective: Add Kerosene Jet Fuel Production & Increase Refinery Profitability

• Quality and quantity of local skilled construction labor• Limited experience refinery project managers and

engineers• On-site safety issues with operating unit• Rainy weather impact on construction• Limited plot space• Tight project schedule

• Location: West Africa• Refinery: 21,000 B/D heavy conversion refinery• Process Units: Atmo distillation, VAC, HCU, DHT, Visbreaker, Reformer

Project Implementation Challenges

• Meet growing local jet fuel demand and decrease imports- Gov’t requirement

• Meet Jet-1 fuel specs• Increase refinery profitability• Use proven technology

Production Needs (Revamp Obj’s)

Refiner Problem


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Modular Fabrication Key to Schedule, Quality, and Implementation

Refinery Benefits

• Addition of a new 5,000 B/D Modular Merox™

Process Unit (fixed price)• Designed for Kerosene treatment to

Jet A-1 specs• Operations Training

UOP Technology Solution

• Production of A-1 Jet Fuel• Increase profitability• Fast track schedule for modules, < 1 year• Low risk project implementation• Easy Installation

UOP Merox process reduces acids and converts mercaptans to

disulfides using UOP’s proprietary fixed-bed catalyst, caustic, and air

UOP Solution

MeroxReactor

WaterWash

SaltFilter

ClayFilter

SweetenedKerosene/Jet Fuel

PrewashCausticSettler

Kerosene/Jet Fuel

DiluteCaustic

Air

UOP is Uniquely Positioned to Modularize UOP Units…With Quality in Mind

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• Basic Design by UOP• Detailed Design including 3D Model• Module Fabrication in Shop • Project Management• Quality Control and Inspection• Preparation for Shipment• UOP Field Operating

Services- Start-Up

3D Model of UOP Merox Unit

UOP Modular Merox Unit Scope

Designed with Operators in MindComprehensive Check Out


15

UOP Modular Merox Process is a Proven Technology Solution for Kerosene Treatment

• UOP Kerosene Merox Unit successful addition to produce A-1 Jet Fuel

• Modular execution provided high quality system with operations in mind

• Fast track schedule and easy installation allowed for trouble free start up

Case Study Conclusions

Installation 2015Modules Design: Easy Transport & Install


16

UOP 8080E-16

Case Study: 25 K B/D Naphtha Complex RevampNew Modular Isomerization Unit

• Tight project schedule with fixed compliance deadline• Short turn-around: implement in 5 - 6 weeks• Minimize disruption to operating plant • Limited / narrow plot space for new Isom unit

• Meet growing local gasoline demand• Upgrade ~50/50 Euro III/ IV production to 100%

Euro IV gasoline specs• Accommodate 25% crude capacity increase• Increase Naphtha utilization / decrease export• Decrease MTBE usage

Objective: Increase Capacity and Improve Product Quality Within Shortest Schedule

13 17

NHT

CCRPlatforming

Unit

Penex Unit

NaphthaNaphthaSplitter

Reformate

Isomerate

SR + HC

NaphthaHC Heavy

DP

C5 to HGUDIH

GasolineBlend

Refiner Problem

Production Needs (Revamp Obj’s) Project Implementation Challenges

Light Isomerate

2nd Penex Unit added+140%

+150%

+200% +70%


18

Increased Gasoline Production + Naphtha Utilization ~ US $200M NPV Increase

• Limited revamp of NHT & CCR Platforming Unit– Capacity increases of 140% for NHT and 150% for CCR

• Addition of a new 10,000 B/D Modular Penex™ Process Unit and integrate with existing 8,000 B/D Penex Unit


• 70% increase in gasoline production from original design• 90+% utilization of lower value naphtha into

gasoline product• Meets Euro IV gasoline product specs• No import / use of MTBE• Fast track execution meeting mandated timeline

– Schedule: 15 months, FCA fabrication shop – 9 Months faster than traditional stick build approach

UOP Solution

UOP 8080E-18

Refinery Benefits

UOP’s Revamp Solution

19

Modules Fabrication Progress February 2017

UOP delivered ~ 60 modules

Modules Delivery and Installation at site March-April 2017

UOP 8080E-19

Compressor Suction & Discharge, Drum & Coolers

Design Complete

7

Ship 1st Modules

11

Install Modules

15

Mechanical Completion

18Month 0

Project KO


20

Increased Production + Naphtha Utilization = US $200M NPV Increase

• Innovative revamp engineering by UOP successfully integrated new flow scheme and Modular Penex unit with existing Naphtha units

• 70% increase in gasoline production

• Upgrade to EURO-IV / V Gasoline without MTBE

• 90+% utilization of lower value naphtha

• New modular Isomerization Unit implemented in 18 months fast track schedule

• UOP managed revamp from design to fabrication, start-up, and production

• Customer managed the installation of the modules with UOP support on-site

Case Study: 25 K B/D Naphtha Complex Revamp: New Modular Isomerization Unit

Case Study Conclusions

UOP 8080E-20

• Fixed Delivery Schedule

• Parallel activities to minimize overall delivery schedule

• UOP offers a Fixed Price minimizing change orders

• Performance Guarantees and Mechanical Guarantees with one partner

• UOP’s technical support helps customers maximize profit by optimizing on-stream reliability

• UOP’s proven commitment to our customer for every project

Schedule Assurance & Fast

Track Delivery

Price Assurance

Performance Assurance

UOP Modular Solutions for Technology Implementation21

UOP Delivers Modular Equipment with Fixed Schedule and Price & Guaranteed Performance

• Single point accountability for the process revamp and critical equipment

• UOP stands with our customer to ensure successful start-up and support over entire unit life

Accountability Assurance

22

UOP 8080E-22

Documents

UOP’s Modular Solutions Implementation for Refiners€¦ · • Revamp of Crude Unit, DHT, NHT, Gas Con, LPG Merox, and CCR Platforming Unit • Addition of a new 14,000 B/D Modular