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Enhance Naphtha Value and Gasoline Reformer Performance Using
UOPs
MaxEneTM Process
Enhance Naphtha Value and Gasoline Reformer Performance Using
UOPs
MaxEneTM Process
2011 UOP LLC. All rights reserved.
1st IndianOil Petrochemical ConclaveMarch 16, 2012Gurgaon,
India
UOP 5614D-1
Mark Turowicz
UOP IPL, A Honeywell Company
Mark Turowicz
UOP IPL, A Honeywell Company
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Contents
MaxEne Technology Introduction
Market Drivers for MaxEne Projects
MaxEne Case Studies
MaxEne Commercial Experience
UOP 5614D-2
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Refining-Petrochemical Integration
The MaxEne Process delivers benefits in an integrated facility
and can also provide substantial benefits to the stand-alone
refiner
The MaxEne Process was developed to help optimize the
integration of refining and petrochemical facilities
Normal paraffins are the preferred feed to naphtha crackers for
optimized yields of light olefins (ethylene + propylene)
Catalytic reforming yields increase significantly (octane
barrels and aromatics yield) when paraffins are removed from the
feed
In an optimally integrated complex with MaxEne Process:
N-paraffins are fed to the cracker resulting in:
Upto a 30% increase in ethylene and propylene yield
Paraffin depletion (and enriching of napthenes/ aromatics) in
the feed to the Platformer results in:
4-6% increase in C5+ yield at constant octane
2-3% increase in aromatics yield
Full Range
Naphtha
Full Range
NaphthaNaphthaCracker
MaxEneUnit
CatalyticReformer
Full Range
Naphtha
Full Range
Naphtha
NaphthaCracker
CatalyticReformer
Typical
Integrated
Complex
Typical
Integrated
Complex
UOP 5614D-3
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How Does the MaxEne Process Work?
Pumparoundpump
AdsorbentChamber
ExtractColumn
RaffinateColumn
Feed to reformer
n-Paraffins feed to steam
crackerDesorbent
Naphtha
Feed
RotaryValve
Adsorptive separation
Based on SorbexTM Technology
The adsorbent has greater affinity for n-paraffins
Simulates a moving bed
The process influent and effluent points move, but the actual
mechanical connections do not
The solid adsorbent is in fixed, non-moving beds
The liquid feed flows counter-currently relative to the
solid
More than 130 process units based on Sorbex Technology licensed
worldwide
UOP 5614D-4
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Extension of Previous UOP Experience in Naphtha Separation
Liquid phase extraction technology widely used to recover
n-paraffins
Gasoline Molex process (C5 to C6) in light naphtha isomerization
applications for octane improvement
15 licensed units
Kerosene Molex process (C10 to C13) for detergent applications.
Heavy Molex process (C14 to C18 ) for other surfactant
applications
35 licensed units
MaxEne process (C6 to C11) bridges the carbon range between
Gasoline and Kerosene Molex
UOP 5614D-5
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Contents
MaxEne Technology Introduction
Market Drivers for MaxEne Projects
MaxEne Case Studies
MaxEne Commercial Experience
UOP 5614D-6
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Average 2010 Steam Cracker Feedstock Slates
Other than in N America and the ME, most steam crackercapacity
is from naphtha -- presents an opportunity to refiners
Source: CMAI 2011 World Ethylene Cost Study
UOP 5614D-7
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Contents
MaxEne Technology Introduction
Market Drivers for MaxEne Projects
MaxEne Case Studies
MaxEne Commercial Experience
UOP 5614D-8
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Case Study 1: MaxEne Process Integration Integration with a
Catalytic Reformer
Goal
Maximize Catalytic Reformer profitability when market demand
requires less gasoline production
Produce high quality petrochemical naphtha for domestic or
export sales
Basis for integration
Feed is a full range naphtha (FRN). FRN rate kept constant.
MaxEne unit, catalytic reformer and steam cracker yields based
on feed composition
Feed, major products, and by-products included
W. Europe price-set assumed with reformate price based on octane
value
Catalytic Reformer originally designed for 102 RONC but
currently running at 96 RONC based on market need
Why was MaxEne considered?
Flexibility to increase reformate yield and/or octane
Minimize changes to catalytic reformer
Increase value of export naphtha
UOP 5614D-9
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Existing Refinery Complex
855kMTA
545 kMTA
Yields, kMTA
C2 = 316
C3= 162
478
96 RONC
795 kMTA
Cracker
NHTNHT
*328 kMTA
Petrochemical Facility
873kMTA
3.22 Wt-% H2 Yield
27.5 kMTA
* Purchased naphtha from other refiner
UOP 5614D-10
93.0 Wt-% C5+ Yield
Full rangenaphtha
1400kMTA
CatalyticReformer
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873kMTA
Refinery Complex with MaxEneConstant Full Range Naphtha
Normals
Non-normals
52 kMTA / 82 RONC(light gasoline to
blending)
Catalyticreformer
207 kMTA
584 kMTA
*192 kMTA
681 kMTA
667 kMTA
3.68 Wt-% H2 Yield
24.5 kmta
Can run catalytic reformer at higher severity with higher
quality feedstock
DeC6 on MaxEne raffinate to remove Bz pre-cursors from reformer
feed
UOP 5614D-11
Full rangenaphtha
531kMTA136 kMTA
NHTNHT
Cracker
Petrochemical Facility
* Purchased naphtha from other refiner
Yields, kMTA
C2 = 337C3= 171
508
104 RONC
607 kMTA
91.0 Wt-%
C5+ Yield
CatalyticReformer
MaxEneUnit
474 kMTA
1400kMTA
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The MaxEne Process EffectCase Study #1 - Refinery Balance
Existing with MaxEne
kMTA kMTA
Full Range Naphtha 1400 1400
Export Naphtha 545 681
n-paraffin Wt-% 42 62
Reformer Feed 855 667
Light Gasoline 0 52
Reformer Gasoline 795 607
RONC 96 104
Hydrogen 28 25
Tail Gas 11 12
LPG 22 24
MaxEne minimizes financial impact of lower reformate production
via:
Production of Light gasoline with 82 RONC
Production of 104 RONC Reformate (within existing unit
constraints of WAIT, Heater Duty and CCR Size)
Production of Higher Quality (higher % n-paraffin) Petrochemical
Naphtha ExportUOP 5614D-12
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The MaxEne Process EffectCase Study #1 - Refinery GM
Comparison
0
200
400
600
800
1000
1200
1400
Feedstock Products Feedstock Products
$M
/yr
Feedstock Export Naphtha Reformate Light Gasoline
Hydrogen LPG Tail Gas
$176M $199M
Existing With MaxEne
MaxEne resulted in $23M/yr incremental gross margin increase
GM increase supports capital investment for MaxEne with simple
payback periods < 3 years
Export Naphtha value increase of $30/MT assumed based on sharing
benefit with Ethylene Cracker
UOP 5614D-13
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Existing w/MaxEne Existing w/MaxEne
KMTA KMTA $M/yr $M/yr
Feed 872 872 654 674
H2 11 9 12 10
Fuel Gas 138 107 36 27
C2= 316 337 462 493
C3= 162 171 243 256
C4s 95 87 89 81
pygas 150 163 135 148
Total 872 872 324 341
GM Increase - 17
The MaxEne Process EffectCase Study #1 - Steam Cracker
Balance
v
+7%
+6%
Increased paraffin content to cracker results in $17M/yr
additional GM with $30/MT
premium on refiner export naphtha price for 500 kmta cracker
(ethylene+propylene).
Pay MaxEne
refiner 4%
premium for
high quality
PC Naphtha
Feedstock to
get 5% GM
increase
UOP 5614D-14
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MaxEne Process Integration Case Study #2Integration with a
Catalytic Reformer
Goal
Maximize yields of catalytic reformate (and hydrogen)
Produce high quality petrochemical naphtha for domestic or
export sales
Basis for integration
Feed is a full range naphtha (FRN). FRN rate allowed to
increase.
MaxEne unit, catalytic reformer and steam cracker yields based
on feed composition
Feed, major products, and by-products included
W. Europe price-set assumed with reformate price based on octane
value
Feed rate to catalytic reformer kept constant and increased.
Catalytic Reformer originally designed for 102 RONC and running
at nameplate conditions
Why was MaxEne considered?
Increase reformate and hydrogen yield
Minimize changes to catalytic reformer
Increase value of export naphtha
UOP 5614D-15
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Existing Refinery Complex
855kMTA
545 kMTA
Yields, kMTA
C2 = 316C3= 162
478
102 RONC
772 kMTA
Cracker
NHTNHT
*328 kMTA
Petrochemical Facility
873kMTA
3.75 Wt-% H2 Yield
32 kMTA
* Purchased naphtha from other refiner
UOP 5614D-16
90.4 Wt-% C5+ Yield
Full rangenaphtha
1400kMTA
CatalyticReformer
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Refinery Complex with MaxEneConstant Reformer Feedrate
Normals
Non-normals
67 kMTA / 82 RONC(light gasoline to
blending)
Catalyticreformer
265 kMTA
748 kMTA
0 kMTA
872 kMTA
855 kMTA
3.46 Wt-% H2 Yield
30 kMTA
Additional FRN required to keep reformer full
DeC6 on MaxEne raffinate to remove Bz pre-cursors from reformer
feed UOP 5614D-17
Full rangenaphtha
1794kMTA
174kMTA
Cracker
Petrochemical Facility
Yields, kMTA
C2 = 347C3= 175
522
102 RONC
789 kMTA
92.4 Wt-%
C5+ Yield
CatalyticReformer
MaxEneUnit
NHTNHT
607 kMTA
681 kMTA
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Refinery Complex with MaxEneConstant Reformer Feedrate
Non-normals
67 kMTA / 82 RONC(light gasoline to
blending)
Catalyticreformer
748 kMTA
0 kMTA
872 kMTA
950 kMTA
3.46 Wt-% H2 Yield
33 kMTA
UOP 5614D-18
Full rangenaphtha
1794kMTA
174kMTA
Cracker
Petrochemical Facility
Yields, kMTA
C2 = 347C3= 175
522
102 RONC
878 kMTA
92.4 Wt-%
C5+ Yield
CatalyticReformer
MaxEne process allows reformer to run at 11% over
existing production rate
95 kMTA
NHTNHT
MaxEneUnit
Normals265 kMTA
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The MaxEne Process EffectCase Study #2 - Refinery Balance
Existing with MaxEne Cases
kMTA kMTA kMTA
Full Range Naphtha 1400 1794 1794
CCR Range Naphtha 95
Export Naphtha 545 872 872
Reformer Feed 855 855 950
Light Gasoline 0 67 67
Reformer Gasoline 772 789 878
Hydrogen 32 30 33
Tail Gas 17 12 13
LPG 34 24 26
Richer feed allowsreformer to run at higher
capacity while still staying within CCR
regenerator capacity,Rx WAIT and heater duty
MaxEne enables:
Production of Light gasoline with 82 RONC
Increase in C5+ gasoline yield at constant octane
Higher quality (higher % paraffin) Petrochemical Naphtha Export
that can command premium pricing
UOP 5614D-19
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The MaxEne Process EffectCase Study #2 - Refinery GM
Comparison
0
200
400
600
800
1000
1200
1400
1600
1800
Feedstock Products Feedstock Products Feedstock Products
$M
/yr
Feedstock Export Naphtha Reformate Light Gasoline
Hydrogen LPG Tail Gas
$208M
$247M$271M
Existing w/MaxEne w/MaxEne w/Max Reformer
MaxEne resulted in $39-63M/yr incremental gross margin
increase
GM increase supports capital investment for MaxEne with simple
payback periods < 2 years
Export Naphtha value increase of $30/MT assumed based on sharing
benefit with Ethylene Cracker UOP 5614D-20
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Existing w/MaxEne Existing w/MaxEne
KMTA KMTA $M/yr $M/yr
Feed 872 872 654 680
H2 11 8 12 9
Fuel Gas 138 103 36 27
C2= 316 347 462 507
C3= 162 175 243 262
C4s 95 83 89 78
pygas 150 156 135 141
Total 872 872 324 344
GM Increase - 20
The MaxEne Process EffectCase Study #2 - Steam Cracker
Balance
v
+10%
+8%
Increased paraffin content to cracker results in $20M/yr
additional GM with $30/MT
premium on naphtha price for 500 kmta cracker
(ethylene+propylene).
Pay MaxEne
refiner 2%
premium for
high quality
PC Naphtha
Feedstock to
get 10% GM
increase
UOP 5614D-21
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Contents
MaxEne Technology Introduction
Market Drivers for MaxEne Projects
MaxEne Case Studies
MaxEne Commercial Experience
UOP 5614D-22
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MaxEne Commercialization Status
First unit to come on-stream in Asia in 2012
Refinery-Petrochemical Integration Application
Licensee is refinery and cracker operator
MaxEne feedrate is 1.2 MMTA (1200 kMTA)
UOP 5614D-23
Ma
xE
ne
fee
dra
te
1.2
MM
TA
Ma
xE
ne
fee
dra
te
1.2
MM
TA
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In Conclusion
European and Asian refiners will need outlet for naphtha as
diesel continues to be transportation fuel of choice.
Over half of the worlds ethylene comes from cracking naphtha
MaxEne can help refiners face the increasing shift towards
diesel by
Maximizing existing catalytic reforming assets
Producing a premium petrochemical naphtha feedstock for sales to
petrochemical producers
MaxEne is an extension of well-proven, reliable commercial
Sorbex technology used in aromatics, refining and detergents
applications.
First commercial unit start-up in 2012 in Asia
UOP 5614D-24
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UOP 5614D-25