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Changing Refinery Configuration Changing Refinery Configuration for Heavy and Synthetic Crude for Heavy and Synthetic Crude
Why Should I Even Think About Why Should I Even Think About Running Synthetics?Running Synthetics?
Oil sands deposits in Western Canada are hugeOil sands deposits in Western Canada are huge–– 1.7 trillion barrels total oil in place1.7 trillion barrels total oil in place–– 174 billion barrels of recoverable oil with 174 billion barrels of recoverable oil with
existing technologyexisting technology–– Cumulative production since 1967 Cumulative production since 1967
only 4 billion barrelsonly 4 billion barrels
Recoverable reserves could Recoverable reserves could increase dramatically with increase dramatically with improved technologyimproved technology
Western Canadian Select (WCS)Western Canadian Select (WCS)Will Become a New Benchmark CrudeWill Become a New Benchmark Crude
Became available in January 2005Became available in January 2005–– Currently at 350 KBPDCurrently at 350 KBPD–– Expected to reach 500 KBPD by 2008Expected to reach 500 KBPD by 2008
Each batch contains:Each batch contains:–– CondensateCondensate–– Hydrotreated synthetic crudeHydrotreated synthetic crude–– Heavy conventional crudeHeavy conventional crude–– Medium conventional crudeMedium conventional crude–– Cold Lake bitumenCold Lake bitumen–– Athabasca bitumenAthabasca bitumen
UOP 4525A-07
BitumenBitumen--derived Crude Composition derived Crude Composition Different from Conventional CrudesDifferent from Conventional Crudes
0%
20%
40%
60%
80%
100%
WTI ArabLight
ANS LloydBlend
BowRiver
DilBit WCS SCO
Resid Vacuum Gas Oil Distillate Naphtha/LPG
0%
20%
40%
60%
80%
100%
WTI ArabLight
ANS LloydBlend
BowRiver
DilBit WCS SCO
Resid Vacuum Gas Oil Distillate Naphtha/LPG
vol-%
UOP 4525A-08
Processing BitumenProcessing Bitumen--derived Crudesderived CrudesAffects All Areas of the RefineryAffects All Areas of the Refinery
Distillate demand growing Distillate demand growing faster than gasoline demandfaster than gasoline demandIncreased dieselization of Increased dieselization of U.S. vehicle fleetU.S. vehicle fleetVGO conversion will shift VGO conversion will shift from FCC to hydrocracking from FCC to hydrocracking for distillate productionfor distillate production
FCC Feed FCC Feed PretreatPretreat Economics Economics Improve as Feed Quality WorsensImprove as Feed Quality Worsens
700700
200200
00BrentBrent Brent +Brent +
Sweet Sweet SynSyn..Blend Blend
Brent +Brent +Sour Sour SynSyn..
BlendBlend
Arab LightArab Light Arab +Arab +Sweet Sweet SynSyn..
BlendBlend
Arab +Arab +Sour Sour SynSyn..
Blend Blend
100100
300300
400400
500500
600600Inc Op Costs, $MM/yrInc Op Costs, $MM/yr ISBL Costs, $MMISBL Costs, $MM NPV, $MMNPV, $MM
UOP 4525A-14
FCC Feed PretreatingFCC Feed Pretreatingis Not Always the Right Solutionis Not Always the Right Solution
FCC capacity still limited by high VGO FCC capacity still limited by high VGO content of bitumencontent of bitumen--derived crudesderived crudesHighHigh--quality distillate fuels quality distillate fuels cannot be produced in an cannot be produced in an FCC unitFCC unit
UOP 4525A-15
Hydrocracking Required to Convert Hydrocracking Required to Convert Incremental VGO and ProduceIncremental VGO and Produce
Right Product MixRight Product MixDieselDiesel
GasolineGasolineUnionfiningUnionfining™™ FCCFCC
DieselDiesel
GasolineGasoline
UnicrackingUnicracking™™
FCCFCC GasolineGasoline
UOP 4525A-16
Is the OnceIs the Once--throughthroughUnicracking Process the Right Choice?Unicracking Process the Right Choice?
Higher yields of naphtha and distillateHigher yields of naphtha and distillate
Flexibility to adjust conversion Flexibility to adjust conversion for seasonal demandfor seasonal demand
UOP 4525A-17
OnceOnce--through Unicracking Process Produces through Unicracking Process Produces FCC Feed with High Hydrogen ContentFCC Feed with High Hydrogen Content
Pretreatment with ULSD ProductionPretreatment with ULSD Production
UOP 4525A-21
Unicracking Process is the Right Unicracking Process is the Right Choice for Converting Choice for Converting
Incremental VGOIncremental VGOOptimizes FCC feed hydrogen contentOptimizes FCC feed hydrogen contentProduces highProduces high--quality distillate fuels to meet quality distillate fuels to meet growing demandgrowing demandDiesel produced can meet all ULSD specsDiesel produced can meet all ULSD specsProduct slate can be seasonally adjustedProduct slate can be seasonally adjustedSmall incremental capital cost to upgrade from Small incremental capital cost to upgrade from FCC feed pretreating to Unicracking processFCC feed pretreating to Unicracking process
UOP 4525A-22
SummarySummary
BitumenBitumen--derived crudes will be an increasing derived crudes will be an increasing crude component for northern US refinercrude component for northern US refinerSignificant processing implications will Significant processing implications will prompt both resid and VGO prompt both resid and VGO hydroprocessing conversionhydroprocessing conversion‘‘IntelligentIntelligent’’ hydroprocessing hydroprocessing solutions will be required to solutions will be required to cost effectively accomplish the cost effectively accomplish the upgrading of synthetic crudes. upgrading of synthetic crudes.