CAPTURING VALUE THROUGH FCC-PT/FCC UNIT INTEGRATION Kevin Carlson Todd Foshee Global Application Manager for FCC Licensing Technology Naphtha & VGO Manager Cautionary note The companies in which Royal Dutch Shell plc directly and indirectly owns investments are separate legal entities. In this presentation “Shell”, “Shell group” and “Royal Dutch Shell” are sometimes used for convenience where references are made to Royal Dutch Shell plc and its subsidiaries in general. Likewise, the words “we”, “us” and “our” are also used to refer to Royal Dutch Shell plc and subsidiaries in general or to those who work for them. These terms are also used where no useful purpose is served by identifying the particular entity or entities. ‘‘Subsidiaries’’, “Shell subsidiaries” and “Shell companies” as used in this presentation refer to entities over which Royal Dutch Shell plc either directly or indirectly has control. Entities and unincorporated arrangements over which Shell has joint control are generally referred to as “joint ventures” and “joint operations”, respectively. Entities over which Shell has significant influence but neither control nor joint control are referred to as “associates”. The term “Shell interest” is used for convenience to indicate the direct and/or indirect ownership interest held by Shell in an entity or unincorporated joint arrangement, after exclusion of all third-party interest. This presentation contains forward-looking statements (within the meaning of the U.S. Private Securities Litigation Reform Act of 1995) concerning the financial condition, results of operations and businesses of Royal Dutch Shell. All statements other than statements of historical fact are, or may be deemed to be, forward-looking statements. Forward-looking statements are statements of future expectations that are based on management’s current expectations and assumptions and involve known and unknown risks and uncertainties that could cause actual results, performance or events to differ materially from those expressed or implied in these statements. Forward-looking statements include, among other things, statements concerning the potential exposure of Royal Dutch Shell to market risks and statements expressing management’s expectations, beliefs, estimates, forecasts, projections and assumptions. These forward-looking statements are identified by their use of terms and phrases such as “aim”, “ambition’, ‘‘anticipate’’, ‘‘believe’’, ‘‘could’’, ‘‘estimate’’, ‘‘expect’’, ‘‘goals’’, ‘‘intend’’, ‘‘may’’, ‘‘objectives’’, ‘‘outlook’’, ‘‘plan’’, ‘‘probably’’, ‘‘project’’, ‘‘risks’’, “schedule”, ‘‘seek’’, ‘‘should’’, ‘‘target’’, ‘‘will’’ and similar terms and phrases. There are a number of factors that could affect the future operations of Royal Dutch Shell and could cause those results to differ materially from those expressed in the forward-looking statements included in this [report], including (without limitation): (a) price fluctuations in crude oil and natural gas; (b) changes in demand for Shell’s products; (c) currency fluctuations; (d) drilling and production results; (e) reserves estimates; (f) loss of market share and industry competition; (g) environmental and physical risks; (h) risks associated with the identification of suitable potential acquisition properties and targets, and successful negotiation and completion of such transactions; (i) the risk of doing business in developing countries and countries subject to international sanctions; (j) legislative, fiscal and regulatory developments including regulatory measures addressing climate change; (k) economic and financial market conditions in various countries and regions; (l) political risks, including the risks of expropriation and renegotiation of the terms of contracts with governmental entities, delays or advancements in the approval of projects and delays in the reimbursement for shared costs; and (m) changes in trading conditions. No assurance is provided that future dividend payments will match or exceed previous dividend payments. All forward-looking statements contained in this [report] are expressly qualified in their entirety by the cautionary statements contained or referred to in this section. Readers should not place undue reliance on forward-looking statements. Additional risk factors that may affect future results are contained in Royal Dutch Shell’s 20-F for the year ended December 31, 2018 (available at www.shell.com/investor and www.sec.gov ). These risk factors also expressly qualify all forward looking statements contained in this presentation and should be considered by the reader. Each forward-looking statement speaks only as of the date of this presentation, 19 September 2019. Neither Royal Dutch Shell plc nor any of its subsidiaries undertake any obligation to publicly update or revise any forward-looking statement as a result of new information, future events or other information. In light of these risks, results could differ materially from those stated, implied or inferred from the forward-looking statements contained in this presentation. We may have used certain terms, such as resources, in this presentation that United States Securities and Exchange Commission (SEC) strictly prohibits us from including in our filings with the SEC. U.S. Investors are urged to consider closely the disclosure in our Form 20-F, File No 1-32575, available on the SEC website www.sec.gov. 2 Speakers Kevin Carlson Todd Foshee Global Application FCC Licensing Manager for Naphtha & Technology Manager VGO Shell Catalysts & Shell Catalysts & Technologies Technologies 3 FCC-PT–FCC integration Isomerisation Reformer NHT CDU Gasoline DHT HCU Alkylation FCC-PT FCC Distillates VDU Coker SDA Resid F.O and asphalt 4 FCC-PT–FCC integration Isomerisation Reformer NHT CDU Gasoline DHT HCU Alkylation FCC-PT FCC Distillates VDU Coker SDA Resid F.O and asphalt 5 FCC-PT–FCC integration CDU NHT Isomerisation Improved refinery profitability Reformer DHT Longer unit cycle lives HCU Reduced operating costs Alkylation Greater reliability FCC-PT FCC VDU Coker SDA Resid Consideration of the constraints and objectives of downstream units is critical 6 Outline ■ About us ■ The continued need for performance gains ■ The importance of FCC-PT/FCC integration ■ Latest-generation FCC-PT catalyst: CENTERA GTTM ■ FCC technology portfolio ■ Key takeaways 7 Our history Strong individually. Stronger together. ■ Three respected brands, each with ■ As one, we’re able to better serve our value-adding solutions, technologies, and customers and create new opportunities for services. an evolving industry. 8 Our future Strong individually. Stronger together. Our Purpose: We exist to enable our industry to provide more and cleaner energy solutions for today and for the future. 9 Shell’s experience as an owner/licensor/technology provider Ghent, Belgium Michigan City, USA Sales and technical service office Shell Technology Centre Amsterdam, the Netherlands Manufacturing facility London, UK Moscow, Russia Edmonton, Canada R&D site CRI Leuna, Germany Port Allen, USA Shell Martinez catalyst plant, USA The Hague, the Netherlands Shanghai, China Shell Catalysts & Technologies HQ, Houston, USA Pittsburg, USA Shell Technology Centre Houston, USA Beijing, China Dubai, UAE Shell Technology Centre Bangalore, India Singapore 10 Shell has unparalleled FCC experience spanning over 70 years as an owner, operator and licensor As an owner and operator 1300 unit-years of operational experience >350 FCC shutdowns 70 years of R&D with continuous learnings and design improvements As a licensor >65 FCC revamps since 1980 >75 TSS (new/revamped) since 1969 33 grassroots FCC units 11 FCC-PT/FCC integration has never been more important There are over 400 FCC operations worldwide processing >17 million bpd of feed with 60–70% pretreating their feed with an FCC unit Ageing assets Declining FCC feed quality Low-sulphur gasoline mandates IMO 2020 Petrochemicals Reliability 12 Identifying your objectives and constraints What current or expected operational constraints are you seeing in your FCC-PT operations? What are your main goals on the FCC unit (gasoline, LCO, propylene, etc.)? When forecasting FCC-PT impact from operating changes, what are the implications for the FCC? What current or expected operational constraints are you seeing in your FCC operations? 13 Three key levers for FCC-PT optimisation The FCC-PT unit’s goals HDS, HDN, HDPNA, Combo Mode Temperature profiles Catalyst selection ■ Decrease the FCC’s constraints ■ Increase FCC profitability ■ Decrease FCC emissions Knowledge of, and communication with, the FCC process and the post-treat process is also key 14 Conversion FCC-PT/FCC: The interaction N, M, C, A Reactor Emission T s S, N Coke Dry gas production C, A, Sulfur Nitrogen M REACTOR Regen Metals T Carbon REGENERATO R RISE R FRACTIONATOR Aromatics M AIR BLOWER Cat circulation C, A API of LCO+ products C, A Sulfur, Nitrogen, Aromatics in products S, N, A 15 FCC-PT/FCC: The interaction Reactor Emission T s S Sulfur REACTOR Regen T REGENERATO R RISE R FRACTIONATOR AIR BLOWER Sulfur, Nitrogen, Aromatics in products S 16 Conversion FCC-PT/FCC: The interaction N Reactor Emission T s S, N Sulfur Nitrogen REACTOR Regen T REGENERATO R RISE R FRACTIONATOR AIR BLOWER API of LCO+ products Sulfur, Nitrogen, Aromatics in products S, N 17 Conversion FCC-PT/FCC: The interaction N, M Reactor Emission T s S, N Dry gas production Sulfur M Nitrogen REACTOR Regen Metals T REGENERATO R M AIR BLOWER RISE R FRACTIONATOR API of LCO+ products Sulfur, Nitrogen, Aromatics in products S, N 18 Conversion FCC-PT/FCC: The interaction N, M, C Reactor Emission T s S, N Coke Dry gas production C Sulfur Nitrogen M REACTOR Regen Metals T Carbon REGENERATO R RISE R FRACTIONATOR M AIR BLOWER Cat circulation C API of LCO+ products C Sulfur, Nitrogen, Aromatics in products S, N 19 Conversion FCC-PT/FCC: The interaction N, M, C, A Reactor Emission T s S, N Coke Dry gas production C, A, Sulfur Nitrogen M REACTOR Regen Metals T Carbon REGENERATO R RISE R FRACTIONATOR Aromatics M AIR BLOWER Cat circulation C, A API of LCO+ products C, A Sulfur, Nitrogen, Aromatics in products S, N, A 20 FCC-PT technology advances – NiMo ■ Highest activity ■ Type II catalyst ■ Global success ■ Broad application ■ Type II catalyst ■ Proven exceptional stability ■ Mixed Type I / Type II catalyst 21 CENTERA GT DN-3655 is designed to improve FCCU feed quality Significant HDN activity increase ■ HDN: >25% increase Boost in HDS activity ■ HDS: up to a 15% increase Improvement in hydrogenation ■ Increased delta-gravity ■ Increased HDPNA saturation Robust applicability ■ Wide feed property range: ■ HSRGO, VGO, HVGO, HKGO ■ High endpoint feeds Performance in medium- and high-pressure operations with challenging feed 22 FCC-PT technology advances – CoMo ■ Highest HDS activity ■ Near NiMo level of HDN ■ Type II catalyst ■ ■ ■ ■ Highest HDS activity Minimum H2 consumption Low press stability Type II catalyst 23 CENTERA GT DC-2655 and CENTERA GT DC-2656 are designed to enhance HDN and HDS performance Significant HDN activity increase ■ DC-2655 HDN: 105–110 RVA [DC-2650=100] ■ DC-2656 HDN: 120–130 RVA (near DN-3651 performance!) Step out HDS activity! ■ DC-2655 and DC-2656 HDS: 120 RVA [DC-2650=100] Robust applicability ■ Wide feed property range: ■ HSRGO, VGO, HVGO, HKGO ■ High endpoint feeds Performance in low- and medium-pressure operations 24 FCC-PT application covers a wide range of operations 25 What is the measure of FCC-PT performance? Operational reliability and feed flex Performance and cycle life ■ Metals capacity vs activity ■ FCC constraints and capabilities ■ Pressure drop vs. activity ■ Hydrogen optimisation ■ Feed flex and swing cuts ■ Cycle life objectives (time, ■ Current HDS targets (SOx, products) ■ Protection from process upsets sulphur, nitrogen, ASAT) ■ MHC (distillate vs mogas yields) ■ Reactor internals and other technology enablers Commercial balance ■ Fill cost sensitivities ■ Stacking (SENTRY, low cost, regen, rejuv) 26 The FCC-PT/FCC integrated solutions We use various tools, techniques, technologies and tactics to help you achieve your objectives HTU reactor internals Frac-tionati on Feed assessmen t Catalyst technology FCC-PT fouling abatement Revamp options Desired product yields Training FCC internals Diagnosis Kinetic models SENTRY Protection 27 FCC units supported by Shell THIRD-PARTY SHELL Deer Park (VGO) Convent (VGO) Puget Sound (VGO) Martinez (VGO) Sarnia (VGO) Pernis (VGO) Norco (Resid) (>2 CCR) TSA WITH SOME SHELL OWNERSHIP • • YOKKAICH SEIBU TOA • SAPREF Raizen • • MIRO PCK • Essar • Equinor • Reliance • Hyundai Oilbank • Petrovietnam • Geelong • Pertamina • Port Dickson • Sriracha • PTT • Orpic • Sonaref • Tupras (2) • Cardon Amuay El Palito CHEMICALS FLUIDIZED • Ecopetrol BED CLIENT • SADAF Petrotrin 28 • Isla Pilot plant, modelling and training offerings Our proven skillset is currently serving Shell’s eight FCCUs, as well as various third-party sites, through a broad range of capabilities such as: Technical support and diagnosis SHARC process modeling Hardware design CFD modeling Pilot plant testing Feed nozzle testing/design Training 29 Diagnosing tools FCC feed impact matrix FCC constraints matrix 30 Shell Catalysts & Technologies licensed FCC hardware 31 Shell Catalysts & Technologies licensed FCC hardware alternate view Regenerator vessel Integrated TSS when plot space is limited Reactor vessel Integrated TSS 32 Shell has operated, developed and continuously improved its revolutionary FCC feed injection nozzles over the last 30 years Improved atomisation – For increased conversion, enhanced feed flexibility and high reliability Benchmarked in both cold flow High frequency opportunity (every 1–2 turnarounds) Low capital revamp (STCH feed atomization pilot plant) and operating units 33 Validated yield benefits to Shell Feed Nozzles Yield shifts – Normalized for feedstock properties and operating conditions Yield shifts, Lvol.% Audited ■ Incremental conversion exceeded expectations (all Conversion 1.1 Bottoms (1.2) Dry gas + Coke 0.4 Gasoline + LCO 1.5 LPG + Gasoline 0.9 Total liquid product 0.2 from bottoms) ■ More gasoline but less LPG contributing towards less total liquid yield than forecasted 34 Shell cyclone systems are designed for reliability, performance and ease of maintenance Cyclones were a major cause of unplanned shutdowns and slowdowns in the 1980s – an R&D program helped reduce shutdowns by 90% in eight years Standard Shell design cyclones (Rg/Rx side) Close-coupled Shell cyclones (Rx side) ■ Proven design ■ First to implement close-coupled cyclones in ■ Vortex stabilizer ■ Gas outlet tube ■ Coke catcher ■ Higher separation efficiency than conventional cyclones 1955 (Anacortes, WA USA) ■ Minimum post riser cracking for minimum HC presence in reactor vessel, minimum coke formation and dry gas ■ Easy access for maintenance 35 Shell is a leader in flue gas technology (TSS) Shell is the original inventor and the leading <50 mg/Nm provider of TSS technology typical particulate emission 3 Proprietary swirl tube plus 76 units worldwide 56 years experience regenerator cyclone protects downstream equipment 36 Shell Third Stage Separator (TSS) & Fourth Stage Separator (FSS) 37 SHARC: Shell’s FCC process model ■ Used in approx. 50 refineries ■ Extensively validated against commercial FCC/RFCC test data ■ Integrates with FCC/RFCC on-line optimization system and refinery planning and scheduling tools Key differentiators ■ Accuracy ■ Easy interface ■ Quick response ■ Versatile projection capability ■ Unit monitoring and data normalization Demonstrated improvement in profitability by 0.10–0.50 US$ per barrel through improved unit operation and catalyst selection validation 38 Commercially proven technology – Shell Deer Park FCC unit 39 FCC Technology translated into refinery success ▪ Can be taken advantage of if properly planned for Feed properties Unit operation Catalyst selection Reliable design Just because the FCC can process something, does not mean it is economical Can most often be leveraged via feed flexibility ▪ Understand long-term E&S drivers, and crude purchasing plan ▪ Stay abreast of FCCU constraints ▪ Monitor unit performance and adjust LP HT of FCCU feed helps improve conversion on the FCC, but must be mindful of unit constraints 40 What does a successfully integrated FCC-PT/FCC solution look like? Feed flexibility ■ Greater aromatic Change FCC-PT run length ■ reduction at SOR ■ Be careful to avoid ■ reducing the overall coke yield too much ■ Economic evaluation is Improve product properties and reduce emissions ■ Tier III – Increased key severity can enable SHARC FCC process model higher-sulfur crudes to quantify FCC yields ■ Higher octane – Catalyst additions or Potentially allows for Consideration of FCC improved feeds can help higher ROT and reduces constraints is key mitigate worsening feed post-treating quality for extended runs requirement ■ 41 Proof point: Leveraging high severity on the CFH – Shell refinery API gravity Sulfur (ppm) CFH product (previous cycle) CFH product (current cycle) 19.3 21.2 2000 Total nitrogen (ppm) 2800 2000 2340 Basic nitrogen (ppm) 900 Total arom (wf%) 15.7 13.5 CCU conv (%) 73.2 74.2 HTU reactor internals Frac-tionati on Feed assessmen t Catalyst technology FCC-PT fouling abatement Revamp options 680 Desired product yields Training FCC internals Diagnosis Kinetic models SENTRY protection 42 Proof point: Increasing FCC-PT severity – Third-party refiner ■ Upgrading catalyst on the CFH allowed the refiner to blend ~2 wt.% of SR into the FCC feed diet ■ Re-route slip stream of SR from coker to FCC ■ FCCU conversion for feed with SR was expected to be lower compared to base – however, new Shell feed FCCU nozzles allowed ~0.5 wt.% conversion pt. to be regained, at low incremental cost Feed assessmen t Catalyst technology FCC internals Diagnosis Kinetic models delivered Training FCC-PT fouling abatement Revamp options Desired product yields Value HTU reactor internals Frac-tionati on SENTRY protection $5.5 million 43 Looking forward: Crude oil to chemicals ■ Increase severity on FCC-PT by changing catalyst, added Reactor volume, etc. ■ Upgrade FCC feed nozzles, and move to close coupled cyclones ■ Tune SHARC model, optimize FCC catalyst (more activity, less coke selective) ■ Upgrade to HiFi trays on the deeth/deprop/debut HTU reactor internals Frac-tionati on Feed assessmen t Catalyst technology FCC-PT fouling abatement Revamp options Desired product yields Training FCC internals Diagnosis Kinetic models SENTRY protection 44 Looking Forward: Processing difficult feeds ■ Add more demet capability and increase severity ■ Upgrade FCC feed nozzles, add PentaFlow baffles, upgrade cyclones matrix, metal trapping, activity) ■ Upgrade post-treat to meet sulphur specs, etc HTU reactor internals Frac-tionati on ■ Tune SHARC model, optimize FCC catalyst (more Feed assessmen t Catalyst technology FCC-PT fouling abatement Revamp options PentaFlow Desired product yields Training FCC internals Diagnosis Kinetic models SENTRY protection 45 Key takeaways 1 Substantial collaborative gains realized when considering the FCC-PT and FCC units as an integrated operation. 2 Capturing maximum margin across the refinery requires a highly customised approach that carefully takes into account your specific constraints and objectives, including those of the downstream units. 3 Shell has unparalleled FCC and FCC-PT experience spanning over 70 years as an owner, operator and licensor, and provides… ■ leading-edge FCC-PT catalysts, reactor internals and services, and ■ FCC hardware, modeling and services …to help operators capture maximum value. 46 47
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