Global drivers and process innovation for
‘unconventional’ conversions
Mark Howard, VP Conversion Technology Centre
September 25th 2014
Hull Research & Technology Centre
- a history of new process development
Acetic acid
/anhydride
CATIVATM
Acetic acid
SaaBreTM
acetic acid
Fixed bed VAM
enhancement
LEAPTM
fluid bed VAM
HummingbirdTM
ethylene
FT
pilot work
AVADATM
ethyl acetate
Biobutanol
demonstration
(with Dupont)
Specialty
processes
1990s
2000s
2010s
2
2
Global drivers for ‘inter-value’ chain
conversion opportunities
Globally high crude oil
and product prices
..strong diesel growth
..fuel oil in steep decline
3
Global drivers for ‘inter-value’ chain
conversion opportunities
Low cost
natural gas
Globally high crude oil
and product prices
..strong diesel growth
..fuel oil in steep decline
4
Global drivers for ‘inter-value’ chain
conversion opportunities
Low cost
natural gas
Indigenous
coal
Globally high crude oil
and product prices
..strong diesel growth
..fuel oil in steep decline
5
Global drivers for ‘inter-value’ chain
conversion opportunities
Low cost
natural gas
Residue
upgrading
incentives
Indigenous
coal
Globally high crude oil
and product prices
..strong diesel growth
..fuel oil in steep decline
6
Global drivers for ‘inter-value’ chain
conversion opportunities
Low cost
natural gas
Biofuels
mandates
Indigenous
coal
Globally high crude oil
and product prices
..strong diesel growth
..fuel oil in steep decline
7
Global drivers for ‘inter-value’ chain
conversion opportunities
Low cost
natural gas
Biofuels
mandates
Indigenous
coal
Low cost
biomass
Globally high crude oil
and product prices
..strong diesel growth
..fuel oil in steep decline
8
Global drivers for ‘inter-value’ chain
conversion opportunities
Low cost
natural gas
Biofuels
mandates
Indigenous
coal
Waste
incentives
Low cost
biomass
Globally high crude oil
and product prices
..strong diesel growth
..fuel oil in steep decline
9
Veba Combi-Cracking (VCCTM)
Hydrogen
Additive
Naphtha
(S<1ppm)
Hydrogen recycle
Resid/Pet Coke
Slurry Phase
Hydrocracker
Hot Separator
< 5% Residue
Heavy Oil
Trickle Bed
Hydrotreater /
cracker
Distillation
Diesel
(S<10ppm,
cetane >45)
Vacuum Gas Oil
(S<100ppm, <1ppm
metals)
Disposal
•
•
•
•
High overall conversion of >95% (+525oC material). Asphaltenes
conversion is typically >90%
Simple flow sheet with conventional refinery equipment.
Technology uses a low cost additive rather than a catalyst;
BP estimates that VCCTM Technology will outperform delayed
cokers when benchmark crude prices exceed $50 per barrel
10
Yulin VCCTM plant
Shaanxi Yanchan Petroleum Group (YCPC)
11
Fischer Tropsch
STANDARD
FUEL
Natural Gas
Coal
Tails Gas Recycle
Syngas
Generation
Hydrogen
Fischer-Tropsch
Syngas
Conversion
UPGRADING
Hydrotreater /
cracker
CHEMICALS
ALTERNATIVES
20%
Naphtha
80%
Diesel
Resid / Pet
Coke
Offsites & Utilities (including air separation unit)
Biomass
Provides a low risk, competitive technology
•
Reforming, Gasification and ASU are all widely deployed and practised
•
BP’s FT conversion is performed using a standard fixed bed multitubular reactor.
Proven catalyst with more than 16,000 hrs operational experience
•
BP Product Upgrading uses commercially-available catalyst, leveraging BP’s
significant operational know-how in hydrocracking
12
Nikiski FT 300bbl per day demonstration plant
13
HummingbirdTM
Ethanol dehydration technology
Widely
available
BP proprietary
technology
Recycle
Ethanol
Reactor
(bio/chemical/
hydrous/
anhydrous)
Separator
Aqueous waste
Purification
Polymer
grade
ethylene
Organic waste
The HummingbirdTM process has the following advantages over existing
technologies:
•
Lower temperature and high selectivity catalyst gives ultra-selective carbon
conversion and overall yields
•
No catalyst regeneration
•
Lower CAPEX and OPEX than competing technologies
14
HummingbirdTM pilot plant
15
…so what about Europe?
• Basic chemicals increasingly challenged by feedstock costs….
• ..but look out for ‘unconventional’ and ‘renewable’ opportunities
• Providing technology solutions across the world, with ongoing
support….
• ..but we will need to compete through innovation
• Not just ‘brand new’ ideas, sometimes ‘old’ ideas in a changed
environment
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