KBR Olefins Technology

Solutions –
The Key is Flexibility
Partap Vijay Singh
1st November 2018, Mumbai

© 2018 KBR, Inc. All Rights Reserved

Typical Refinery and Steam
Cracker

FCC Isom Gasoline

Crude Distillate
Oil CDU Hydrotreaters Others Jet / Kero
De- Fuel Oil
Coker
asphalting
Naphtha
LPG

Ethylene
Hot Section Cold Section Propylene
Butadiene
PyGas

© 2018 KBR, Inc. All Rights Reserved

Flexibility is Key for Olefins
Profitability

s Typical project justification uses anticipated feed, product

and utilities pricing as an operating expenses
s Capital investment for an initial period of 2-4 years
AND
– 20 year project life

“There is nothing permanent except Change”

-- Heraclitus
Greek Philosopher
535-475 B.C.
© 2018 KBR, Inc. All Rights Reserved
Flexibility is Key for Olefins
Profitability

s Typical project justification uses anticipated feed, product

and utilities pricing
s Capital investment for an initial period of 2-4 years
AND
– 20 year project life
s Actual experience is that these continuously fluctuate
s Thus, FLEXIBILITY is the key to maintain plant profitability
throughout the project life time
“There is nothing permanent except Change”
-- Heraclitus
Greek Philosopher
535-475 B.C.
© 2018 KBR, Inc. All Rights Reserved
 KBR Technology Portfolio

Refining Ammonia and

• ROSE®
Fertilizers
• KBR-AiMS™ • Ammonia
• VCC™ • Weatherly Nitric Acid
• FCC, MAXOFIN, • Weatherly Ammonium
MAXDIESEL Nitrate
• Hydroprocessing • Weatherly UAN
• Advanced Distillation • Syngas, Coal Gasification Proprietary
• Aromatic Extraction • Hydrogen Equipment
• K-SAAT™, MAX-ISOM
Evaporation • Refining
and • Olefins
Olefins Crystallization • Chemicals
• Ammonia and
• SCORE™ • KBR Ecoplanning
Fertilizers
• K-COT™ • Evaporation and
Acid Treatment Crystallization
• Acid Treatment
• KBR Plinke

Chemicals Automation and

• Phenol/Acetone
Process
• BPA
Technologies
• PCMAX™ • InSite™ Performance
• PVC Monitoring
• Acetic Acid • OTS
• Vinyl Acetate Monomer • OMS
• NExOCTANE™, • Technical Services
NExETHERS™

© 2018 KBR, Inc. All Rights Reserved

KBR Olefins (Ethylene) Experience

• >67 Years Ethylene Experience

1951 - 2018 • First Plant Completed in 1951
• Imperial Chemical Co., Wilton, England

Grassroots • 99 Grassroots Ethylene Facilities

Facilities • Design Feedstocks: Ethane to Heavy Gas Oils

Largest Design • 1800 KTA Ethylene (Ethane Feedstock)

Capacity • GCGV, US Gulf Coast (Completion ~2021)

© 2018 KBR, Inc. All Rights Reserved

 SCORETM Ethylene Technology

Selective Cracking Coil Type Residence SCORE Competitors

Time (sec)
Four pass 0.4 SC-4 Yes
Two pass 0.2 SC-2 Yes
SC-2
One pass 0.1 SC-1 No

SCORETM

Depropanizer-first
Deethanizer-first
Optimum REcovery
© 2018 KBR, Inc. All Rights Reserved
 Typical Steam Cracking Yields
90.0
P/E = 0.025
80.0

70.0

60.0 Ethylene
Propylene
50.0 P/E = 0.348 Mixed C4's
Weight %

Gasoline
40.0 P/E = 0.490 P/E = 0.427
P/E = 0.443
Fuel Gas
P/E = 0.477
30.0 Fuel Oil
Other
20.0

10.0

0.0
Ethane Propane Butane LN FRN AGO
Feed © 2018 KBR, Inc. All Rights Reserved
 Cracking Severity Impact on
Steam Cracking Yields
40.0
P/E = 0.427
P/E = 0.443
35.0
P/E = 0.569
P/E = 0.548 P/E =0.477
30.0
P/E =0.585
Ethylene
25.0 Propylene
Weight %

Mixed C4's
20.0
Gasoline
Fuel Gas
15.0
Fuel Oil
10.0 Other

5.0

0.0
LN LN Low FRN FRN Low AGO AGO Low
© 2018 KBR, Inc. All Rights Reserved
SCORETM Furnace Flexibility

Multi-Feed (Hybrid) Cracking

SCORETM Furnaces
1 2
• Large Capacity
• Single Cabin Firebox
3 4
• 8 individually flow controlled passes
• Number of Feeds only limited by inlet piping
arrangement 5 6

• Each Feed can be cracked at optimum

conditions:
- Temperature 7 8
- S:HC Ratio

Flexibility of 8 mini furnaces within a single firebox

Reference: Lanzhou Petrochemicals, China 2006
© 2018 KBR, Inc. All Rights Reserved
Combined Olefins Process

Recycles

K-COTTM

Other Feeds
(Optional)
R
Tail gas
E
Fresh Feeds C Ethylene
O Propylene
V
Raw C4s
E
R BTX-gasoline
Y
Pyrolysis Fuel oil

Recycles

© 2018 KBR, Inc. All Rights Reserved

K-COTTM TECHNOLOGY
KBR Catalytic Olefins Technology

© 2018 KBR, Inc. All Rights Reserved

Introduction to K-COT™

s K-COT™ is KBR’s Catalytic Olefins Cracking Technology

(FCC) that processes light Olefinic, Paraffinic or mixed
feeds, resulting in high propylene yields with ethylene and
aromatic-rich gasoline by-products.
Typical P/E = 2 (olefinic) or 1 (paraffinic)

High
Feed
Value K-COT™
Flexibility
Products

© 2018 KBR, Inc. All Rights Reserved

K-COTTM Reactor Converter

s Proven FCC-based technology

s Tailored ZSM-5 catalyst maximizes propylene yield
s Simple operation
s Wide feed flexibility

© 2018 KBR, Inc. All Rights Reserved

K-COT Recovery Section

R
E Ethylene
C s Similar to
Propylene
Reactor O
V traditional steam
Effluent Tail gas
E
R
crackers
BTX gasoline
Y
s Removal of trace
impurities from
FCC
s Energy efficient
s Low CAPEX
s Proven technology

© 2018 KBR, Inc. All Rights Reserved

Typical Ultimate Yields from
K-COTTM unit
The overall Olefins yield for ‘K-COT’ unit is around 25% higher than the traditional
Steam Cracker unit & achieving a P/E ~ 1
Paraffinic Feed Olefinic Feed
100

75
Other
Gasoline
50
Propylene
Ethylene

25

0
Steam Catalytic
Cracker Olefins

For Olefinic feed ,the PE~ 2 is achieved while keeping the overall Olefins yield
around 55-60%
© 2018 KBR, Inc. All Rights Reserved
Typical Refinery and Steam
Cracker

FCC Isom Gasoline

P ~ 35%, O ~ 40%
Crude Distillate
Oil CDU Hydrotreaters Others Jet / Kero
De- Fuel Oil
Coker
asphalting P ~ 40%, O ~ 50%

Naphtha
LPG

Ethylene
Hot Section Cold Section Propylene
Butadiene
PyGas

© 2018 KBR, Inc. All Rights Reserved

 Typical Refinery and Steam
Cracker

FCC Isom Gasoline

P ~ 35%, O ~ 40%
Crude Distillate
Oil CDU Hydrotreaters Others Jet / Kero
Non- De- Fuel Oil
traditional: Coker
asphalting P ~ 40%, O ~ 50%

Oxygenates Naphtha
(MeOH, LPG K-COT
EthOH) Recovery
MTO/MTP by-
products
Ethylene é
FT by- Hot Section Cold Section Propylene é
products Butadiene
PyGas

© 2018 KBR, Inc. All Rights Reserved

Combined Olefins Process

C4C5C6NA Recycles

K-COTTM
Other Feeds
(Optional)
R
Tail gas
E
Fresh Feeds C Ethylene
O Propylene
V
Raw C4s
E
R BTX-gasoline
Y
Pyrolysis Fuel oil

C2C3 Recycles

© 2018 KBR, Inc. All Rights Reserved

 $ / Ethylene ton

100
120

0
20
40
60
80
Jan 2006
May 2006
Sep 2006
Jan 2007
May 2007
Sep 2007
Jan 2008
May 2008
Sep 2008
Jan 2009
May 2009
Sep 2009
Jan 2010
May 2010
Sep 2010
Jan 2011
May 2011
Sep 2011
Jan-2012
May-2012
Sep-2012
Margin Improvement for K-COT

Jan-2013
May-2013
Sep-2013
Jan-2014
$58/Ethylene ton Average for Entire Period

May-2014
Integration (vs. Steam Cracker Only)

Sep-2014
Side K-COT Simple Payout < 3 Years

Jan-2015
May-2015
Specific Energy Slightly < Steam Cracker

Sep-2015
Jan-16
May-16
Sep-16
Jan-17
© 2018 KBR, Inc. All Rights Reserved
K-COT Can Simplify Refiners’
Growth to Petrochemicals

s Use of K-COT minimizes investment in downstream units

– Only ethylene and propylene derivatives together with either
aromatics or high-octane gasoline
– All C4’s and light C5/C6NA gasoline can be recycled without
hydrogenation to minimize by-products and enhance light olefins
yields
s Stand-alone K-COT can be economic even for small
naphtha feed quantities or ethylene production rates
s KBR is already working on such projects in China

Lotte Titan K-COT Converter

© 2018 KBR, Inc. All Rights Reserved

Summary - KBR Olefins Technology

Suite of technologies are applicable across a wide range of scenarios:,

including steam cracking, refinery upgrade, MTO/MTP/CTL upgrade,
refinery and petrochemical integration

KBR has much experience in both FCC design and Olefins plant
design

SCORE is a versatile high yield and low CAPEX steam cracking

technology

K-COT is extremely flexible in terms of feed and products, and its

versatility can enhance economic performance of steam crackers and /
or refiners in a number of ways

KBR’s technologies are ideal to enhance margins in integrated refinery

/ petrochemical plants

© 2018 KBR, Inc. All Rights Reserved

Thank You.
Questions?

© 2018 KBR, Inc. All Rights Reserved