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TRANSCRIPT
Management PresentationJanuary 14, 2008
Refining 101: Refinery Basic OperationsRefining 201: Solvent Deasphalting and Reformers/CCRs
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Disclaimer Statement
The information contained within has been obtained from various sources; we do not represent that this information (including, but not limited to, prices, quotes and statistics) is complete or accurate and it should not be relied upon as such. All information is subject to change without notice. This document is provided for informational purposes only and should not be regarded as an offer to sell or as a solicitation of an offer to buy any product to which this information relates.
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Safe Harbor Statement
Statements contained in this presentation that state the Company's or management's expectations or predictions of the future are forward–looking statements intended to be covered by the safe harbor provisions of the Securities Act of 1933 and the Securities Exchange Act of 1934. The words "believe," "expect," "should," "estimates," and other similar expressions identify forward–looking statements. It is important to note that actual results could differ materially from those projected in such forward– looking statements. For more information concerning factors that could cause actual results to differ from those expressed or forecasted, see Valero’s annual reports on Form 10-K and quarterly reports on Form 10-Q, filed with the Securities and Exchange Commission, and available on Valero’s website at www.valero.com.
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Rich MarcoglieseValero Energy CorporationExecutive Vice President &
Chief Operating Officer
Refining 101: Refinery Basic Operations
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Crude Oil Characteristics
Crudes are classified and priced by density and sulfur contentCrude density is commonly measured by API gravity• API gravity provides a relative measure of crude oil density • The higher the API number, the lighter the crude
−
Light crudes are easier to process −
Heavy crudes are more difficult to process
Crude sulfur content is measured as a percentage• Less than 0.7% sulfur content = sweet• Greater than 0.7% sulfur content = sour• High sulfur crudes require additional processing to meet regulatory specs
Acid content is measured by Total Acid Number (TAN)• Acidic crudes highly corrosive to refinery equipment• High acid crudes are those with TAN greater than 0.7
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Crude Oil Basics
Majority of global reserves are light/medium sourMost quoted benchmark prices are light sweet crudes
• WTI (West Texas Intermediate), Western Hemisphere• Brent (North Sea Crude), Europe
Historical trend shows global crude supply becoming heavier and more sour
Estimated Quality of Reserves (2006)
13%
20%
66%
2%
High Acid(Sweet)
Source: Oil & Gas Journal, Company Information
Light/MediumSour
HeavySour
Sweet
SWEE
T
SU
LFU
R C
ON
TEN
T
S
OU
R
HEAVY API GRAVITY LIGHT
Crude Quality by Types
Source: Industry reportsNOTE: Red line represents the average crude quality by decade (actual and projected)
Arab Heavy
Arab Medium
Arab Light
Alaskan North Slope
Iran Heavy
DubaiMars
TapisWTIBrent
Bonny LightCabinda
Napo
Cold Lake
WCSMaya
Ameriven-Hamaca
M-100 (resid)
1980
19902000
2010Urals
Cerro Negro
0.0%
0.5%
1.0%
1.5%
2.0%
2.5%
3.0%
3.5%
4.0%
15 20 25 30 35 40 45 50
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What’s in a Barrel of Crude Oil?
48%
26%
24%
2%
63%
21%
15%1%
35%
30%
32%
3%> 34 API Gravity
< 0.7 % Sulfur
35% Demand
Most Expensive
24 – 34 API Gravity
> 0.7 % Sulfur
50% Demand
Less Expensive
< 24 API Gravity
> 0.7 % Sulfur
15% Demand
Least Expensive
Refineries upgrade crude oil to higher value products
2006 U.S. Production
8% Propane/Butane
49%
GasolineRFGConventionalCARBPremium
33% DistillateJet FuelDieselHeating Oil
Heavy Fuel Oil & Other
10%
Source: EIA Refiner Production
Refinery Gases8%
Light Sweet Crude(e.g. WTI, LLS, Brent)
Medium Sour Crude(e.g. Mars, Arab Light,Arab Medium, Urals)
Heavy Sour Crude(e.g. Maya, Cerro Negro, Cold
Lake, Western Canadian Select)
Crude Types Characteristics Yields
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Basic Refining Concepts
DistillationTower
(CrudeUnit)
Propane, Butane and lighter
• Refinery fuel gas • Propane• NGLs
< 90°F
Straight Run Gasoline (low
octane)• Gasoline (high octane)
90–220°F
Naphtha • Gasoline (high octane)• Jet fuel
220–315°F
Kerosene• Kerosene • Jet fuel• Diesel • Fuel oil
315–450°F
Light Gas Oil• Gasoline (high octane)• Diesel• Fuel oil
450–650°F
Heavy Gas Oil650–800°F
Resid, Pitch800+°F
Furnace
VacuumUnit
More
• Gasoline (high octane)• Diesel• Fuel oil
• Gasoline (high octane)• Diesel• Heavy Fuel Oil, Asphalt• Lube stocks
Intermediates Final Products
processing
More
processing
More
processing
More
processing
More
processing
More
processing
Crude oil
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Hydroskimming/Topping Refinery
LightSweetCrude
100% Total Yield
Heavy Fuel Oil & Other
30%GasolineRFGConventionalCARBPremium
Simple, low upgrading capability refineries run sweet crude
Propane/Butane
Hydrogen
Crude Unit
Vacuum Unit
Reformer
Propane/Butane
High Octane Gasoline
Heavy Fuel Oil / Resid
LS Diesel/Heating Oil
Distillate Desulfurizer
HS Diesel/Heating Oil
HS Kerosene/Jet Fuel
Gas Oil
4%
32%
34%DistillateDieselHeating OilJet Fuel
Dis
tilla
tion
Tow
er
Low Octane Gasoline and Naphtha
LS Kerosene/Jet Fuel
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Medium Conversion: Catalytic Cracking
Moderate upgrading capability refineries tend to run more sour crudes while achieving increased higher value product yields and volume gain
Hydrogen
Light Cycle Oil (LCO)
Crude Unit
Vacuum Unit
Reformer
Alkylation Unit
Propane/Butane
High Octane Gasoline
Heavy Fuel Oil / Resid
FCC Gasoline
Alkylate
Distillate Desulfurizer
HS Diesel/Heating Oil
HS Kerosene/Jet Fuel
Gas OilFluid Catalytic Cracker (FCC)
104% Total Yield
Heavy Fuel Oil & Other24%
Dis
tilla
tion
Tow
er
Propane/Butane8%
27%DistillateDieselHeating OilJet Fuel
45%GasolineRFGConventionalCARBPremium
LightSour
Crude
Low Octane Gasoline and Naphtha
LS Kerosene/Jet Fuel
LS Diesel/Heating Oil
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Medium Conversion: Catalytic Cracking/Deasphalting
Improved upgrading capability allows refiner to run heavier crudes while achieving increased higher value product yields and volume gain
Hydrogen
Light Cycle Oil (LCO)
Crude Unit
Vacuum Unit
Reformer
Alkylation Unit
Propane/Butane
High Octane Gasoline
Heavy Fuel Oil /
FCC Gasoline
Alkylate
Distillate Desulfurizer
HS Diesel/Heating Oil
HS Kerosene/Jet Fuel
Gas OilFluid Catalytic Cracker (FCC)
PitchSolvent
Deasphalting
105% Total Yield
Heavy Fuel Oil & Other
11%
Dis
tilla
tion
Tow
erPropane/Butane9%
56%GasolineRFGConventionalCARBPremiumLight/
MediumSour
Crude 29%DistillateDieselHeating OilJet Fuel
Low Octane Gasoline and Naphtha
LS Kerosene/Jet Fuel
LS Diesel/Heating Oil
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High Conversion: Coking/Resid Destruction
Complex refineries can run heavier and more sour crudes while achieving the highest light product yields and volume gain
108% Total Yield
Heavy Fuel Oil & Other
15%
Propane/Butane
7%
28%DistillateJet FuelDieselHeating Oil
58%GasolineRFGConventionalCARBPremium
Hydrogen
LCO
Reformer
Medium Gas Oil
Propane/Butane
High Octane
Heavy Fuel Oil
FCC Gasoline
Kerosene
Alky Gasoline
Hydrogen Plant
Coke
Gas
Diesel
Kerosene/Jet Fuel
Diesel/Heating Oil
Low Octane Gasoline
DelayedCoker
Fluid Catalytic Cracker (FCC)
Alkylation Unit
DistillateDesulfurizer
Crude Unit
Vacuum Unit
Light Gas Oil Hydrocrackate Gasoline
Ultra Low Sulfur Jet/Diesel
Hydrocracker
Medium/ Heavy Sour
Crude Dis
tilla
tion
Tow
er
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Conversion Economics
Need conversion capacity to capitalize on sour crude discounts• Hydroskim – Breakeven or moderate margins; High resid yield
−
When margins are positive – increase crude runs−
When margins are negative – decrease crude runs• Cracking – Better margins; Lower resid yield• Coking – Best margins; Lowest resid yield
−
Maximize heavy crudes
U.S. Gulf Coast Refinery Margins
(10)
(5)
0
5
10
15
20
25
30
Jan-00 Jan-01 Jan-02 Jan-03 Jan-04 Jan-05 Jan-06 Jan-07
U S
$ / B b
l
Arab Medium Hydroskimming LLS Cracking Maya Coking
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Comparison of Conversion Capacity
Valero is an industry leader in upgrading capacityValero’s upgrading capacity provides superior operational flexibilitySignificant capital investment and long lead time required to add conversion capacity
0
200
400
600
800
1,000
1,200
1,400
1,600
1,800
VLO XOM COP BP RDS CVX MRO SUN TSO
Cat Cracking
Hydrocracking
Coking
U.S. Conversion Capacity1MBPD
Source: Oil & Gas Journal, Company Websites 1 Conversion Capacity = Sum of Coking, Hydrocracking and Cat Cracking Capacity
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Deasphalting Basics
Deasphalting is a solvent extraction process• Original application in lubes feedstock preparation• Expanded to recover cat cracker feed from vacuum resid
Vacuum resid feed yields Deasphlated Oil (DAO) and Asphaltenes(Pitch or DAU Rock)
Solvent Extraction differentiates by solubility differences while Distillation by boiling points
Solvents used are propane, butane, and pentane• Heavier the solvent, the more extraction (pentane allows for “deepest”
extraction)• Heavier solvent, higher operating costs for solvent recovery
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Naphtha Reforming Basics
Reformers improve the octane of naphtha making it a higher valuegasoline blending componentReformers produce large amounts of hydrogen (H2) which supports the desulfurization process in hydrotreaters and hydrocrackersReforming employs precious metals catalystCoke formation on catalyst as a byproduct requires burn-off
HydrotreatedNaphtha
(50-60 octane)
Reformate/Aromatics
(96-102 octane)
Hydrogen Fuel Gas/LPG
ReactorReactor Gas SeparationGas Separation StabilizerStabilizer
Regenerator (CCR)
Regenerator (CCR)
50 to 500 PSI950 to 1000 °F
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FiredHeater
StackedReactor
Structure
Reformer Units
Corpus Christi CCRBenicia Cyclic (Fixed-Bed)
Fixed-BedReactor
Structure
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Map of Valero Refineries
Valero Marketing Presence
Quebec, Canada• 215,000 bpd capacity
Three Rivers, Texas• 100,000 bpd capacity
Corpus Christi, Texas• 340,000 bpd capacity
Wilmington, California• 135,000 bpd capacity
Benicia, California• 170,000 bpd capacity
McKee, Texas• 170,000 bpd capacity
Krotz Springs, Louisiana• 85,000 bpd capacity
Texas City, Texas• 245,000 bpd capacity
Houston, Texas• 130,000 bpd capacity Port Arthur, Texas
• 325,000 bpd capacity
St. Charles, Louisiana• 250,000 bpd capacity
Ardmore, Oklahoma• 90,000 bpd capacity
Memphis, Tennessee• 195,000 bpd capacity
Paulsboro, New Jersey• 195,000 bpd capacity
San Nicholas, Aruba• 275,000 bpd capacity
Delaware City, Delaware• 210,000 bpd capacity
Capacity shown in terms of crude and feedstock throughput
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Major Refining Processes – Crude Processing
Definition• Separating crude oil into different hydrocarbon groups • The most common means is through distillation
Process• Desalting – Prior to distillation, crude oil is often desalted to remove
corrosive salts as well as metals and other suspended solids.• Atmospheric Distillation – Used to separate the desalted crude into specific
hydrocarbon groups (straight run gasoline, naphtha, light gas oil, etc.) or fractions.
• Vacuum Distillation – Heavy crude residue (“bottoms”) from the atmospheric column is further separated using a lower–pressure distillation process. Means to lower the boiling points of the fractions and permit separation at lower temperatures, without decomposition and excessive coke formation.
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Major Refining Processes – Cracking
Definition• “Cracking” or breaking down large, heavy hydrocarbon molecules into
smaller hydrocarbon molecules thru application of heat (thermal) or through the use of catalysts
Process• Coking – Thermal non–catalytic cracking process that converts low value
oils to higher value gasoline, gas oils and marketable coke. Residual fuel oil from vacuum distillation column is typical feedstock.
• Visbreaking – Thermal non–catalytic process used to convert large hydrocarbon molecules in heavy feedstocks to lighter products such as fuel gas, gasoline, naphtha and gas oil. Produces sufficient middle distillates to reduce the viscosity of the heavy feed.
• Catalytic Cracking – A central process in refining where heavy gas oil range feeds are subjected to heat in the presence of catalyst and large molecules crack into smaller molecules in the gasoline and surrounding ranges.
• Catalytic Hydrocracking – Like cracking, used to produce blending stocks for gasoline and other fuels from heavy feedstocks. Introduction of hydrogen in addition to a catalyst allows the cracking reaction to proceed at lower temperatures than in catalytic cracking, although pressures are much higher.
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Major Refining Processes – Combination
Definition• Linking two or more hydrocarbon molecules together to form a large
molecule (e.g. converting gases to liquids) or rearranging to improve the quality of the molecule
Process• Alkylation – Important process to upgrade light olefins to high–value
gasoline components. Used to combine small molecules into large molecules to produce a higher octane product for blending with gasoline.
• Catalytic Reforming – The process whereby naphthas are changed chemically to increase their octane numbers. Octane numbers are measures of whether a gasoline will knock in an engine. The higher the octane number, the more resistance to pre or self–ignition.
• Polymerization – Process that combines smaller molecules to produce high octane blending stock.
• Isomerization – Process used to produce compounds with high octane for blending into the gasoline pool. Also used to produce isobutene, an important feedstock for alkylation.
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Major Refining Processes – Treating
Definition• Processing of petroleum products to remove some of the sulfur, nitrogen,
heavy metals, and other impurities
Process• Catalytic Hydrotreating, Hydroprocessing, sulfur/metals removal – Used to
remove impurities (e.g. sulfur, nitrogen, oxygen and halides) from petroleum fractions. Hydrotreating further “upgrades” heavy feeds by converting olefins and diolefins to parafins, which reduces gum formation in fuels. Hydroprocessing also cracks heavier products to lighter, more saleable products.
• Deasphalting – A process in which the asphaltic constituents of a heavy residual oil are separated by mixing with a liquid solvent. Everything will dissolve in the solvent but the asphaltics, which are subsequently removed.
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List of Refining AcronymsAGO – Atmospheric Gas OilATB – Atmospheric Tower BottomsB–B – Butane–Butylene FractionBBLS – BarrelsBPD – Barrels Per DayBTX – Benzene, Toluene, XyleneCARB – California Air Resource BoardCCR – Continuous Catalytic RegeneratorDAO – De–Asphalted OilDCS – Distributed Control SystemsDHT – Diesel HydrotreaterDSU – Desulfurization Unit EPA – Environmental Protection AgencyESP – Electrostatic PrecipitatorFCC – Fluid Catalytic CrackerGDU – Gasoline Desulfurization UnitGHT – Gasoline HydrotreaterGOHT – Gas Oil HydrotreaterGPM – Gallon Per MinuteHAGO – Heavy Atmospheric Gas OilHCU – Hydrocracker UnitHDS – HydrodesulfurizationHDT – HydrotreatingHGO – Heavy Gas OilHOC – Heavy Oil Cracker (FCC)H2 – HydrogenH2S – Hydrogen SulfideHF – Hydroflouric (adic)HVGO – Heavy Vacuum Gas OilkV – Kilovolt
kVA – Kilovolt AmpLCO – Light Cycle OilLGO – Light Gas OilLPG – Liquefied Petroleum GasLSD – Low Sulfur DieselLSR – Light Straight Run (Gasoline)MON – Motor Octane NumberMTBE – Methyl Tertiary–Butyl EtherMW – MegawattNGL – Natural Gas LiquidsNOX – Nitrogen OxidesP–P – Propane–PropylenePSI – Pounds per Square InchRBOB – Reformulated Blendstock for Oxygen Blending RDS – Resid DesulfurizationRFG – Reformulated GasolineRON – Research Octane NumberRVP – Reid Vapor PressureSMR – Steam Methane Reformer (Hydrogen Plant)SOX – Sulfur OxidesSRU – Sulfur Recovery UnitTAME – Tertiary Amyl Methyl EtherTAN – Total Acid NumberULSD – Ultra–low Sulfur DieselVGO – Vacuum Gas OilVOC – Volatile Organic CompoundVPP – Voluntary Protection ProgramVTB – Vacuum Tower BottomsWTI – West Texas IntermediateWWTP – Waste Water Treatment Plant