uop oleflex™ pdh technology - globuc · 2020. 7. 17. · uop oleflex pdh technology evolution e...

UOP OLEFLEX™ PDH TECHNOLOGY: INNOVATION, PERFORMANCE AND RELIABILITY

JEFFREY WERY TECHNOLOGY MANAGER – OLEFINS

July 10, 2020

©2020 by Honeywell International Inc. All rights reserved.

GBC⏐ Moscow, Russia

Agenda

❑ Market Need for On-Purpose Propylene ❑ UOP Oleflex™ Technology Evolution ❑ Latest Catalyst & Process Innovations ❑ Why Customers Choose Oleflex ❑ Honeywell Forge Process Advisor (Connected Solution) ❑ Market Success of Oleflex

2


Propylene Market: CIS Supply/Demand Growth

Historic Demand Growth Returns in 2021 ; Lost Year due to COVID©2020 by Honeywell International Inc. All rights reserved.

• Healthy growth rate over next 10 years (8.0% CAGR) • Majority of demand comes from polypropylene (75%) • Steam crackers main source for propylene (60%) • 2.7 MMTA of new capacity forecasted by 2029 • Majority of new capacity will come from PDH (56%) • Region will remain net exporter of propylene

0

50

100

150

200

250

300

350

400

14 15 16 17 18 19 20 21 22 23 24 29Imports Exports

CIS & Baltic States: PG/CG Propylene Trade

Source: IHS Markit © 2020 IHS Markit

Forecast

Thou

sand

Met

ric T

ons

Propylene Supply & Demand - Global

• “Propylene Gap” is growing - Steam Crackers shifting to lighter feedstocks,

which produce less propylene - Refiners limited by flat gasoline growth in

some regions, which limits propylene from FCCs

• “On-Purpose Propylene” is filling the gap - Propane Dehydro (PDH) - MTO (from gas & coal) - High Severity FCC - Olefin Cracking - Metathesis

On-Purpose Propylene will supply >30% of global propylene by 2027Data Source: IHS Markit (2018)


UOP Oleflex PDH Technology EvolutionC

CO

P R

educ

tion

from

Bas

e

80 %

82 %

84 %

86 %

88 %

90 %

92 %

94 %

96 %

98 %

100 %

% ROI Improvement from Base

0 9 18 27 36 45

Oleflex 1990 DeH-6 Catalyst 1.25 MT C3/MT C3=

Oleflex 1997 DeH-12 1.21 MT/MT

Oleflex 2004 DeH-14 1.18 MT/MT Energy Reduction

Oleflex 2011 DeH-16 1.16 MT/MT Energy Reduction

Oleflex 2015 1.14 MT/MT Energy Reduction

Oleflex 2020 DeH-26

Catalyst Innovation to Increase Capacity/Reliability

New DeH-26

Shorter Startup Time

Extended Run Length

Increased Hydraulic Capacity

• Larger diameter pills

• 4 year catalyst life expected

• Custom-designed support using recently enhanced manufacturing techniques & know-how

• Optimized metals content achieve high yields & excellent activity

- Continuing use of Platinum as active metal

• First commercial installation 2020

For 600 kMTA unit, can deliver up to an additional $36M of gross margin

6


Process Innovations to Extend Onstream Time

Incorporated into Operating Units and New Designs Since 2018

Achieve 4 Year Run

Length

Significantly Lower Reactor Temperatures

(Reduce carbonaceous

fouling)

New Reactor Internals w/ Even More Open Area (Increase fouling

tolerance)Enhanced Sulfur

Injection (Reduce iron

sulfide fouling)


Enhanced Reactor Internals With More Open Area

Generation 1 Generation 2 Generation 3

Rx

Del

ta P

Ris

e

Time

More Open Area, Greater Fouling Tolerance, Increased Onstream Time

In Use

DeH-26 Catalyst (20% larger diameter)

DeH-16 Catalyst

+50% from Base +70% from Base Open Area:

350 kMTA Unit (Gen 2 vs Gen 1)


Commercializing Soon

Base

Process Innovations to Lower Cash Cost of Production

Lower H2 / HC Ratio in Reactor

(enabling lower Rx

temperatures)

New Cryogenic Separation

System Design

(enabling lower H2/HC

ratio) Lower Propane

Consumption (

Process Innovations to Reduce Capital Cost

Lower CAPEX Improves Project Economics

10


• Three (3) Reactor Design for PDH Unit • Removes one Reactor, Fired Heater and associated CCR equipment • Lowers CAPEX by ~5% saving ~$20MM USD (for 600 KMTA) • Reduces plot area & maintenance turnaround scope

• Improved Hot Combined Feed Exchanger (HCFE) • Replaces “Texas Tower” design with Spiral Tube exchanger

• Reduced # of shells lowers CAPEX by $8MM USD (for 600 KMTA)

• Improved efficiency lowers OPEX by $1.1MM/yr fuel (for 600 KMTA at $7/MMBtu)

• Maintains UOP’s Latest Process Innovations • Reduced Fouling via Lower Reactor Temperatures • Increased Fouling Tolerance via More Open Reactor Internals • Improved Yield with Low Propane Consumption

CCR

Comparison of Oleflex with Competing PDH Technology

Characteristic Competing PDH Technology Oleflex

Reactor Type Fixed Bed Cold Wall

Radial Flow Hot Wall

Relative Catalyst Inventory 20 x Base Base

Catalyst Changeout 30-day shutdown No shutdown required On-the fly changeout

# of Reactors• 3 (300 kMTA) • 5 (600 kMTA) • 8 (750-900 kMTA)

4 (all plant sizes up to 900 kMTA) 3 (reduced CAPEX for under 660 KMTA) Easily scalable

Mode of OperationCyclical

(Swing Bed System)Continuous

(Continuous Catalyst Regeneration)

Reaction Cycle Time Frequent (< 10 min/cycle)

Continuous, Stable Operation

Oleflex: Easily Scalable & Continuous Stable Operation©2020 by Honeywell International Inc. All rights reserved.

12Benefits of UOP Oleflex vs. Competing Technology

Lower CAPEX• $55M-75M savings

(15-20% lower) • (US Gulf Coast

basis; 600 kMTA unit)

Lower OPEX• $6M/year savings or

$10/MT propylene • (600 kMTA unit)

High Plant Productivity• Up to $10-15M/year additional

gross margin from higher onstream availability

Smaller Environmental Footprint• Significantly lower emissions

(NOx, NH3, CO2, VOC, waste water)

• Lower impact on environment

Fast Execution• Fast-to-Market approach

enables startup as fast as 24-36 months

Oleflex Benefits

Dependable Investment• Safe, proven and reliable

process & catalyst technology

Customer Validation• Extensive global acceptance of technology • UOP awarded 68 of 94 units since 2011 • Multiple repeat customers and switches from

competing technology

C3 Oleflex can deliver up to $20M/year lower Net Cost of Production and an additional $80M of NPV and +3% ROI


Honeywell Forge Process Advisor Connected Plant Solution for Oleflex

What is behind it? • Matches unit configuration • Tuned UOP process models • Technology-specific fault models • Embedded UOP knowledge,

context, and background

What does it do? • Monitoring of unit performance • Identify process constraints • Event detection and mitigation • Knowledge transfer

13

13

Connected Process

Improve Operation

• Continuously identifying key process constraints • Interacting with the customer to implement improvements • Driving the unit to its ultimate performance

Knowledge Access

• Essential information is delivered quickly • Continuous upgrades as new information becomes available

Reduce Issue Response Time

• Issues are quickly identified and the appropriate action is recommended.

• Fast response ensures stable production and potentially avoids an unplanned shutdown

$5.7M total in gross

margin improvement

Typical ValueGap How

Value of Process Advisor for Oleflex14

Assumptions: 450 KMTA production, $350/MT Feed/Product Spread @ 8000 hr/yr Avoiding a 7 day shutdown, ½% production increase, 3 yr

14

UOP Leads in Dehydrogenation


UOP awarded 68 out of 94 dehydrogenation projects globally since 2011 Since first commercialized, 15 repeat customers & 9 switches from competing technology

uop oleflex™ pdh technology - globuc · 2020. 7. 17. · uop oleflex pdh technology evolution e...

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