Leveraging Synergies Between Refining and Petrochemical Processes

149 Pages·2020·5.435 MB·English

by  Eberhard Lucke, Edgar Amaro Ronces

Leveraging Synergies
Between Refining and
Petrochemical Processes

Leveraging Synergies
Between Refining and
Petrochemical Processes
Eberhard Lucke and Edgar Amaro Ronces
First edition published 2021
by CRC Press
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Library of Congress Cataloging-in-Publication Data
Names: Amaro Ronces, Edgar, author. | Lucke, Eberhard, author.
Title: Leveraging synergies between refining and petrochemical processes /
Edgar Amaro Ronces, Eberhard Lucke.
Description: First edition. | Boca Raton, FL : CRC Press, 2020. | Includes
bibliographical references and index. | Summary: “This book provides a
detailed description of the interfaces and connections between crude oil
refining and petrochemicals. It offers a view of global and regional
markets and economic opportunities for synergies between these sectors.
The work serves as a reference that provides introductory and
explanatory material as well as in-depth insight into future technology
and market developments to help engineers and industry professionals
understand the challenges and the potential benefits of developing
expansion or optimization projects that may bridge the line between
refining and petrochemicals”— Provided by publisher.
Identifiers: LCCN 2020043360 (print) | LCCN 2020043361 (ebook) |
ISBN 9780367076771 (hbk) | ISBN 9780367649845 (pbk) |
ISBN 9780429022043 (ebk)
Subjects: LCSH: Petroleum—Refining. | Petroleum chemicals.
Classification: LCC TP690 .A63 2020 (print) | LCC TP690 (ebook) |
DDC 665.5/3—dc23
LC record available at https://lccn.loc.gov/2020043360
LC ebook record available at https://lccn.loc.gov/2020043361
ISBN: 978-0-367-07677-1 (hbk)
ISBN: 978-0-429-02204-3 (ebk)
Typeset in Times
by codeMantra
Contents
Prefaceix
Authors xi
Chapter 1 Introduction 1
11 Self-Respect 2
12 Respect for Others 3
13 Communication 3
14 Passion 3
Chapter 2 Fundamentals 5
21 Historical Development of Petrochemical-Refining
Synergies 5
22 Evolution of Key Technologies 6
221 Syngas Production 6
222 Ethylene Production 9
223 Aromatics Production 13
224 Propylene Production 24
2241 Metathesis 24
2242 Propane Dehydrogenation24
2243 Methanol to Olefins (MTO) 25
2244 Interconversion of Heavier
Olefins into Propylene 28
225 Petroleum Refining 28
2251 Octane Improving 30
2252 Isomerization 31
2253 Gasoline Reforming 32
2254 Catalytic Cracking 32
2255 Hydrocracking 35
2256 Hydrotreating 35
23 Role of Hydrogen in Synergies 37
24 Opportunities in the Near Future 38
241 Reduction of Fuel Consumption 38
242 Strategies to Share Infrastructure 38
243 Environmental Challenges 39
Bibliography 39
Chapter 3 Economic and Market Outlook 41
31 Global Energy Markets42
311 Coal 44
312 Renewables 45
v
vi Contents
313 Wind/Solar 47
314 Nuclear 49
315 Crude Oil–Petroleum 50
316 Natural Gas 51
32 Market Outlook Refining 54
321 Impact of IMO 2020 58
322 Changes in Private Transportation 59
323 Long-Term Outlook 59
33 Market Outlook Petrochemicals 61
34 Market Outlook Natural Gas 64
35 Market Challenges and Opportunities66
351 Trends of Integration by Region 67
3511 North America 68
3512 South America 68
3513 Western Europe 68
3514 Eastern Europe/Russia 69
3515 Middle East 69
3516 Africa 69
3517 Asia Pacific 70
352 Impact on Product Value Chains 70
3521 Feedstock 71
3522 Offgas and Light Products 72
3523 Naphtha and Gasoline Blend Pool 72
3524 Heavier Products 73
3525 Hydrogen 73
353 Impact on Storage, Logistics,
and Infrastructure 73
Bibliography 74
Chapter 4 Technical View 75
41 Feedstocks and Products 76
411 Crude Oil Selection 76
412 Refinery Product Value Chains 80
4121 Refinery Gases 80
4122 Naphtha 81
4123 Other Refinery Products 82
4124 Aromatics (BTX) from Refinery Units 82
4125 Olefins from Refinery Units82
413 Petrochemical Product Value Chains 82
4131 Ethylene 82
4132 Propylene 84
4133 C Hydrocarbons 85
4
4134 Pyrolysis Gasoline (Pygas) 85
Contents vii
4135 Methanol 86
4136 Other Petrochemical Products 86
414 Selection of Integration Options86
4141 Grassroots Refinery/Petrochemical
Complex or Petrochemical Refinery 89
4142 Existing Refinery 90
4143 Existing Petrochemical Units 90
4143 Existing Integrated Complex 91
415 Role of Alternative Feedstocks 91
4151 Coal 91
4152 Natural Gas 92
4153 Biomass and Renewables 92
42 Energy Efficiency 92
421 General Recommendations 97
422 Opportunities from Integration 97
4221 Energy Management 98
4222 Monitoring and Control Systems 99
4223 Economy of Scale 101
4224 Process Integration 102
4225 Fuel Management 104
4226 Water Management 105
4227 Steam Management 107
4228 Plant Air/Instrument Air Management 108
423 Human Factor 109
43 Technology Development 109
431 Flow Schemes for Integration 110
4311 Refining Products Flowing to
Petrochemical Units 110
4312 Petrochemical Products Flowing to
Refining Units 110
432 Role of Steam Crackers and Catalytic Crackers
on Integration 112
4321 Steam Cracking 112
4322 Catalytic Cracking 114
433 Role of Catalytic Reformers and Steam Crackers
on the Integration of Aromatic Streams 115
434 Impact of New Developments in Technologies 116
4341 Oxidative Dehydrogenation 116
4342 Biomass Processes 117
4343 Dehydrocyclodimerization of LPG 118
4344 Shock Wave Pyrolysis 118
4345 Methanol to Aromatics 118
435 Capital Cost of Integrated Schemes 118
44 Technical Challenges and Opportunities 120
viii Contents
441 Interfaces during Integration 120
442 Planning and Scheduling 121
443 Impact on Operational Staff 124
444 Safety and Environmental Challenges 125
Bibliography 126
Chapter 5 Conclusions 129
Index 133
Preface
Writing a book takes a lot of dedication, patience, and hard work. You must be
passionate about the story you want to tell; otherwise, you won’t be able to finish it.
It starts with the research and gathering of information, which to us was the fun part
and could have lasted so much longer. But at some point, you must stop researching
and gathering, and start analyzing, sorting, and aligning information along the train
of thought you have for the book. At that time, you may have new ideas and change
the concept you had laid out for each chapter to accommodate additional information
or to compensate for lack of other information. Either way, it is easy to get lost in
the process of putting the pieces together and of finalizing the chapters. Having the
final goal in mind and knowing what you are trying to achieve helped us with staying
focused on the task at hand, which was simply to write a book.
So, how do you know what potential readers might be interested in? To be hon-
est, you don’t. Yes, you ask around and do a survey to make sure there is some
level of interest. But in the end, you believe that if you – the authors – find the
topic interesting and want to know more about it, there will be others, with simi-
lar interests, with similar jobs, or with similar motivation to learn more about the
topic. And these are the people you write the book for. But you try to write it in a
way that it will be helpful for others as well. We live in a world that is subject to
constant change. New technologies influence the way we communicate, the way
we move from point A to point B, and the way we solve problems. Once you get
used to something, it is outdated and replaced by something better. Technology has
improved the speed in which we can do things, and the comfort from which we
can do things. And sometimes, it is necessary to stop and take a high-level look at
the mechanisms and technologies that allow us to do all these things that we have
accepted as normal. We believe that understanding the source of our comfort and
what it depends on allows for a much better appreciation of where we are today and
how we got here.
The industry we both, Edgar and I, work in has a bad reputation and is blamed
for a lot of bad things that are happening around us. And we are not saying that it is
wrong to point these issues out and try to find a better solution. We just want to raise
awareness of the fact that a lot of good things come out of the industry as well, and
that it would be wrong and naïve to believe we could just walk away from it and do
something else. It takes time and patience and the same innovative spirit that got us
to where we are today to get us where we need to be in the future.
Writing a book and spreading information are only two of the many things that
need to happen in order to focus the right minds with the right tools to work on
the right issues. There is so much more that needs to be done. But it is a start, and
we hope that we can do our part in the whole process to build a solid basis for the
ix