technology evolution in refining and petrochemicals technology makes more than 60% of the world’s...
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1914 - 2014 A Century of Innovationin the Oil and Gas Industry
© 2015 UOP LLC. All rights reserved. UOP 6696-1
Technology Evolution in Refining and Petrochemicals
Gavin TowlerChief Technology Officer and VP R&DUOP LLC
GPCA Innovation ConferenceDubaiMarch 17, 2015
Today’s Discussion
How UOP became what it is today
What it takes to be successful at innovation
Business factors driving UOP’s growth
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Look Around You…
…Using UOP Technologies…The Hydrocarbon Industries Make the Modern World Possible…
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A Century of Innovation
The Age of PowerAlkylation, Isomerization, Polymerization (1938)Fluid Catalytic Cracking (1944)
Transportation RevolutionDubbs Cracking Process (1914)Clean Circulation (1919)
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A Century of Innovation
Birth of PetrochemicalsPlatforming™ Process (1949)Synthetic Zeolites (1953)Parex™ Process (1970)Oleflex™ Process (1990)Methanol to Olefins (2008)
The Drive for YieldCCR Platforming™ Process (1971)Uniflex™ Process (2011)
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A Century of Innovation
Natural Gas RevolutionSeparex™ Membranes (1979)UOP Russell (2012)
A Better EnvironmentUnleaded Gasoline (1960)Biodegradable Detergents (1968)Honeywell Green Diesel™ (2006)Honeywell Green Jet Fuel™ (2008)
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UOP: A Century of Innovation
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UOP creates technology for the oil and gas industry
Better Economics Continuous Innovation Reliability Expertise
800+R&D employees
3,000+ Active patents
2,500
200 with PhDs
Engineers and scientists
31out of 36refining technologies
in use today were developed by
UOP
• Process Technology• Catalysts • Adsorbents• Equipment• Services
UOP technology makes more than 60% of the world’s gasoline, 70% of its polyester and 90% of biodegradable detergents, and processes more than 40% of its LNG
UOP technology makes more than 60% of the world’s gasoline, 70% of its polyester and 90% of biodegradable detergents, and processes more than 40% of its LNG
Petrochemicals Natural GasRefining Renewables
UOP technologies offer a high return on investment
Continuous technology improvement allows customer operations to remain cutting edge
UOP technologies are among the most widely proven in the world
UOP has a century-long record leading technology development for the oil and gas industry
Largestprocess licensing organization in the world
Upstream Midstream DownstreamExploring, drilling and producing crude oil
and natural gasProcessing, storage and transportation
Refining oil and gas into fuels and chemicals
Refining, Petrochemical and Gas Industries
Participate only when gas processing close
to wellhead
Technology and materialsfor natural
gas processing
Process technology, equipment, materials,
services
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Global Customer Base
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Global Locations
North AmericaDes Plaines, ILHouston, TXTulsa, OK
EuropeAntwerp, Belgium Guildford, UKAsia Delhi, India Kuala Lumpur
Engineering Centers
North AmericaAnaheim, CABaton Rouge, LABeggs, OKCatoosa, OKMcCook, ILMobile, ALShreveport, LATonawanda, NYTulsa, OK
EuropeBrimsdown, UKReggio de
Calabria, Italy
AsiaShanghai, ChinaPenang, Malaysia
Manufacturing
North AmericaDes Plaines, ILHouston, TXMt Laurel, NJTulsa, OK
South AmericaRio de Janeiro, Brazil
Europe/RussiaAntwerp, Belgium Erkrath, Germany Guildford, UK Milan, ItalyMoscow, RussiaRolle, Switzerland
Asia/Middle EastDelhi, IndiaBangkok, ThailandSingaporeSeoul, South KoreaTokyo, JapanBeijing, ChinaShanghai, China
Kuala Lumpur, MalaysiaJakarta, IndonesiaBaghdad, IraqDubai, UAE
Sales & Service Offices
North AmericaAnaheim, CADes Plaines, ILMobile, AL Riverside, IL Shreveport, LA
Middle East Dhahran, KSA AsiaDelhi, India Shanghai, ChinaHiratsuka, Japan
Research & Development
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What Makes Innovation Work at UOP?
TalentCapabilities
Work ProcessesBusiness Alignment (Portfolio)
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UOP R&D OverviewExperienced, multidisciplinary team 2,500 Scientists and engineers in UOP• 820 employees in R&D: ChE, ME, Chemists, Technicians• >2,700 patents, 420 inventors, >200 new patents every year• 120 inventors with >10 patents, 46 with >25Extensive facilities, global footprint• More than150 pilot plants and semi-works plants for rapid
scale-up and commercialization• Characterization and combinatorial methods for discovery• More than 3.5 billion data points/day, 350,000 offline analyses/year• Demonstration units at customer sites• More than 100 outside innovation and alliance relationships• Global reach: Tech Centers in India, China, Saudi Arabia
Strong Technical TeamUOP 6696-1212
Investment in Innovation
Investment in Top Talent Keeps UOP at the Frontier of Innovation
How Do We Drive Innovation?It Starts with Investing in People!
Attract top technical talent Strong career development
– On-boarding, training programs and mentoring– Career Development Program and Field Operating Service– Promote longevity, growth and wider scope – Career rotations, projects, assignments
Incentives for Innovation
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UOP Patents in Oil & Gas and Petrochemicals
Investment – Fundamentals, Tools, Science, People,Innovation Focused
020406080
100120140160180200
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
# U
S Pa
tent
s G
rant
ed
• 6,700+ Granted US Patents Over Past 50 Years• In the 100th Year:
~1,300 Granted US Patents~900 Pending US Applications~1,500 Granted Non-US Patents~2,600 Pending Non-US Applications
Honeywell acquires full
ownership of UOP
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MaterialsDiscovery
Capabilities: How R&D is Organized
Exploratory
Development Scale-up
AnalyticalCapabilities
Spend80%20%
Research Development & Commercialization
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Naphtha DistillateVacuum Gas
Oil (VGO)Vacuum
Residue (VR)
GC HPLC GC×GC HRMS
Find Pathways For Every Molecule To be Used Most Effectively
Latest Techniques Let Us Optimize Molecule Management
0.0034 amu
448.312462
448.315833C14H29
S
C15 H
31
Mass to Charge Ratio (amu)
C34H40
C31H44S
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Molecule Management: Catalysts by Design
New Catalysts forBetter Yields Less Hydrogen
Less EnergyMore Efficient Processes
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Alignment to Business Strategies Drives Technology
Competitiveness• All UOP product lines have strong competitors• Technology differentiation is key to price, market share & margins• UOP continues to invest in technologies so that our customers
can keep improving their profitability
Growth• Enter new markets: gas to chemicals, gas, new petrochemicals
and new adsorbent applications• Support new plant expansions• Expand scope of our offerings
Leadership Ensures Business AlignmentUOP 6696-1818
+22% ROI+15% ROIBase ROI
2004 2005 2006 2007 2008 2009 2010 2014+
UOP ADS-47 Parex™ Adsorbent• Over 25% extra throughput• 7 operating units
Recently Commercialized• UOP R-334 PlatformingTM Catalyst
− Maximizes aromatics yields• UOP TA-32 Tatoray™ Catalyst
− Improved activity & yields
+30% ROINet Energy RequiredReduced by 1/3 vs.Best 2009 Designs
Additional 14%+ Energy Reduction vs.
Best 2010 Design
20122011
Upcoming Product Launches• Next Gen Aromatics Complex Design • ImpX Rx System for Platforming™ Unit• UOP I-600 Isomar™ EB Isom Catalyst
Energy Efficient Aromatics Complex• First unit s/u in 2014UOP TA-30 Tatoray™ Catalyst• Max conversion of heavy aromatics • 3 operating units
Substantial CAPEX/OPEX Reductions Over Last 4 Years
+45% ROICAPEX and OPEX
Reductions vs.Best 2012 Design
2013
UOP I-500 Isomar™ EB Dealk Catalyst• Low xylenes losses• 3 operating units
UOP Tatoray PTD Process• Low xylenes losses• First unit s/u in 2014
UOP R-284 Platforming™ Catalyst• Improved aromatics yields• First unit s/u in 2014
Continuous Innovation at UOP Drives Technical Leadership in Aromatics
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Challenges by 2050 9 billion people
– 5 billion in cities Energy demand grows by 40%
– Electricity +90%, Natural gas +65%, Oil +25% Chemicals demand grows by 50% Vehicle population doubles to 2 billion
– Moving food, goods and people– New engine technologies requiring new fuels
We need to get energy from where it is found to where it is neededIn the most efficient ways we canMaximizing the value we createMinimizing the damage to the environment
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Energy Challenges: Utilization
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Big Incentive to Increase Conversion Need to Maximize Refinery Value Add
8% of Refinery input energy is used to run the refinery8 – 10 % of feed ends up as coke / heavy fuel oil
For the same number of people the world could use 16% less crude!This is $ 670 Million/day of Lost Value
ResidueConversion
Uniflex Process
Petro-Canada Montreal Unit• Slurry hydrocracking technology• Makes diesel instead of coke or fuel oil• Increases high value fuel products by 10%• Increases refinery margins by $1.80/bbl
Molecule Management for Heavy Hydrocarbons22 UOP 6634-22
Molecule Management: MaxEne™ Process Send the right molecules to the right process and make
better yields! Maxene Process: Separation of naphtha into n- and i-paraffins
– Full range naphtha (C6 to C12)– Extract: normal paraffins are superior steam cracker feed– Raffinate: superior catalytic reformer feed due to higher aromatics
potential of isoparaffins
Successfully Commercialized 15% Less Naphtha to Make Same Petrochemicals Yield Worth $200 Million/Year in Typical Complex
MaxEneUnit
Catalytic Reformer
NaphthaCracker
Full RangeNaphtha C7
-
C7+
+40% Ethylene
+15% Aromatics
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Environmental: Cleaner Safer Products
Water
Sulfur
Particulates
BiodegradablesRenewables
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UOP Water Technologies• Contaminant removal with high
selectivity ion exchange zeolites– Cesium– Strontium– Iodine
• UOP Immobilized Cell Bioreactors– Over 15 years experience– Broad applications
• Organics/TOC• Heavy Metals• Denitrification
• Hydrocarbon Processing Water Contaminants- Selenium, Chromium, Mercury, …
Solving the Most Challenging Water Problems25 UOP 6634-25
Chemistry Breakthroughs Keep Coming…New Materials
55 new zeolites invented since 2000 Zeolite crystal engineering Structures tailored to maximize selectivity New Aluminas that optimize acidity and pore
volume for Hydroprocessing, Platforming
New Chemistries
Ionic Liquids
Organometallics
Enabling New Chemistries for the IndustrySafer. Higher Yields. More Efficient
Improved IL for Motor Fuel Alkylation Inherently safer processing
New routes to petrochemicals: more efficient, cheaper feedstocks
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NN
R CH3
CH3+ X
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Dubbs’ Patent US 470,911
New Chemistry Concepts and New ToolsWill Lead to New Process and Catalyst Technologies27 UOP 6634-27
The invention consists in desulphurizingcrude Lima and other mineral oils contain-ing a large percentage of sulphur by forcingthrough the same a gas rich in hydrogen,whereby the sulfur in the oil will unite withthe hydrogen of the gas, passing off in theform of incondensable sulphureted hydrogenand preventing the formation of indestruct-ible and deleterious carbon sulphides.
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SummaryThe Refining and Petrochemical sectors have benefited from continuous innovation
UOP Invests in Technology to Deliver Growth
Investment in effective R&D is key to our success
• Attract top talent
• Enable innovation
• Build world-class capabilities
Societies’ needs will continue to require adoption of new technologies
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