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Integraci N de Plantas Petroqu¡mica y Refiner¡a Como Una Aproximaci N para Competir El Mercado de Hidrocarburos
Integraci N de Plantas Petroqu¡mica y Refiner¡a Como Una Aproximaci N para Competir El Mercado de Hidrocarburos
Abstract:
The recent shift from local markets to a large global one increased the competitive
pressures on petrochemical industries. Further, because of fluctuations in products' price
and high price of feedstocks, economical attractiveness of petrochemical plants can be
considered as a main challenge. The ever-increasing cost of energy and more stringent
environmental regulations impacted the operational costs. When cheap feedstocks are not
available, the best method of profitability is to apply integration and optimization in
petrochemical complexes with adjacent refineries. This is valid for installed plants and
plants under construction. Petrochemical-refinery integration is an important factor in
reducing costs and increasing efficiencies. Moreover, it guarantees the supply of
feedstock for petrochemical industries. Integrated schemes take the advantage of the
economy of scale as well. On the other hand, an integrated complex can produce more
diverse products. Petrochemical-refinery integration avoids selling crude oil, optimizes
products, economizes costs and increases benefits. Nowadays, there is an integration
approach in various commercial processes of well-known licensing companies.
This paper tries to reveal the advantages of such integration between petrochemical and
refinery plants. The incentives, benefits and challenges will be discussed. Some typical
examples are provided. The emphasis is on integration of petrochemical plants and
refineries as a key factor in sustainable competitiveness in the market using the advantage
of the synergy between petrochemical plants and refineries.
1. Introduction
Currently, hydrocarbon-based industries have faced the problem of increased feedstock
and energy prices as well as environmental tight restrictions. Therefore, optimum
utilization of hydrocarbons in chemical industries has been received special attention.
The approaches commonly use improvements in processes and their catalysts to increase
the yield, reduce the wastes and using byproducts of a process as a feedstock for another
process. Consequently, the integration approach of the plants to maximize the use of
feedstocks has been applied in petrochemical plants and refineries. As a good example a
similar approach has been applied in term of energy in chemical plants to integrate
energy consumption through pinch technology [1]. Integration includes diverse areas
with further examples including integration of products and power generation, integration
of technology (for example automation technology in petrochemical plants) and
integration for optimization of scheduled equipment maintenance.
Stand-alone petrochemical plants and refineries exhibit limited flexibility for product reprocessing and by-product distribution. The inter-relation of petrochemical-refining plant
has been of interest since earlier times and many petrochemical plants have been
constructed adjacent to refineries to use their byproducts. Domestic examples are
common. Table 1 shows a number of refining streams which can be high quality feed
when used in petrochemical industry. In normal case, these cuts are used as fuel or fuel
additives in refineries.
Table 1- Alternative usage of refinery streams in petrochemical industry [2]
To improve the refining margins, the strategy is to integrate refinery and petrochemical
plants so that to produce high price petrochemical feedstocks (such as propylene and
aromatics). In general, in Asia, part of refinery capacity has been devoted to
petrochemical feedstocks and fuel as by-product.
Potential types of petrochemical-refining integrations can be divided in three main
categories [3]:
35
30
Petrochemical
25
Refining
20
15
10
5
0
2000
2001
2002
2003
2004
Year
2005
2006
2007
39%
24%
BP
Shell
Total
Exxon Mobil
Part of the synthesis gas can be directly converted to methanol in a two-stage synthesis
(Lurgi MegaMethanol Technology). The produced methanol is separated by cooling the
gases below dew point and the raw methanol is purified afterwards in a two- or threestage distillation unit. The unconverted feed gas is recycled to the reactors and a small
amount is purged for use as fuel.
The balance of synthesis gas is used for production of ammonia. Hence, this stream is fed
to a CO-shift reaction stage to convert the undesired carbon monoxide and increase the
hydrogen content of the product gas. The converted syngas is rigorously cleaned by
means of a Rectisol wash and a Liquid Nitrogen Wash to remove the carbon dioxide as
well as other inerts such as carbon monoxide, methane and argon. The nearly pure
hydrogen is enriched with the required amount of nitrogen, which is a by-product of the
air separation unit. The hydrogen/nitrogen mixture is then converted in a proprietary twostage ammonia synthesis section using well-proven Casale technology. The ammonia is
separated from the un-reacted feed gas, which is recycled to the reactors.
This integrated plant with production capacity of 5000 mtpd methanol and 4000 mtpd
ammonia, results in a reduction of capital costs by 15% compared to a separate Mega
Methanol and a separate Mega ammonia plant and by 25% compared to separate Mega
Methanol and conventional ammonia plants.
Overall advantages of this integrated technology can be summarized as follow:
Large scale production of more than one product;
Cost reduction due to shared process equipment and utilities;
Reduction in gas consumption and CO2 emissions to atmosphere;
High efficiency;
Flexibility in methanol and ammonia productions;
Pure CO2 production as a by-product to be used in ammonia conversion to urea.
Figure 4- Lurgis integrated process for co-production of methanol and ammonia [10]
4.2. ATOFINA/UOP Olefin Cracking Process
Propylene has been a key interface between the refinery and petrochemical processes
[11]. The rapidly increasing demand of propylene has resulted in development of some
on-purpose production technologies using side stream products of processing streams.
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to product recovery section and the downstream is sent to steam cracker furnaces.
Another option is co-cracking of olefinic stream with straight run naphtha.
Figure 7. Propylene to ethylene ratio as a function of coil outlet temperature for various
feeds [13]
Chemicals decided to integrate Ras Tanura refinery and Jua`ymah gas processing unit as
a joint venture project. Ras Tanura refinery complex deliver naphtha, vacuum gas oil
(VGO) and reformate to petrochemical plants from which more than 30 value-added
products will be produced. By-products will recycle back to refinery for re- processing.
This integrated plant, valued $20 billion, would be the largest plastic and chemical
producer in the world that produce approximately 8 million ton product per year.
Ethylene, propylene, aromatic and chlorine derivatives are main products of this
integrated plant. The original project scope includes production units for polyethylene,
ethylene oxide and glycol, propylene oxide, chlor-alkali, vinyl chloride monomer,
polyurethane components, epoxy resins, polycarbonate, amine and glycol ethers. An
industrial park is considered to be developed adjacent to the integrated plant with the aim
of providing business opportunities for industries and products consumers.
Figure 8- Integrated plant of Ras Tanura refinery complex and Jua`ymah gas processing
plant [14]
5. The petro-refinery in Iran
In Iranian oil industry terminology, integrated petrochemical and refinery plants are
known as petro-refinery. Construction of petrochemical complexes adjacent to refineries
for feed provision is samples of this approach, for example, in the case of Abadan,
Tabriz, Isfahan, Bisotun and Arak petrochemical complexes. Abadan petrochemical
complex is the first one in Iran and Middle East to use propylene and refinery off-gas as a
part of its feedstock.
The Northern Isfahan Petro-Refinery Complex (NIPRC) is a private joint-stock company
established in Meime, Northern Isfahan Province, Iran, is first private project to
implement in the field of oil and gas nationally. Investments made in the project amount
to four Billion Euros in foreign currency and 4,500 Billion Rials in local currency. The
feedstock needed by the complex is 150,000 barrels of crude oil daily and 2.4 billion
10
cubic meters of gas annually, with the aim to operate a refinery plant, two petrochemical
plants, olefin and aromatic, and seven chemical sub-plants.
This complex, with two olefin and aromatic petrochemical units, one refinery unit and
seven related chemical units, needs an investment of more than 4 billion Euros. In this
plant, 150,000 barrel per day crude oil, 4.2109 m3/y gas, 18106 m3 water and 200,000
kW power is consumed. In refinery section of this plant C4, gasoline, white oil, fuel oil,
gas oil, naphtha, sulfur, lube cut and grease are produced from crude oil. In petrochemical
section of this plant, polyethylene, polypropylene, polybutadien, polyester and gasoline,
acetaldeyhde, acetic acid, vinyl acetate, butanol, 2 ethyl hexanol, ethylene oxide and
glycols are produced from natural gas. Adjacent to this plant, seven chemical units
including maleic anhydride unit, sulfuric acid unit, lubricant and industrial grease unit,
graphite electrode unit and linear alkyl benzene unit will be constructed [15].
6. Conclusions
Nowadays, construction of refinery and petrochemical plants as separate plants is not
economically attractive in the global hydrocarbon market; however, when integrated,
they will balance one another. The future petrochemical refinery aimed at production of
petrochemical feedstock could extend the petrochemical feedstock to unusual
hydrocarbon sources such as heavy oils and residues. By-products can be re-processed to
increase more valuable products.
Petrochemical-refinery integration, as a developing goal, results in synergies between
refinery and petrochemical and results in competitive and strategic advantages. This
integration will cause optimization between petrochemical and refinery products,
increasing cash margin and damp the influence of fluctuations of feed and products cost.
Security of feed supply and optimum utilization of energy are other benefits.
The resulted benefits suffer from increased complexity and reduced operational
flexibility. This necessitates employing more sophisticated process technologies which
bring about the licensors to develop joint venture cooperation.
References
1. J. N. S. Neto, J. G. Pacheco, L. dos Anjos Sacramento, R. Kalid, S. L. F. de
Magalhes, E. M. Queiroz, F. L. P. Pessoa, "Energy Integration- An example in a
retrofit of a petrochemical plant", 2nd Mercosur Congress on Chemical
Engineering and 4th Mercosur Congress on Process Systems Engineering, Rio de
Janeiro, Brazil, 2005, pp 1-10.
2. "Petrochemcomplex shields refining profits", Oil & Gas Journal; 96 (1998) 62-65.
3. K. Al-Qahtani, "Petroleum Refining and Petrochemical Industry Integration and
Coordination under Uncertainty", PhD Dissertation, University of Waterloo,
Waterloo, Ontario, Canada, 2009.
4. M. M. Ramrez-Corredores, "Catalysis: New Concepts and New Materials", 16th
World Petroleum Congress, Calgary, Canada, 2000.
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