Professional Documents
Culture Documents
Michael Tallman
“What” is SUPERFLEX?
1
“Where” is SUPERFLEX?
Secunda
Houston Jilin
Sasol,
Sasol, RSA
RSA
R&D
R&D Center
Center
JiHua,
JiHua, PRC
PRC
© 2008 KBR, Inc. All Rights Reserved.
“Who’s” of SUPERFLEX?
2
“When” SUPERFLEX?
SUPERFLEX™
SUPERFLEX™
100
Sasol,
Sasol, Secunda,
Secunda, 2006
2006
JiHua,
JiHua, Jilin,
Jilin, 2009
2009
80
Propylene
kta 60
MMt/y 40
20
0
2005 2010
Planned Capacity Forecast Demand
“When” SUPERFLEX?
NOW
3
SUPERFLEX Technology
♦ Shape selective, medium pore, ZSM-5 catalyst
Orthoflow
Reactor
100%
C6+
80%
C2-
60% Propane
60
60––70%
70%
Olefin 40% Ethylene
Olefinyield
yield
22––2.5
2.5::11 20% Propylene
P/E
P/Eratio
ratio
0%
Mixed C4 Mixed C5 Light Cat Light Coker
Naphtha Naphtha
4
SUPERFLEX – Reaction Section
To Flue
Gas System Reactor Effluent
CW
To Recovery
Steam
Catalyst Fuel
Fines Oil
BFW
Oil Wash
SUPERFLEX Tower
Orthoflow Catalyst Storage
Reactor / And Handling
Regenerator
Ethylene
Hot Propylene
Naphtha
HotSection
Section Cold
ColdSection
Section Additional Butadiene
Additional PyGas
Treating
Treating
Ethylene Plant
Naphtha
EthyleneÏ
Hot PropyleneÏ
HotSection
Section Cold
ColdSection
Section Additional Butadiene
Additional PyGas
Treating
Treating
Ethylene Plant
Integrated with
SUPERFLEX
5
SUPERFLEX – Integration with Cracker
Pyrolysis Pyrolysis +
Only SUPERFLEX
Feed Consumption (Kt/a)
1891 1995
Naphtha Feedstock
Product Rates (Kt/a)
Ethylene 700 700
Propylene 419 535
Propylene to Ethylene ratio 0.6 0.76
FCC
FCC Isom
Isom
Gasoline
Crude Distillate
Oil CDU Hydrotreaters
Hydrotreaters Others Jet / Kero
Others
Fuel Oil
ROSE
ROSE Coker
Coker
Naphtha
Ethylene
Hot Propylene
HotSection
Section Cold
ColdSection
Section Butadiene
PyGas
6
SUPERFLEX – Petrochemical Refinery
FCC
FCC Isom
Isom
Gasoline
Crude Distillate
Oil CDU Hydrotreaters
Hydrotreaters Others Jet / Kero
Others
Fuel Oil
ROSE
ROSE Coker
Coker
Naphtha
SUPERFLEX
SUPERFLEX
EthyleneÏ
Hot PropyleneÏ
HotSection
Section Cold
ColdSection
Section ButadieneÏ
PyGas
♦ Objectives
Clean fuels
Polymers expansion
SUPERFLEX addresses
both of these issues!
7
SUPERFLEX at Sasol
8
Sasol Conceptual Flow Scheme
Existing Olefins
Rich Streams High octane C5+
blending components
Propylene to polymers
(>500 kta)
Ethylene to polymers
(>200 kta)
Fresh
Olefinic Ethane/propane
C6/C7 Feed
Converter
Section
Recovery Mixed C4s to alky
Section
C1 & lighter fuel
9
SUPERFLEX – Development
SUPERFLEX - Engineering
FRONT-END
FRONT-END LOADING
LOADING PHASE
PHASE EPC
EPC PHASE
PHASE
INFLUENCE POTENTIAL
10
SUPERFLEX - Engineering
FRONT-END
FRONT-END LOADING
LOADING PHASE
PHASE EPC
EPC PHASE
PHASE
INFLUENCE POTENTIAL
1
Produced By ASD Pipe Router on Apr 06, 1999
Unit
Plant Name = son
Building Name = ali5
Material
XMax = 10000.000 feet YMax = 10000.000 feet ZMax = 10000.000
feet
---------------------------------------------------------------------------------------------------------------
---------
Line - Id PipeSpec Schedule Nom Dia(in) Part Quantity Remarks
Insul Thk(in)
---------------------------------------------------------------------------------------------------------------
2 Take-off
---------
01-pr-1001 6p5 S40 6.00 STRAIGHT 107.123 ft 3.0
STRAIGHT 272.411 ft For Rack Seg
BEND 9
BRANCH 1 6.0 in X 6.0 in
VALVE 1
3 01-pr-1020
01-pr-1021
4
6p5
6p5
S40
S40
6.00 STRAIGHT 53.320 ft
BEND
BRANCH
6.00
BEND
5
1 6.0 in X 6.0 in
STRAIGHT
4
27.113 ft
3.0
3.0
SUPERFLEX - Procurement
Global Supply Issues
Freight
Finite Costs
Commodity
Supplier/
Price
Inflation
Subcontractor
Capacity Diminished
Quality
Procurement
Coinciding
Dramatically
Growing
Demand
Technology
Projects
Sub Supplier/
Currency &
Financial
Risk
Subcontractor
Management Early Supplier
“Stronger than currently expected wage
developments pose substantial
Engagement
upward risk to price stability”
Local Jean-Claude Trichet – President European Wage Rates
Content Central Bank & Staff
Requirements
Turnover
11
SUPERFLEX – EPCm Worldwide
Monterey Johannesburg
Jakarta Houston
© 2008 KBR, Inc. All Rights Reserved.
12
SUPERFLEX – Concept to Commercial
SUPERFLEX - Innovations
♦ Hydraulics
13
SUPERFLEX - Innovations
♦ Hydraulics
♦ Heat Balance
SUPERFLEX - Innovations
♦ Hydraulics
♦ Heat Balance
♦ Catalyst
Filtration
14
SUPERFLEX Summary
♦ “Propylene on Purpose”
♦ Value added, low cost
feeds to propylene
Pilot Plant ♦ Byproduct value in
Concept Commercialization ethylene and aromatic
gasoline
Sasol, Feb 2004
♦ Applications
Ethylene plant, refinery
integration
Stand alone
♦ Commercially proven
Questions?
15