On–Purpose Propylene

Adding Value with SUPERFLEXTM

Michael Tallman

© 2008 KBR, Inc. All Rights Reserved.

“What” is SUPERFLEX?

♦ Catalytic olefin cracking

♦ Built on custom formulation of ZSM-5
catalysts
♦ Utilizes fluidized reactors
ƒ Over 60 year of KBR experience in FCC
♦ Cryogenic purification
ƒ KBR: Leading optimum olefins recovery
licensor

© 2008 KBR, Inc. All Rights Reserved.

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?

♦ ARCO / Lyondell – Development

ƒ 1990s
♦ KBR – Licensor and Technology
ƒ 1998 - current
♦ SASOL – First Adopter
ƒ 2002 - current
♦ JiHua – Second Adopter
ƒ 2006 - current

© 2008 KBR, Inc. All Rights Reserved.

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

© 2008 KBR, Inc. All Rights Reserved.

“When” SUPERFLEX?

NOW

© 2008 KBR, Inc. All Rights Reserved.

3
SUPERFLEX Technology
♦ Shape selective, medium pore, ZSM-5 catalyst

Orthoflow
Reactor

The key is a custom

catalyst specified by
…coupled with KBR
the hardware
© 2008 KBR, Inc. All Rights Reserved.

SUPERFLEX – Typical Ultimate Yields

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

© 2008 KBR, Inc. All Rights Reserved.

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

Regn Air Recycle C4/C5

Fresh Feed (paraffins will crack)

© 2008 KBR, Inc. All Rights Reserved.

Ethylene Plant with SUPERFLEX

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

© 2008 KBR, Inc. All Rights Reserved.

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

© 2008 KBR, Inc. All Rights Reserved.

Typical Refinery and Steam Cracker

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

© 2008 KBR, Inc. All Rights Reserved.

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

© 2008 KBR, Inc. All Rights Reserved.

Sasol Project Turbo

♦ Objectives
ƒ Clean fuels
ƒ Polymers expansion

SUPERFLEX addresses
both of these issues!

© 2008 KBR, Inc. All Rights Reserved.

7
SUPERFLEX at Sasol

♦ With elimination of lead, how can Sasol

ƒ Maintain octane in petrol pool?
ƒ Make this a growth opportunity?

The answer is Project Turbo

© 2008 KBR, Inc. All Rights Reserved.

Six Major “Modules” in Project Turbo

Module Description Licensor

Synfuels High octane gasoline, with
Catalytic significant amounts of
Cracker (SCC) propylene and ethylene
PP2 300 kta polypropylene unit

Unit 24 Major expansion of existing

steam cracker

Support Infrastructure, OSBL

Poly X Modifications to Poly 2,

infrastructure, OSBL
Poly 3 220 kta LDPE, high pressure
tubular process

© 2008 KBR, Inc. All Rights Reserved.

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

© 2008 KBR, Inc. All Rights Reserved.

KBR Project Role and Scope

♦ Basic process design for Sasol

SUPERFLEX
♦ EPCm for SUPERFLEX
ƒ Detailed engineering in Houston and
Monterrey
ƒ Global procurement of equipment from
Houston and Johannesburg
ƒ SUPERFLEX construction management
♦ Operator Training Simulator (OTS)

© 2008 KBR, Inc. All Rights Reserved.

9
SUPERFLEX – Development

© 2008 KBR, Inc. All Rights Reserved.

SUPERFLEX - Engineering
FRONT-END
FRONT-END LOADING
LOADING PHASE
PHASE EPC
EPC PHASE
PHASE
INFLUENCE POTENTIAL

Conceptual Feasibility Definition Detailed Construction Turnover &

FEL-1 FEL-2 FEL-3 Design Startup

© 2008 KBR, Inc. All Rights Reserved.

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

Region Name = new

Region Boundaries XMin = -10000.000 feet YMin = -10000.000 feet ZMin = -

10000.000 feet

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

01-pr-1002 6p5 S40 12.00 STRAIGHT 0.131 ft 3.0

STRAIGHT 298.668 ft For Rack Seg

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

01-pr-1022 6p5 S40 6.00 STRAIGHT 13.599 ft 3.0

BEND 5

Conceptual Feasibility Definition Detailed Construction Turnover &

FEL-1 FEL-2 FEL-3 Design Startup

© 2008 KBR, Inc. All Rights Reserved.

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

© 2008 KBR, Inc. All Rights Reserved.

11
SUPERFLEX – EPCm Worldwide

Monterey Johannesburg

Jakarta Houston
© 2008 KBR, Inc. All Rights Reserved.

SUPERFLEX – Concept to Commercial

C3 Splitter Fractionation Reactor Flue

525 ktpa Regenerator Gas

© 2008 KBR, Inc. All Rights Reserved.

12
SUPERFLEX – Concept to Commercial

C3 Splitter Fractionation Reactor Flue

525 ktpa Regenerator Gas

© 2008 KBR, Inc. All Rights Reserved.

SUPERFLEX - Innovations

♦ Hydraulics

© 2008 KBR, Inc. All Rights Reserved.

13
SUPERFLEX - Innovations

♦ Hydraulics
♦ Heat Balance

© 2008 KBR, Inc. All Rights Reserved.

SUPERFLEX - Innovations

♦ Hydraulics
♦ Heat Balance
♦ Catalyst
Filtration

© 2008 KBR, Inc. All Rights Reserved.

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
ƒ Ethylene plant, refinery
integration
ƒ Stand alone
♦ Commercially proven

© 2008 KBR, Inc. All Rights Reserved.

Thank you very much…

Questions?

© 2008 KBR, Inc. All Rights Reserved.

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