Technologies For Conversion Of Unconventional and Renewable

Technologies For Conversion Of Unconventional and
Renewable Feedstocks From BP
Philip M J Hill, BP International
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Downstream Technology Programmes
3
The CTC’s strategic purpose is to develop proprietary technologies
aimed at business renewal for BP
Strategic themes
Access to growth regions and markets
Participation options in renewable fuels and materials
Enabling value from challenging feedstocks, intermediates
and by-products in BP’s portfolio
Leveraging in-house technology positions and capability in
process development and catalysis
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• Conversion from
biomass, natural gas,
coal and or petcoke
via syngas to diesel
and naphtha at a split
of 80% and 20%
• Demonstration plant at
300 barrels/ day scale
• Compact reformer, has
innovative mechanical
design reducing size
and weight.
Hummingbird®
• A slurry phase
hydrocracking/hydrogen
ation process for
converting petroleum
residues and coal into
directly marketable
lighter products
• Our VCCTM technology
was operated at
commercial scale from
1981 – 2000 in 3.5k bpd
unit in Bottrop, Germany
• 4 licenses sold, first
commercial plant start
up 2014
Compact Reformer & Fischer-Tropsch
Veba Combi-Cracking (VCCTM)
CTC is licensing four technologies with its collaboration partners
• Ultra-selective second
generation ethanol
dehydration
technology
• Fully recycling pilot
plant
• Identification of a
collaboration licensor
5
BP and JM Davy Process Technology (Davy) Fischer-Tropsch (FT) History
BP has been actively developing FT technology since 1981 and has
invested over $500 million to date
1980
Initiated R&D
programme
1985
1990
Commissioned
Hull Pilot Plant
Discovered
cobalt based FT
catalyst
1995
2000
2005
2010
Technology
Established
Completed
Commercialisation
technology cofirst FT run
operation with
at Nikiski
Davy
Nikiski plant met
Sanctioned
all technical
Nikiski
targets
demonstration
plant ($86m)
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BP-Davy GTL Demonstration Unit
Nikiski, Alaska
- Demonstration plant met all performance
targets
- No negative impact to catalyst performance
from (externally caused) unplanned shut
downs
- The catalyst was contained in thousands of
commercial scale tubes
- FT converter demonstrated 100%
availability
- 300 barrel a day scale plant
- 16,000 hours on stream
© BP 2013
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Introduction
BP FT Technology
Tails Gas Recycle
Natural Gas
Coal
Widely
available
Hydrogen
Syngas
Generation
FischerTropsch
Syngas
Conversion
UPGRADING
Hydrotreater /
cracker
BP – Davy
proprietary
technology
UPGRADING
Fractionation
Products
Resid / Pet Coke
Offsites & Utilities (including air separation unit)
Biomass
Export Steam /
Power
BP FT
Provides a low risk, competitive FT and upgrading technology. Syngas generation
technologies are all widely deployed and practised. Robust fixed bed technology uses
standard industry multi-tubular reactors.
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Population growth and GDP growth will drive increasing ethylene
demand.
‘In the next 10 years, IHS estimates global ethylene demand
will grow at approximately 4 percent a year, reaching nearly
196 MMT by 2023’
Source:http://press.ihs.com/press-release/countryindustry-forecasting-media/trading-places-abundantethane-supplies-fuel-resurg
Source: BP 2030 Outlook: 2012
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Bio-ethylene demand is predicted to increase substantially
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What is driving bio-ethylene demand?
Energy demand and Global warming
According to the Intergovernmental Panel on Climate Change (IPCC), warming of the
climate system is happening. Over the next 20 years, it’s predicted that global energy
demand will increase by nearly 40%.
Bio-ethylene product creates substantial environmental benefits
Referencing the International Renewable Energy Agency’s (IRENA) paper; ‘bio-ethylene
can reduce GHG emissions by up to 40% and save fossil energy by up to 60%
compared to petrochemical ethylene’1 .
Change in consumer attitudes
Awareness of sustainability and global warming has affected consumer preferences
creating a market for ‘green products’ where premiums of up to 30% for bio-MEG2 have
been publically stated.
1. IEA-ETSAP and IRENA© Technology Brief I13 – January 2013
2. ICIS news; 09 May 2013 ; APIC '13: Greencol Taiwan Corp to keep 67% ops at bio-EG units
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Non-bio factors are also shaping demand for bio-ethylene
Ethylene cracker
E2E Plant
Ethylene
Polyethylene
Shanghai Ethylene Cracker Complex
•
•
•
Economies of scale
Capacity of a typical single-train
steam cracker >1 million tpa
Situated on / near a chemicals or
refinery complex
•
•
•
•
Ethylene Oxide
(MEG)
Vinyl acetate
monomer
(VAM)
Ethyl benzene
(Styrene)
Ethylene DiChloride
LAOs / det.
alcohols
20 – 300 Kte
Integration for derivative production
Ease of transportation of ethanol versus ethylene
Speciality chemicals with niche demand
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BP has developed a proprietary ethanol to ethylene (E2E) technology, now
being demonstrated on a large, fully integrated pilot plant
2004
2005
Initial test
completed on
alcohol
dehydration
2006
High
throughput
catalyst
screening
2007
Pilot plant
sanctioned
(~$10m)
2008
2009
Commissioned
Hull pilot plant
2010
2011
2012
First bioethanol First polytests completed ethylene
successfully
on pilot plant
produced
2013
Pilot plant
optimised
demonstration
run
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The ultra selective BP Ethanol to Ethylene Process: Hummingbird®
technology
BP proprietary technology
Liquid Recycle
CH3CH2OH
Ethanol
(bio / chemical/
hydrous/ anhydrous)
Reactor
Separator
Purification
Ethylene
Hummingbird® is a next generation dehydration technology
Facilitated by proprietary catalyst technology, the Hummingbird® technology’s milder
operating regime gives superior conversion efficiency to existing technologies.
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The Hummingbird® process benefits from ultra high selectivity at lower cost
Carbon selectivity (%)
100
Hummingbird
o
200-270 C, proprietary catalyst
The Hummingbird® process has the
following advantages:
• Ultra selective catalyst gives
>99.0% overall carbon conversion to
polymer grade ethylene
98
• Simplified product separation and
purification
• Results in 5% lower opex and 25%
lower capex when compared to first
generation technologies
96
First generation technology
315-460oC
94
Pressure
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With a more energy efficient process Hummingbird® is leading the
way in GHG savings for ethanol dehydration technology
GWP from Process Energy Demands
Kg CO2e / Kg C2H4
0.5
0.4
Gas
Electricity
Steam
0.3
0.2
0.1
0.0
Hummingbird®
1st Gen
GWP – Global Warming Potential
•
‘Bio’ ethylene production from sugar cane ethanol saves ~3.65 kgCO2e per kg bioethylene if compared with
conventional ‘fossil’ ethylene
•
Carbon capture for Hummingbird® technology assessed as 2.2 kg/kg (‘credits minus debits’)
•
Independent of scope. Location: Brazil
•
Process energy – Hummingbird® technology does not require gas combustion
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Philip M J Hill
MEng CEng MIChemE
Project Manager
Conversion Technology Centre
BP International Ltd
Chertsey Road
Sunbury-on-Thames
Middlesex TW16 7LN
United Kingdom
Direct +44 203 401 2177
Mobile +44 7825 273243
[email protected]
www.bp.com
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