Technologies For Conversion Of Unconventional and Renewable Feedstocks From BP - Philip M J Hill, BP International
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Technologies For Conversion Of Unconventional and Renewable Feedstocks From BP Philip M J Hill, BP International
Disclaimer
Copyright © 2013 , 2014 BP plc. All rights reserved. Contents of this presentation do not necessarily reflect the
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2
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
4
CTC is licensing four technologies with its collaboration partners
Compact Reformer & Fischer-Tropsch
Hummingbird®
Veba Combi-Cracking (VCCTM)
• A slurry phase • Conversion from • Ultra-selective second
hydrocracking/hydrogen generation ethanol
biomass, natural gas,
ation process for
converting petroleum coal and or petcoke dehydration
residues and coal into via syngas to diesel technology
directly marketable and naphtha at a split • Fully recycling pilot
lighter products of 80% and 20% plant
• Our VCCTM technology • Demonstration plant at • Identification of a
was operated at 300 barrels/ day scale collaboration licensor
commercial scale from • Compact reformer, has
1981 – 2000 in 3.5k bpd innovative mechanical
unit in Bottrop, Germany
design reducing size
• 4 licenses sold, first and weight.
commercial plant start
up 2014
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 1985 1990 1995 2000 2005 2010
Initiated R&D Commissioned Established Completed Technology
programme Hull Pilot Plant technology co- first FT run Commercialisation
operation with at Nikiski
Discovered Davy
cobalt based FT Sanctioned Nikiski plant met
catalyst Nikiski all technical
demonstration targets
plant ($86m)
6
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
7
Introduction
BP FT Technology
Widely
available
Natural Gas
Tails Gas Recycle
Hydrogen BP – Davy
proprietary
technology
Fischer-
UPGRADING UPGRADING
Coal Syngas Tropsch
Hydrotreater / Fractionation
Generation Syngas Products
Conversion cracker
Resid / Pet Coke
Offsites & Utilities (including air separation unit) Export Steam /
Power
Biomass
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.
8
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/country-
industry-forecasting-media/trading-places-abundant-
ethane-supplies-fuel-resurg
Source: BP 2030 Outlook: 2012
9
Bio-ethylene demand is predicted to increase substantially
10What 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
11Non-bio factors are also shaping demand for bio-ethylene
Ethylene cracker E2E Plant
Ethylene
Vinyl acetate
Ethylene Oxide Ethyl benzene Ethylene Di- LAOs / det.
Polyethylene monomer
(MEG) (Styrene) Chloride alcohols
(VAM)
• 20 – 300 Kte
Shanghai Ethylene Cracker Complex • Integration for derivative production
• Ease of transportation of ethanol versus ethylene
• Economies of scale • Speciality chemicals with niche demand
• Capacity of a typical single-train
steam cracker >1 million tpa
• Situated on / near a chemicals or
refinery complex
12BP has developed a proprietary ethanol to ethylene (E2E) technology, now
being demonstrated on a large, fully integrated pilot plant
2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
First bioethanol First poly-
Pilot plant tests completed ethylene
Initial test sanctioned successfully Pilot plant
High on pilot plant
completed on (~$10m) produced optimised
throughput Commissioned
alcohol demonstration
catalyst Hull pilot plant
dehydration run
screening
13The ultra selective BP Ethanol to Ethylene Process: Hummingbird®
technology
BP proprietary technology
Liquid Recycle
CH3CH2OH
Ethanol Reactor Separator Purification
(bio / chemical/
Ethylene
hydrous/ anhydrous)
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.
14The Hummingbird® process benefits from ultra high selectivity at lower cost
Hummingbird The Hummingbird® process has the
100 200-270 C, proprietary catalyst
o
following advantages:
• Ultra selective catalyst gives
>99.0% overall carbon conversion to
Carbon selectivity (%)
98 polymer grade ethylene
• Simplified product separation and
purification
96 • Results in 5% lower opex and 25%
lower capex when compared to first
First generation technology generation technologies
315-460oC
94
Pressure
15With a more energy efficient process Hummingbird® is leading the
way in GHG savings for ethanol dehydration technology
GWP from Process Energy Demands
0.5
0.4
Kg CO2e / Kg C2H4
0.3 Gas
Electricity
0.2 Steam
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
16Philip M J Hill MEng CEng MIChemE
Project Manager
Conversion Technology Centre
BP International Ltd
Chertsey Road
Sunbury-on-Thames Direct +44 203 401 2177
Middlesex TW16 7LN Mobile +44 7825 273243
United Kingdom philip.hill@uk.bp.com
www.bp.com
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