Technologies For Conversion Of Unconventional and Renewable Feedstocks From BP - Philip M J Hill, BP International

 
Technologies For Conversion Of Unconventional and Renewable Feedstocks From BP - Philip M J Hill, BP International
Technologies For Conversion Of Unconventional and
Renewable Feedstocks From BP

 Philip M J Hill, BP International
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
Downstream Technology Programmes

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Technologies For Conversion Of Unconventional and Renewable Feedstocks From BP - Philip M J Hill, BP International
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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Technologies For Conversion Of Unconventional and Renewable Feedstocks From BP - Philip M J Hill, BP International
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

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Technologies For Conversion Of Unconventional and Renewable Feedstocks From BP - Philip M J Hill, BP International
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)

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Technologies For Conversion Of Unconventional and Renewable Feedstocks From BP - Philip M J Hill, BP International
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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Technologies For Conversion Of Unconventional and Renewable Feedstocks From BP - Philip M J Hill, BP International
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.

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Technologies For Conversion Of Unconventional and Renewable Feedstocks From BP - Philip M J Hill, BP International
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

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Technologies For Conversion Of Unconventional and Renewable Feedstocks From BP - Philip M J Hill, BP International
Bio-ethylene demand is predicted to increase substantially

                                                             10
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

                                                                            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

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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     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

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The 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.

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The 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

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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
                                                                                                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

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Philip 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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