OrthoflowTM – KBR’s

Platform for Catalytic

Olefins Production
Curtis Eng

© 2008 KBR, Inc. All Rights Reserved.

APAC Propylene Value is High

Product Pricing in $/Metric Ton

1200

1000

800

600

400

200

0
2007 2008 2009 2010 2011 2012 2013 2014 2015 2016

Ethylene Propylene

Source, CMAI
© 2008 KBR, Inc. All Rights Reserved.

1
Steam Crackers Produce Propylene Byproduct

100.0
C3, C4 & Liquid Feed Steam Cracker
Ethane Feed
Steam Cracker
Ethylene Yield, wt%

10.0

1.0

0.1
1 10 100

Propylene Yield, wt%

Relatively low propylene to ethylene ratio is not consistent with market requirements.

© 2008 KBR, Inc. All Rights Reserved.

Sources of Propylene

C3 Dehydro, 4%
Refineries, 30%

Others, 2%
Steam Crackers, 64%

Refiners moving toward high

olefins mode FCC operations

© 2008 KBR, Inc. All Rights Reserved.

2
Typical FCC Propylene Yield

100.0
Ethylene Yield, wt%

10.0

1.0

FCC

0.1
1 10 100

Propylene Yield, wt%

FCC propylene to ethylene ratio is high, but higher propylene yields

would improve the economics.
© 2008 KBR, Inc. All Rights Reserved.

Typical Steam Cracker

ETHANE
STEAM CRACKER
PROPANE ETHYLENE
PLUS PRODUCT RECOVERY
BUTANES PROPYLENE
NAPHTHA

C4’s PYROLYSIS GASOLINE

Potential for economic improvement – ???

produce propylene from C4’s and
pyrolysis gasoline

© 2008 KBR, Inc. All Rights Reserved.

3
Steam Cracker with Catalytic Olefins

ETHANE
STEAM CRACKER
PROPANE ETHYLENE
PLUS PRODUCT RECOVERY
BUTANES PROPYLENE
NAPHTHA

Propane and
Ethane Recycle
C4’s LIGHT PYGAS

PROPYLENE Catalytic Olefins

ETHYLENE (Orthoflow)
FCC GASOLINE

© 2008 KBR, Inc. All Rights Reserved.

What Is the Orthoflow Way?

♦ How does the technology

work?
♦ What are the advantages?
♦ What are the components?

ConocoPhillips Ferndale

© 2008 KBR, Inc. All Rights Reserved.

4
 How Does FCC Work?
C2’S
C3’S
FEED
C4’S
REACTOR
GASOLINE
LCO
CATALYST COKED
CATALYST SLURRY OIL

FLUE GAS

REGENERATOR

AIR
© 2008 KBR, Inc. All Rights Reserved.

KBR Orthoflow FCC Tour

Reaction products routed

to fractionation section
Products and catalyst
separated by riser termination
Flue gas collected at top
of regenerator
Feed and catalyst flow up riser, Entrained hydrocarbons
cracking reactions occur stripped from coked catalyst

Coked catalyst distributed

at top of regenerator bed
Feed and catalyst mixed
at bottom of riser

Combustion air distributed

Regenerated catalyst at bottom of bed
recirculated to riser
© 2008 KBR, Inc. All Rights Reserved.

5
What Are the Features and Benefits?

♦ One Piece Vertically Stacked Unit

ƒ Minimizes plot space
ƒ Minimizes supporting structure
ƒ Minimizes expansion joints
ƒ Potential for shop fabrication
♦ Stripper Submerged in
Regenerator
ƒ Minimizes vertical height
♦ Cold Wall Construction
ƒ Carbon steel easier to weld
ƒ Minimizes temperature embrittlement
ƒ Minimizes thermal expansion ExxonMobil Altona

© 2008 KBR, Inc. All Rights Reserved.

Elevation Comparison

Side by Side KBR

© 2008 KBR, Inc. All Rights Reserved.

6
KBR FCC Technology Is Well Proven

♦ Units licensed by KBR

♦ Constructed world’s first FCC
ƒ Exxonmobil Baton Rouge -- 1942
♦ Licensed world’s first RFCC
ƒ Phillips Borger -- 1961

© 2008 KBR, Inc. All Rights Reserved.

Recent Orthoflow FCC Units

Nippon Oil Sendai KPI Chiba

© 2008 KBR, Inc. All Rights Reserved.

7
Sasol South Africa

Johannesburg Pretoria ♦ Maximize

Headquarters Capital
propylene and
ethylene
Secunda ♦ Process light
hydrocarbon
olefinic feed
♦ Produce high
octane gasoline
blending
component
Sasolburg
© 2008 KBR, Inc. All Rights Reserved.

KBR Recommendations to Sasol

♦ SUPERFLEX™ technology
using an Orthoflow converter
section
♦ Catalyst system designed to
crack light olefinic feeds into
ethylene and propylene

Light
Feed
Fuel

© 2008 KBR, Inc. All Rights Reserved.

8
Orthoflow Converter Cost Advantages

♦ Reduced structural and

foundation costs
♦ Smaller footprint than side
by side arrangement
♦ Shipment in one piece -
less welding in field
♦ Carbon steel construction
♦ Lower cost

Sasol Superflex Converter

© 2008 KBR, Inc. All Rights Reserved.

Best Existing Technology for Sasol

Clean
Flue Gas
♦ Closed Cyclones
ƒ Minimize post riser residence
FLOW

ƒ No internal expansion joints

♦ DYNAFLUX™ STRIPPING
ƒ Better stripping efficiency, even in
high flux strippers
ƒ Easily accessible Plenum
Cyclones

♦ Third Stage Separator (TSS)

ƒ Removes fines from flue gas
Closed Cyclones
ƒ Achieves less than 50 mg/Nm3
DynaFlux™
DynaFlux™ Catalyst
Fines

© 2008 KBR, Inc. All Rights Reserved.

9
Issue #1 – Maintain Regen Temperature

♦ Cracking reactions are

endothermic
♦ Light feed produces little
coke
♦ External heat source
required
♦ KBR patented catalyst well
for continuous fuel firing
♦ Commercially proven

© 2008 KBR, Inc. All Rights Reserved.

Issue #2 – Avoid Catalyst in Naphtha

Solids Free ♦ Light feeds generate no

Light Products
heavy oil
Wash ƒ Catalyst fines in
OILWASH TOWER

Oil
naphtha product?
Reactor ♦ KBR patented catalyst
Products removal
ƒ Catalyst fines
Backflush recycled to unit
Oil SOLIDS
REMOVAL ♦ Commercially proven

Fines
Recycle

© 2008 KBR, Inc. All Rights Reserved.

10
Catalytic Olefins Summary

P/E Wt%
What Feeds Comments
Ratio Olefins
Advanced Paraffinic naphtha, ~0.7-1.1 55-65% SK to commercialize
Catalytic Olefins light distillates by 2010
(ACO)
SUPERFLEX Olefinic C4-C10 ~1.8-3.0 45-65% Sasol startup 2006
feeds JiHua 2nd licensee

MAXOFIN™ Gas oil and resids ~3.0-4.0 25-40% Commercially Ready

© 2008 KBR, Inc. All Rights Reserved.

Technology Options
Production of Ethylene vs. Propylene

100.0
C3, C4 & Liquid Feed Steam Cracker
Ethane Feed
Steam Cracker ACO
Ethylene Yield, wt%

10.0
SUPERFLEX
MAXOFIN

1.0

FCC

0.1
1 10 100

Propylene Yield, wt%

© 2008 KBR, Inc. All Rights Reserved.

11
Conclusions

♦ Catalytic routes to olefin

production maximize propylene
yields

♦ Orthoflow FCC technology

platform proven and flexible

♦ Three different catalytic olefins

processes available depending
on feedstock

Sasol Superflex

© 2008 KBR, Inc. All Rights Reserved.

Thank you very much…

Questions?

© 2008 KBR, Inc. All Rights Reserved.

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