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ThefirstESTindustrialplantatSannazzaroRefinery:oneyearofoperationG.Rispoli,N.PanaritiERTC19thAnnualMeeting18-20November2014EST:theanswertomarketneeds1ESTresultsandoperationexperience3FirstESTCommercialUnitateni’sSannazzaroRefinery2ESTeconomics4Conclusions5ESTisahydrocrackingprocessbasedontwouniquefeatures:1.Nanodispersed(slurry)nonageingcatalyst2.Homogeneous&isothermalslurrybubblecolumnreactorTherecycleofunconvertedheavyendsallowsthetotalconversionofthebottomofthebarreltogoodqualitymiddledistillates(feedstockconversion97%)H2Refinedproducts(SCO)GasSlurryReactorFeedPurgeFractionationSystemCatprecCatalyst&ResidueRecycleH2Rec.ReactionProductsESTcaneasilyhandleveryheavyfeedstockWhatisEST?EniSlurryTechnology(EST)isanewtechnologyforthefullconversionofthebottomofthebarreltodistillatesTheavailabilityatindustriallevelofESTenablestheoilindustrytosolvecrucialneeds:MeetthedecliningdemandofFuelOilconvertingsurplusofRefineryResiduesintoDistillates(ZeroFuelOil-zerocokeRefinery)MeettheincreasingdemandofcleanerdistillateswithoutincreaseoftheCDUcapacityIncreasetherefineryflexibilitytosupplyofheaviercrudesInthiscontext,ESTallowsabetteruseoftheconventionaloilresourcesandpromotestheuseofnonconventionaloilresourcessuchasheavyandextraheavyoilsandoilsandsbitumenESTMeetsFundamentalNeedsofRefiningIndustryMarch2014:theSECAsestablishedtolimitSOxandparticulatematteremissionsare:1.BalticSeaarea–asdefinedinAnnexIofMARPOL2.NorthSeaarea(includingtheEnglishChannel)–asdefinedinAnnexVofMARPOL3.NorthAmericanarea(enteredintoforceon1stAugust2012);and4.UnitedStatesCaribbeanSea(enteredintoforceon1stJanuary2014)MarinefuelsSulphurstandards:keystepsSulphurinMarineFuels:towardsnewspecificationsNewmaritimeregulationscomingintoeffectstartingin2015significantreductionofresiduedemand(Source:MARPOL73/78,AnnexVIRegulationsforthePreventionofAirPollutionfromShips)6ESTSannazzaro:theindustrialprojectDieselLPGGasolineKeroOILMovementHDS1/2HDS3Reformer2/3TIPALKMTBEO.C.BitumenPitchToppingHDC1/2VACUUM1/2FCCVSBIGASSyngasROSEESTIntegrationofESTComplexintheSannazzaroRefinery:Totalrefiningcapacity11Mt/yAuxiliariesunits:-H2unit100kNm3/h-(runningsinceJan2013)-SRU160t/dBunkerizedcontrolroom(inoperationsinceJan2013)Slurryreactionunit23000bbl/dUpgradingprocessunitPTUESTComplexLay-outESTSannazzarotodayESTstart-upandfirstyearofoperationTheESThydrocrackerunithassuccessfullyandsafetybegunoperationsandisproducinghighqualitydistillates(oil-in:2013,October14th)Syncronizedstartup/operationofalltheauxiliaryfacilitiesassociatedwiththeUnitFirstresultsconfirmtheproperdesignoftheplant:majorequipmentsprovidedtheexpectedperformance(asperdesign)someminoradjustmentsinordertoimprovetheglobalESTplantperformanceESTfirstresultsSlurryreactors:perfectlyisothermalandhomogeneous(axialT2°CandradialT0.1°C)Gas/liquidseparation:Highefficiencyofgas-liquidseparation(nofoamingoccurrence)Conversion:ESTplanthasrunatnearly70-80%ofdesigncapacity(therearemarketconstraintsrelatedtothereductionofpurgevolumeacceptedbycementfactoriescomparedtothetheirplannedabsorptioncapacity).Feedconversionupto95-96%withoutcokeformationProductslateandquality:Resultsareingoodagreementwiththeexpectedproductdistributionascalculatedbyprocesssimulation(basedonESTDemonstrationplantdata).EuroVdieselyieldsishigherthan40wt.%ESTresults:Slurryreactorstemperatureprofile41041542042543043518/10/201420/10/201422/10/201424/10/201426/10/201428/10/201430/10/201401/11/201403/11/201405/11/201407/11/201409/11/201411/11/201413/11/2014Temperature[°C]Tint.Liv.A[TXI-468]Tint.Liv.B[TXI-467]Tint.Liv.D[TXI-465]Tint.Liv.E[TXI-464]Tint.Liv.G[TXI-462]Tint.Liv.H[TXI-461]T=2°C051015202530354045ExpectedESTUnitDatawt.%C1-C2LPGNaphthaDieselVGOPurgeESTresults:productyieldsTypicalESTFeedd15°C:1026g/cm3C5-Asph:15.4wt.%S:2.9wt.%Ni:88ppmN:0.6wt.%V:199ppmCCR:20.1wt.%Fe:41ppmEuroVdieselDesulphurizednaphthaCatfeed0.1%S(ormarinefuel0.1%S)PitchESTsecondrunApowerfailureoccurredinSannazzarorefinery(about3monthsafterstart-up),causingtheupsetofSteamReformerplantFollowingthisevent,thedecisionofESTshutdownwastaken,alsosupportedbythefollowingreasons:theadversescenarioforcementindustrythatlimitedESTmaximumproduction(duetoreductionofpurgevolumeacceptedbycementindustrywhosecapacityinItalydroppedby40%inthelastfewyears)theopportunitytotakeadvantageofmaintenanceactivitiestoimproveplantreliability,efficiencyandoperatingproceduresNewstartupofESTunit:June2014UnitoperatinginaverystablemodeStillpresentconstrainsincementmarketPartofthepitchissenttoSannazzaroexistinggasificationunitESTIndicativeeconomics:EuropeScenarioESTUnit-Economics05101520253035404550EARNINGSCostforH2(FuelEquiv.)OtherVariableCosts(FG,PW)CatalystandChemicalsOtherFixedCostsAmortizationEBIT$/BBLInputDataValueFO-GOSpread314$/tonNaturalGasCost10,4$/MMBTUDesignCapacity23.000BPSDESTIndicativeeconomics:FU-GOspreadsensitivityESTUnit-Economics05101520253035404550556065EARNINGSCostforH2(FuelEquiv.)OtherVariableCosts(FG,PW)CatalystandChemicalsOtherFixedCostsAmortizationEBIT$/BB