Hydrocarbon Processing - December 2021 - GP-17

SPECIAL FOCUS: PLANT DESIGN
& PROCESS CONTROL
The path to midstream profitability:
Retrofit to improve returns
J. ARLOTTA, Honeywell UOP, Des Plains, Illinois; and J. ANGUIANO, Honeywell UOP, Midland, Texas
The U.S. shale revolution has matured. Due to higher oil
prices, shale production has shifted from natural gas basins to
oil-rich basins. Oil-focused drilling typically produces associated
gas as a byproduct, which is a blend of natural gas and
natural gas liquids (NGLs). The U.S. is the world's largest NGL
producer, supplying 11 MM metric t, or 29% of the global NGL
supply, earlier this year. To manage these volumes, the U.S. has
more than 400 gas processing plants that separate the associated
gas into distinct streams of NGLs and natural gas.
Most gas processing plants recover NGLs, such as ethane
and propane, using a process technologya
developed in the late
1970s. Downstream of the gas processing plant, ethane and propane
are feedstocks for producing ethylene and propylene. The
abundance of these products has boosted U.S. petrochemical
production and has driven the dramatic increase in petrochemicals
exports to the global market.
Pivoting to profitability. Oil markets recently have faced three
significant downturns: the 2007 global financial crisis, a global
price war in 2014 and the severe drop in demand caused by the
COVID-19 pandemic in 2020. Prior to COVID-19, particularly
between 2018-2019, the growth rate of U.S. oil production had
already begun to slow because of years of oil production growth
without a focus on profitability. Overall, investor returns of Standard
& Poor's 500 index dramatically surpassed that of the exploration
and production sector, causing investors to pressure shale
producers to focus more on slower but more profitable growth.
Gas processors responded by modifying existing assets
to improve returns. In a capital constrained environment, gas
processors can typically upgrade or retrofit their existing equipment
for less than 5% of the total installation cost of a new gas
processing plant. By doing so, they can efficiently improve product
recovery, operational flexibility, energy efficiency and plant
capacity. Given the historical volatility of the oil market, gas
processors can ensure profitability by increasing the flexibility
of their assets in preparation for a range of market conditions.
The value of ethane and propane. As the global economy
recovers from COVID-19, the growth of U.S. oil production is
forecast to be slower than it was pre-COVID-19, reducing the
growth of NGL supply. Simultaneously, global demand for petrochemical
feedstocks (e.g., ethane and propane) is forecast to
surpass pre-COVID-19 growth rates.
Global ethylene demand is forecast to increase 5%/yr to approximately
200 MM metric t by 2025. Forty percent of ethylene
production will be derived from ethane as a feedstock. Global
ethane demand is forecast to increase to 5.2 MMbpd in 2025
(FIG. 1), a large portion of which is driven by U.S. demand centers
along the U.S. Gulf Coast. To match the increase in ethane
demand, U.S. gas processors will recover more ethane from associated
gas. During this period, U.S. ethane supply will increase
by 5%/yr, ultimately supplying 49% of global ethane in 2025.
Ethane will be more valuable for gas processors with close
geographical proximity to the major demand centers-such
as the U.S. Gulf Coast, where most U.S. petrochemical facilities
and export terminals are located. For example, the Permian
Basin-the fastest growing oil production basin in the U.S.-is
near U.S. Gulf Coast export terminals and local demand centers.
In addition, the Permian Basin has lower production costs due
to an abundance of oil reserves and established infrastructure.
Ethane pricing at the Mont Belvieu terminal will continue to
increase through 2025. Because of these economic advantages,
gas processors in the Permian Basin have shifted their operations
to ethane recovery-the practice of recovering ethane and
other high-value NGLs, such as propane.
Conversely, due to smaller profit margins, the same may not
be true for capturing ethane in basins with higher production
costs (e.g., the Niobrara Basin in northeast Colorado and southeast
Wyoming). These basins tend to operate under ethane
rejection, where ethane is not recovered but simply left in the
natural gas stream to be sold at lower natural gas prices. For this
reason, ethane's price floor is the price of natural gas. The profitability
of either operation mode-ethane rejection or ethane
recovery-will depend on the market price of ethane at a point
in time. As the price of ethane continues to increase, there are
new opportunities for swing basins to switch from ethane rejection
to ethane recovery to capture ethane's additional value.
1
2
3
4
5
6
Global ethane demand
U.S. ethane supply
2015
2016
2017
2018
2019
2020
2021
2022
2023
2024
2025
FIG. 1. Global ethane demand (MMbpd), 2015-2025. Source: IHS Markit.
Gas Processing & LNG | NOVEMBER/DECEMBER 2021 17
Volume, MMbpd

Hydrocarbon Processing - December 2021

Table of Contents for the Digital Edition of Hydrocarbon Processing - December 2021

Contents
Hydrocarbon Processing - December 2021 - Cover1
Hydrocarbon Processing - December 2021 - Cover2
Hydrocarbon Processing - December 2021 - Contents
Hydrocarbon Processing - December 2021 - 4
Hydrocarbon Processing - December 2021 - 5
Hydrocarbon Processing - December 2021 - 6
Hydrocarbon Processing - December 2021 - 7
Hydrocarbon Processing - December 2021 - 8
Hydrocarbon Processing - December 2021 - 9
Hydrocarbon Processing - December 2021 - 10
Hydrocarbon Processing - December 2021 - 11
Hydrocarbon Processing - December 2021 - 12
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Hydrocarbon Processing - December 2021 - 33
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Hydrocarbon Processing - December 2021 - 81
Hydrocarbon Processing - December 2021 - 82
Hydrocarbon Processing - December 2021 - Cover3
Hydrocarbon Processing - December 2021 - Cover4
Hydrocarbon Processing - December 2021 - GP-1
Hydrocarbon Processing - December 2021 - GP-2
Hydrocarbon Processing - December 2021 - GP-3
Hydrocarbon Processing - December 2021 - GP-4
Hydrocarbon Processing - December 2021 - GP-5
Hydrocarbon Processing - December 2021 - GP-6
Hydrocarbon Processing - December 2021 - GP-7
Hydrocarbon Processing - December 2021 - GP-8
Hydrocarbon Processing - December 2021 - GP-9
Hydrocarbon Processing - December 2021 - GP-10
Hydrocarbon Processing - December 2021 - GP-11
Hydrocarbon Processing - December 2021 - GP-12
Hydrocarbon Processing - December 2021 - GP-13
Hydrocarbon Processing - December 2021 - GP-14
Hydrocarbon Processing - December 2021 - GP-15
Hydrocarbon Processing - December 2021 - GP-16
Hydrocarbon Processing - December 2021 - GP-17
Hydrocarbon Processing - December 2021 - GP-18
Hydrocarbon Processing - December 2021 - GP-19
Hydrocarbon Processing - December 2021 - GP-20
Hydrocarbon Processing - December 2021 - GP-21
Hydrocarbon Processing - December 2021 - GP-22
Hydrocarbon Processing - December 2021 - GP-23
Hydrocarbon Processing - December 2021 - GP-24
Hydrocarbon Processing - December 2021 - GP-25
Hydrocarbon Processing - December 2021 - GP-26
Hydrocarbon Processing - December 2021 - GP-27
Hydrocarbon Processing - December 2021 - GP-28
Hydrocarbon Processing - December 2021 - GP-29
Hydrocarbon Processing - December 2021 - GP-30
Hydrocarbon Processing - December 2021 - GP-31
Hydrocarbon Processing - December 2021 - GP-32
Hydrocarbon Processing - December 2021 - GP-33
Hydrocarbon Processing - December 2021 - GP-34
Hydrocarbon Processing - December 2021 - GP-35
Hydrocarbon Processing - December 2021 - GP-36
Hydrocarbon Processing - December 2021 - GP-37
Hydrocarbon Processing - December 2021 - GP-38
Hydrocarbon Processing - December 2021 - GP-39
Hydrocarbon Processing - December 2021 - GP-40
https://www.nxtbook.com/gulfenergyinfo/gulfpub/HPI-Market-Data-2023-v3
https://www.nxtbook.com/gulfenergyinfo/gulfpub/hpi-market-data-2024-v2
https://www.nxtbook.com/gulfenergyinfo/gulfpub/hpi-market-data-2024
https://www.nxtbook.com/gulfenergyinfo/gulfpub/gas-processes-handbook-2022_v2
https://www.nxtbook.com/gulfenergyinfo/gulfpub/gas-processes-handbook-2022
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https://www.nxtbook.com/nxtbooks/gulfpub/petrochemical_processes_handbook_2021_v2
https://www.nxtbook.com/nxtbooks/gulfpub/petrochemical_processes_handbook_2021
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https://www.nxtbook.com/nxtbooks/gulfpub/catalyst_handbook_2020_v2
https://www.nxtbook.com/nxtbooks/gulfpub/catalyst_handbook_2020
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202012
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202011
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202010
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2021
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202009
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202008
https://www.nxtbook.com/nxtbooks/gulfpub/refining_processes_handbook_2020
https://www.nxtbook.com/nxtbooks/gulfpub/refining_processes_handbook_2020_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202007
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https://www.nxtbook.com/nxtbooks/gulfpub/hp_201912
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201911
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2020_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2020
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201910
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201909
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https://www.nxtbook.com/nxtbooks/gulfpub/hp_201901
https://www.nxtbook.com/nxtbooks/gulfpub/petrochemical_2018_v2
https://www.nxtbook.com/nxtbooks/gulfpub/petrochemical_2018
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201812
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2019_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2019
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201811
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https://www.nxtbook.com/nxtbooks/gulfpub/hp_201801
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201712
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201711
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https://www.nxtbook.com/nxtbooks/gulfpub/hp_201701
https://www.nxtbook.com/nxtbooks/gulfpub/hp_2017mediaplanner
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201612
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201611
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201610
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201609
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