2010.1817.FLEXICOKING-BBTC-Final-10-5.ppt

Research and EngineeringFLEXICOKING Coking and Integrated Steam/Air GasificationCoking and Integrated Steam/Air GasificationExxonMobil Research&Engineering CompanyDr.Girish Chitnis,Dr.Simon Hacker and Mr.Tim HilbertInternational BBTCOct 5-6,2010LondonFLEXICOKING:Integrated Coking and GasificationIntegrated Coking and GasificationFLEXICOKINGTM Integrated Coke GasificationKey features of technologyCommercial experienceFLEXIGAS Utilization-Clean Fuel GasUtilization in refinery or for power productionRotterdam and TOA Oil FLEXICOKING ExperienceCommercial operationsExpansion and joint venture for power production Rosneft(Tuapse,Russia)joins the list of Hellenic(Elefsis,Greece)and PetroPeru(Talara,Peru)as a New Licensee1FLEXICOKING:Integrated Coking and GasificationIntegrated Coking and GasificationFLEXICOKINGTM Integrated Coke GasificationKey features of technologyCommercial experienceFLEXIGAS Utilization-Clean Fuel GasUtilization in refinery or for power productionRotterdam and TOA Oil FLEXICOKING ExperienceCommercial operationsExpansion and joint venture for power production Rosneft(Tuapse,Russia)joins the list of Hellenic(Elefsis,Greece)and PetroPeru(Talara,Peru)as a New Licensee2Coking ProcessCoking is the Most Widely Used Resid Conversion Approach Worldwide!Delayed Coking Furnace&Drum,Batch Process,Coke PitsFLUID COKING Fluidized Bed,Continuous,Coke Silos and Closed System Environmental considerations important for bothCoke by-product Yield Typically 1/3 of FeedSimilar amount for other resid conversion processes3Heavy CrudesResidsCoke Dispositions Can Have A Major Impact on Project Economics!Delayed Coking(several providers)FLUID COKINGTM(ExxonMobil)Product:Product:(a)(a)Yield(wt%)Yield(wt%)Fuel Gas&LPG10C5+Liquids55Coke(b)35Total100FLUID COKING Technology and Commercial ExperienceDeveloped by ExxonMobil Research and Engineering Company(EMRE)as an Extension of FCC Fluid Solids TechnologyHeavy feed injected into fluidized coke bed with feed rings/nozzlesPartial combustion of coke in burner and coke circulation provides heat for reactionScrubber preheats feed,separates coke fines,and sets recycle cut pointLiquid products split in down stream fractionatorsCoke pneumatically conveyed and stored in silos for fuel coke market4Reactor Products to FractionatorsHot CokeCold CokeScrubberReactorReactorHeavy FeedBurnerBurnerAirProduct CokeFlue Gas to CO BoilerFirst commercialized in ExxonMobils Billings,Montana Refinery in 1954!Over 420 kB/D of Operating Capacity Worldwide7 Units with last S/U in 06-Unit Rates from 10 110 kB/DSame Liquid Yields as Fluid or Delayed CokingCoke Gasified in Integrated Steam Air GasifierProduces Clean CO/H2 Fuel Gas Product Instead of CokeFLEXSORB Hindered Amine Reduces H2S to Low Level Low SOXNitrogen Diluent Reduces BTU Content,But Low NOXFLEXIGAS Burned in Refinery or Third Party Furnaces/BoilersFLEXICOKING SteamGenerationFLEXIGASFLEXIGASClean FuelClean FuelReactor Products to FractionatorsAirHot CokeCold CokeScrubberGasifierGasifierCokeFinesFinesRecoveryTertiaryCyclonesTO FLEXSORB Gas TreatingDirect Contact CoolerSour WaterSteamReactorReactorHeavy FeedCoke Withdrawal FLEXIGAS Users:RefineryThird Party ConsumersHeaterHeaterAir Blower5FLEXICOKING:Reactor Product/YieldsFLEXICOKING:Reactor Product/YieldsSimilar to Other Coking Processes-Thermal ConversionFeed and Recycle Cut point Differences can complicate Comparisons6FLEXIGASCoke,Wt%Coke,Wt%Net Product Coke1.7Gasified Coke28.6Total30.3Gas&LiquidsGas&LiquidsWt%FFLV%FFC2 Fuel Gas6.7C3/C4 LPG4.4Total C4-11.1C5/430 F15.320.8430/650 F11.012.6650/975 F32.233.2Total C5+58.666.6GGR RH HAir&SteamProducts FeedFeedTypeVR Nominal cut point,C565 Nominal cut point,F1050Feed Properties Gravity,API6.9 Sulfur,wt%4.6 Conradson Carbon,wt%26 Nickel,wppm18 Vanadium,wppm108Bold the font in the text boxesFLEXICOKING:Produces a Significant Quantity of Valuable Clean Fuel GasProduces a Significant Quantity of Valuable Clean Fuel Gas7COKE:3.mtons/hrFEED:208 mtons/hr (31 kb/D)GAS:23 mtons/hr LIQUIDS:122 mtons/hrGGR RH HAir&SteamFLEXIGASFLEXIGAS Users:Pipestill FurnacesHydrogen Plant FurnacesReformer FurnacesSteam Super heatersWaste Heat BoilersPower Plant BoilersThird Party ConsumersFLEXIGAS Clean Fuel GasFLEXIGAS Clean Fuel GasCompositionmol%CO/H240N248Other12Total100RatesMetricEnglishCoke Gasified,mtons/hr60FLEXIGAS,mtons/hr351Heating Value,kj/kg(BTU/SCF)4,800128Heat Rate,MW(th)(MBTU/hr)460158FLEXICOKING:Operating Commercially for 30 YearsOperating Commercially for 30 YearsTOA Oil-First Commercial Unit S/U in 1976,Expanded in 2002Currently 5 Units Operating With a Total Capacity of 200 kB/D Hellenic Petroleum Unit under construction PetroPeru Unit under design Rosneft is latest unit and also under design8COMPANYLOCATIONFEED RATE,kB/DTOA OilJapan27PDVSAVenezuela65ShellCalifornia22ExxonMobilNetherlands42ExxonMobilTexas42HellenicGreece21PetroPeruPeru22RosneftRussia50Processing Configurations Comparable to Processing Configurations Comparable to FLEXICOKINGFLEXICOKINGFLEXICOKING Commercially Proven With Integrated Steam/Air GasificationMilder Conditions and Lower Capital Cost than POX9Competing Options Delayed CokingEbullating BedSDAConversion StepPartial OxidationGasificationGasification StepCO/H2SynGas AirSeparationOxygenSEPARATE PROCESSFluid BedCokeGasificationFLEXICOKING CO/H2/N2Fuel Gas Fluid BedCokingConversion StepGasification StepFULLY INTEGRATEDSteam/AirFLEXIGAS UtilizationFLEXIGAS Fuel is Rich in CO and H2Heating value reduced by nitrogen diluentFLEXSORB Amine Gas Treating Reduces Sulfur to Very Low Levels(10 ppm H2S)Burns very cleanly ultra-low SOx and NOxBurns with constant heating value(unlike refinery fuel gas)FLEXIGAS Burns Very Readily in a Wider Range of Services in a Variety of Commercially Available Burners Process heaters(pipestills,naphtha reformers,hydrogen plant furnaces)Utility boilers(steam generation,steam super heaters)Over-the-fence sales to power plants or other nearby consumersBurner Conversion and Fuel Distribution Costs Are LowBurners commercially available at same cost as conventional burnersLow pressure pipes/ductsRefinery Fuel Balance Planning is ImportantOverall fuel requirements in conversion projectLocation and size of refinery consumersThird party fuel consumers10FLEXICOKING Commercial Experience ExxonMobil RotterdamExxonMobil RotterdamStarted Up in 1986Currently 42 kB/DGasifier in Center(green)Coke Silos on LeftHeater and Reactor/Scrubber on Right11FLEXICOKING Unit Added in Major Upgrade to Hydroskimming RefineryRefinery has high degree of integration/efficiencyRefinery is Entirely Gas FiredRefinery fuel gasFLEXIGASSupplemental natural gasReal Time Optimization(RTO)Control System Used to Manage Fuel Gas Sources/BalanceLarge number of Furnaces,Fired Heaters&Boiler On Site ConsumersRotterdam FLEXIGAS ConsumersPrimary UsersPrimary UsersFurnace/Heaters/BurnersFurnace/Heaters/BurnersBoilers(2)Boilers(2)Grass RootsGrass RootsAtmospheric Pipestill Furnace(2)Atmospheric Pipestill Furnace(2)RevampRevampVacuum Pipestill FurnaceVacuum Pipestill FurnaceGrass RootsGrass RootsNaphtha Reformer FurnaceNaphtha Reformer FurnaceGrass RootsGrass RootsSteam Reforming HSteam Reforming H2 2 Plant Furnace Plant FurnaceGrass RootsGrass RootsStabilizer ReboilerStabilizer ReboilerRevampRevampSplitter ReboilerSplitter ReboilerRevampRevampSteam Super HeaterSteam Super HeaterGrass RootsGrass Roots12FLEXICOKING Low Joule Gas FiringLJG BurnerHJG Burners(3)Dual Fuel Gas Fired Burner13Recap of Rotterdams FLEXIGAS UseOverall Refinery Fuel Balance and Design of FLEXIGAS Distribution System Consider Refinery Consumers that are Large and Close to FLEXICOKING FirstSecondary Refinery Consumers Selected Based upon Fuel Savings versus Cost of Burners and DuctsRefinery Scenario Planning to Identify:Source of alternate fuel gas for consumers and dual fired burners for added flexibilityDisposition of FLEXIGAS when selected consumers are downLarge Nearby Consumer Helps Fuel Balance and Provides Flexibility14TOA Oil Refinery FLEXICOKING Unit15TOA Oil Keihin186 kB/DMizue65 kB/DOhgimachi120 kB/DOhgimachi and Mizue Plants 1.2 km ApartKPL(Kawasaki Underground Pipeline(5)Enables Two Sites to Operate as Integrated RefineryTOA Keihin Refinery:Process ConfigurationVacuum Distillation Unit at Mizue Processes Long Residue from Both Sites and Provides Feed to FLEXICOKING UnitIntermediate/Finished Products Transported Between Plants Through Underground Pipelines16CrudeOhgimachi RefineryMizue RefineryPropyleneGasolineSolventKeroseneLight OilHeavy OilCokeCrudeAtmospheric Distillation(120,000)HDS Unit(Light Oil)HDS Unit(Vac.Gas Oil)Vacuum Fractionation UnitFLEXICOKING UnitFCC UnitPolymerizationAtmospheric Distillation(65,000)Vacuum Residue(58,000)(42,000)(27,000)Underground PipelineUnits:BPSDTOA Oil FLEXICOKING Unit17FLEXICOKING UnitFLEXICOKING UnitStarted up in 1976(21 kb/SD)Started up in 1976(21 kb/SD)Current Capacity:27 kb/SDCurrent Capacity:27 kb/SDFluid Solids Vessels:Fluid Solids Vessels:Gasifier on Left Gasifier on Left Heater in CenterHeater in Center Reactor on RightReactor on RightEarthquake-Proof StructureEarthquake-Proof StructureFLEXIGAS UsersFLEXIGAS Users Refinery FurnacesRefinery Furnaces50%50%Power Plant BoilersPower Plant Boilers50%50%TOA Oil FLEXICOKING Reactor Products/Yields Reactor Products/Yields Process Long Residue from Both Ohgimachi and MizueAlso process H-Oil Bottoms from nearby Tonen Kawasaki refineryFLEXIGASGRHPurgeCokeAir&SteamFeed(Vacuum Residue)Density1.01 1.03Sulfur(wt%)4.0 4.7CCR(wt%)19 22Ni+V(wtppm)230PRODUCTSGas and LiquidsYield(wt%)DispositionC2-8.5 10.0Gas Turbine Fuel for Power PlantC3-C44.8 6.5C3H8,C3H6 recoveryFeed for Poly Naphtha PlantNaphtha19.0 21.0Light:Caustic Treatment for MogasHeavy:Hydrotreated for Platformer FeedGas Oil36.0 39.0Light:Hydrotreated to be Diesel Oil ProductHeavy:Hydrotreated to be FCC FeedProduct CokeYield(wt%)DispositionTotal26 28Gasified23 27Converted to Low Calorie GasNet Product2 4Sales to Cement Company18Keihin Refinery Participates in Wholesale Keihin Refinery Participates in Wholesale Electricity BusinessElectricity BusinessOperation Began in 2003 in Cooperation with Electric Power CompanyLCG is Supplied as Fuel for Steam-Generating BoilerSteam is Used for Power Generation and also by RefineriesStable Supply of Electricity and Steam19Vacuum Residue FractionLow Calorie GasHigh Calorie GasLPG(C3,C4)Genex(Power-Generating Plant)Gas TurbineWaste Heat BoilerSteam BoilerGRHAir&SteamRefinery furnacesTOA OIL Keihin RefineryFrac.L/EProducts(LCG)(C1,C2)Gas Turbine:80 MWSteam Turbine:190 MWTotal 270 MW37%21%33%9%100%FCC HCG GasRosneft RefineriesNEW FLEXICOKING UNIT 20Rosneft Tuapse RefineryRefinery Expansion and UpgradeIncreasing refining capacity to 240 kB/D from current 100 KB/DLaunching production of high-quality Euro-4 and Euro-5 products Two stages(2009 Start)Construction Phase for First Stage Units includes Crude and Vacuum Units Design Phase for Second Stage Units includes coking technology for resid destruction21Why Rosneft Selected EMREs FLEXICOKING TechnologyWhy Rosneft Selected EMREs FLEXICOKING TechnologyVisbreaking and Resid Hydrocracking options were not viableReduced Coke Production versus Delayed Coking -Eliminates need to dispose of over 600 KTPA of Coke -Reduces environmental impact on surrounding areaFLEXICOKING became the lead technology due to following attractive benefits of FLEXIGAS for the Refinery:-Meets a large%of refinerys energy needs -Lower emission levels of SOx,NOx and particulates as compared to burning LSFO -No particulate emission issues as with Delayed CokingOverall Better Economic Returns22Tuapse A Birds Eye ViewTuapse A Birds Eye ViewRefinery23Major Advantages of FLEXICOKING TechnologyMajor Advantages of FLEXICOKING TechnologyFLEXICOKING Produces Valuable Liquids Like Other Conversion ProcessesYields are similar to other coking processes FLEXICOKING Minimizes Product Coke with Integrated Air GasificationApprox.1-4%compared with approx.30%for other coking processesFLEXICOKING Produces Large Quantity of Valuable Clean Fuel GasFLEXIGAS is primarily CO/H2,with N2Sulfur content 10 ppm H2S and burns cleanly with very low SOx and NOxFLEXIGAS Burns Readily in a Wide Range of Consumers in a Variety of Commercially Available Burners Process heaters;Utilities;Power Plants or over-the-fence salesFLEXICOKING Fits Best in Locations with Large Demand for Clean Fuel24Sunset at TOA Oil,Keihin Refinery(Mizue)FLEXICOKINGCoking and Integrated Steam/Air GasificationCoking and Integrated Steam/Air GasificationQuestions