0
Research and Engineering
FLEXICOKING™Resid. Upgrading TechnologyCoking without Coke
FLEXICOKING™Resid. Upgrading TechnologyCoking without Coke
James Stanley Girish ChitnisMarie WrightGlen PhillipsEnrique Féliz
James Stanley Girish ChitnisMarie WrightGlen PhillipsEnrique Féliz
11-12 July, 2012; México D.F.Advances of the Refining Industry,
XVIII Forum and Exhibition
1 Research and Engineering1
Coking Process• Coking is the Most Widely Used Resid Conversion Approach Worldwide!– Delayed Coking – Furnace & Drum, Batch Process, Coke Pits
– FLEXICOKING™ – Fluidized Bed, Continuous, Coke Silos and Closed System
– Environmental considerations important for both
• Coke by‐product Yield Typically 1/3 of Feed– Similar amount for other resid conversion processes
Heavy CrudesResids
Delayed Coking (several providers)
FLEXICOKINGTM (ExxonMobil)
Product: Yield (wt%)Fuel Gas & LPG 10
C5+ Liquids 55
Coke 35Total 100
FLEXICOKING Eliminates the Coke!
22 Research and Engineering
ColdCoke
FLEXICOKING Technology: Simple Air + Steam Integrated Gasifier Design
Feed
Heater
Gasifier
Steam
Purge coke
FLEXIGAS to Coke‐Fines, Water & Sour Component Removal
Products to Fractionator
HotCoke
Air fromBlower
Reactor
4 Research and Engineering4
FLEXICOKING Products• Same Liquid Yields as Delayed Coking• Coke Gasified in a Simple Integrated Steam + Air Gasifier• Produces Clean CO/H2 Fuel Gas (FLEXIGAS) Product Instead of Coke• FLEXSORB® Hindered Amine Reduces H2S to Low Level Low SOX
• Nitrogen Diluent Reduces BTU Content, But Low NOX
• FLEXIGAS Burned in Refinery, Third Party Furnaces / Boilers or for Power
Research and Engineering
Steam
55 Research and Engineering
3 4 5 6 7
150.0
90.0
60.0
30.0
0.0
-30.0
120.0
FLEXIGAS at Parity with NG Price, $/mm Btu
FLEX
IGA
S M
argi
n ov
er D
elay
ed C
oke,
M
$/Ye
ar
FLEXIGAS Gives Positive Margin Over Delayed Coke, as Fuel
Delayed Coke Price
$20 / tonne
$100 / tonne
FLEXICOKING Achieves Higher Margins over Delayed Coking
Shaded Region: FLEXICOKING becomes
More Attractive …
…. and Delayed Coking Becomes Less Attractive
66 Research and Engineering
FLEXICOKINGGasification
Partial OxidationGasification
Product Fuel Gas Syngas / H2 / Fuel GasComponents CO/ H2 / N2 CO / H2
Heat Content, kJ/kg 5250 9375
Process Gases Steam / Air Oxygen (a)
Temperature, °C 870 - 980 1090 - 1370
Pressure, barg 2 – 4 20 – 70
Slag Avoids formation Disposal is an Issue
MaterialsRefractory-Lined
Carbon SteelSimple Inlet Distributor
Brick-LinedComplex Alloy Nozzles
Cycle Length, months 36 - 48 < 6 (b)
CAPEX $ $$$
FLEXICOKING Gasification & POX Comparison
a. Typically Requires air separation plantb. Per Gasifier. Overall reliability improves with spares
8 Research and Engineering88
FLEXIGAS Use in Commercial FLEXICOKING Units• Significant Fraction of FLEXIGAS Consumed within Refineries• Excess FLEXIGAS Used for Fuel in Nearby Power Plants• Rotterdam Exports Higher BTU Content Fuel Gas
SITE FLEXIGAS (MW)
FLEXIGAS Used in Refinery (%)
Off Site Consumers
1 PDVSA,Venezuela
600 28 • Large boiler / power plant consumes majority of Flexigas
2 ExxonMobilBaytown
430 100 • Flexigas used on site• Very large / complex refinery with large number of onsite fuel users
3 ExxonMobil Rotterdam
450 82 • Burn majority of FLEXIGAS onsite• Sells ~270 MW high BTU fuel gas offsite
4 ShellCalifornia
~300 ~100 • Primarily uses FLEXIGAS in refinery
5 Showa ShellJapan
300 50 • Large nearby power plant consumes ~50% of FLEXIGAS in boilers
99 Research and Engineering
FLEXICOKING Low Joule Gas FiringFLEXICOKING Low Joule Gas FiringDual Fuel Burner Assembly
L J G Burner
RHJG Burner
Pilot (HNJG)
Video Clip 1
Video Clip 2
1111 Research and Engineering
FLEXICOKINGRotterdam Refinery Environmental
Dutch Refineries
XOM Refinery
EmissionSO2
kt/jr 30,3 3,0NOx
kt/jr 9,9 1,0Dust kt/jr 2,7 0,09
Capacity mt/jr 61 10
Low Sulphur Products kt/jr 35-45 10
12
Research and Engineering
FLEXIGAS FOR POWERGENERATION USING
STEAM CYCLE
FLEXIGAS FOR POWERGENERATION USING
STEAM CYCLE
1313 Research and Engineering
TOA FLEXICOKING Unit
FLEXICOKING UnitCommissioned in 1976 (21 kb/SD)Current Capacity: 27 kb/SDFluid Solids Vessels: • Gasifier on Left • Heater in Center• Reactor on RightEarthquake-Proof Structure
FLEXIGAS Users• Refinery Furnaces 50%• Power Plant Boilers 50%
14 Research and Engineering14
TOA Power Generation using FLEXIGAS• Power Generation Began in 2003, in Cooperation with Electric Power Company• LCG is Supplied as Fuel for Steam‐Generating Boiler• Steam is Used for Power Generation and also by Refineries• Stable Supply of Electricity and Steam• Power Plant Demand Outpaces FLEXIGAS Production
Vacuum Residue Fraction
Low Calorie Gas (LCG)
High Calorie Gas (C1, C2)
LPG (C3, C4)
GENEX Power Generation Plant
Gas Turbine
Waste Heat Boiler
Steam Boiler
GR H
Air & Steam
Refinery furnaces
TOA OIL Keihin Refinery
Frac.L/E
Products
Gas Turbine: ~ 80 MWSteam Turbine: ~ 190 MWTotal ~ 270 MW
37 %
21 %
33 %
9 %100 %
FCC HCG Gas
15
Research and Engineering
FLEXIGAS FOR POWERGENERATION USING
COMBINED CYCLE
FLEXIGAS FOR POWERGENERATION USING
COMBINED CYCLE
16 Research and Engineering16
FLEXICOKING and GTCC: A Case Study
Material reproduced with permission from Mitsubishi Heavy Industries (MHI). All rights reserved
1717 Research and Engineering
Approx. 200 m
App
rox.
60
m
Gas CoolerGas Compressor
BFG
GasMixer
COG
E.P.
Steam TurbineGenerator
Gas Turbine
HRSG
StackInlet Air FilterTransformer
MHI’s Equipment Layout
Material reproduced with permission from Mitsubishi Heavy Industries (MHI). All rights reserved
18
Research and Engineering
CAPEX FOR POWERGENERATION USING
STEAM OR COMBINEDCYCLE
CAPEX FOR POWERGENERATION USING
STEAM OR COMBINEDCYCLE
1919 Research and Engineering
Relative Total Investment Cost (TIC)
1.01.3*
2.52.9 3.1
4.0
Base Process Power Options
* Add a Simple Gasifier for Only 30% More Capex than Delayed Coker
2020 Research and Engineering
Simple Payout versus Electricity Price
2.0
4.0
6.0
8.0
10.0
0.04 0.06 0.08 0.10 0.12
Payo
ut, Y
ears
$/Kw-h
FXK+GTCC
DC+IGCC
Shorter Payout Time with FLEXICOKING + Power Generation
21
Research and Engineering
FLEXIGAS FOR H2, N2, CO2, AMMONIA ANDUREA PRODUCTION
FLEXIGAS FOR H2, N2, CO2, AMMONIA ANDUREA PRODUCTION
2222 Research and Engineering
Flexibility of H2, CO2, NH3, Urea and Power Production From FLEXIGAS
Ammonia
Urea
FLEXICOKING Heater
Overhead and FLEXSORB®
FLEXIGAS Compression
Hydrogen Shift
CO2Removal
Ammonia Production
Power Generation
• Combined Cycle• Rankine Cycle
Excess FLEXIGAS Used as Refinery Fuel
Urea Production
HydrogenHydrogen Production
CO2
MW‐hr
Purge Gas
PSA Offgas
23 Research and Engineering23
FLEXICOKING:Operating Commercially for 35+ Years
• Currently 5 Units Operating With a Total Capacity of ~200 kB/D• TOA Oil ‐ First Commercial Unit Commissioned in 1976, Expanded in 2002• Hellenic Petroleum Unit is Approaching Commissioning • PetroPeru Unit under design • Rosneft is the latest unit and is also under design
COMPANY LOCATION FEED RATE, kB/D
TOA Oil Japan 27PDVSA Venezuela 65
Shell California 22ExxonMobil Netherlands 42ExxonMobil Texas 42
HELPE Greece 21PetroPeru Perú 22Rosneft Russia 50
24 Research and Engineering24
SUMMARY FLEXICOKING Technology is Well Proven Eliminates Coke Production Coke Upgraded into a Clean FLEXIGAS by Gasification Gasification using Steam + Air is Cheaper, More Reliable and
Simpler than POx
FLEXIGAS is Suitable as a Cheap Refinery Fuel No Limitations in Using FLEXIGAS for Power Generation Power generation Payout is More Attractive than the Delayed
Coking Route Power Generation Schemes are Commercially Proven FLEXIGAS is suitable for ammonia/urea production or for
production of H2, N2 and CO2