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8/19/2019 Em Flexicoking

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FLEXICOKINGThe Flexible ResidUpgrading Technology


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Flexicoking Technology at Hellenic

Petroleum S.A. refinery in Elefsis, Greece.

Commissioned in 2012.


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The Cost-Effective Coking Technology, without the Coke

FLEXICOKING™ technology is a commercially proven, cost-effective, fluidized bed process that thermally converts

heavy oils to lighter products and flexigas — “Coking without the Coke.” Low-cost feeds such as deep-cut vacuum resid;

atmospheric resid; oil sands bitumen; heavy whole crudes; and DAU, FCC, and ebullated-bed bottoms are converted

to high-value products. FLEXICOKING technology with integrated steam/air gasification offers greater flexibility thanconventional Delayed Coking, and does it economically. The FLEXICOKING technology not only produces clean liquids of

equivalent quantities and similar quality to Delayed Coking, but also gasifies the low-value coke to produce a clean, high-

value flexigas that can be used in place of natural gas and conventional fuel gas in refinery processes. Flexigas can also be

used to generate electric power and to produce H2, N2, and CO2.

Key Advantages

• Proven: Commercially proven for more than38 years in ExxonMobil and in licensed third-partyunits. All FLEXICOKING units are operating todayat capacities greater than original design. Currentcombined operating capacity is 227 kbd/12 MTA.

• FLEXible: A robust process, capable of handling a variety of feeds with a wide range of high ConradsonCarbon Residue (CCR), sulfur, and heavy metals, withoutthe need for a feed furnace.

• Multi-Purpose: The high-sulfur, low-value coke isconverted to a clean, economical multi-purposeflexigas, which can be used in refinery furnaces,boilers, and gas turbines, or processed to recover H2,N2, and CO2. ExxonMobil’s FLEXSORB™ process isincorporated to reduce H2S in flexigas to 10 wppm,or as needed.

• Optimizable: Coke gasification can be optimizedon the run, to debottleneck the unit, or to satisfyoperational requirements such as changes in feedformulations and variations in flexigas consumption.

• Economic: Integrated “simple” steam/air gasification,carbon steel construction throughout, and theabsence of feed furnaces are key factors resulting insignificantly lower capital investment when comparedto Delayed Coking with “complex” oxygen gasification.Expect greater comparative savings in electric power-generation applications (steam or combined cycle).

• Environmental: Continuous, non-batch operation andclosed coke handling system results in low-particulateand fugitive hydrocarbon emissions. Much lower SOxand NOx emissions are realized by burning the cleanflexigas, when compared to burning high sulfur coke.

• Reliable: Continuous, steady state operation incombination with cold-wall carbon steel constructioncontributes to high reliability and service factors thatroutinely exceed 92 percent.

These benefits come to you in a compact package. Thelayout of modern FLEXICOKING units offers reduced

plot space — about 20 percent less than that of a basicDelayed Coking unit of similar capacity.

FEED SELECTOR

TOUGH FEED 1

TOUGH FEED 2 TOUGH FEED 3

COMBINATION

FLEXIGAS USE

FUEL GAS

POWER GENERATION H2/N2/CO2 RECOVERY

COMBINATION

CONTROL PANEL

GA S I FICAT I O N

C O K E MA K

E

Min.

Max.

0 1 2 3 4

Power(Combined Cycle)

Power(Steam Cycle)

Flexigas forRefinery Fuel

Coke for Sale A P P L I C A T I O N S

CAPITAL INVESTMENT FACTOR

2.53.1

1.31.0

2.94.0

DELAYED COKING FLEXICOKING


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How FLEXICOKING Technology WorksThe vacuum resid feed enters the scrubber for “direct-

contact heat exchange” with the reactor overhead

product vapors. The higher-boiling point hydrocarbons

(~975°F+/525°C+) present in the reactor product vapors

condense in the scrubber and return to the reactor, in

mixture with the fresh feed. Lighter overhead product

vapors in the scrubber go to conventional fractionation

and light-ends recovery. The feed is thermally cracked inthe reactor fluidized bed to a full range of gas and liquid

products, and coke. Coke inventory is maintained by

circulating the bed coke from the reactor to the heater via

the cold coke transfer line.

In the heater, the coke is heated by the gasifier products

and circulated back to the reactor via the hot coke

transfer line to supply the heat that sustains the thermal

PRODUCT TO

FRACTIONATOR

CLEAN

FLEXIGAS

TO USERS

SCRUBBER

FEED MIX TO

INJECTORS

HOT

COKE

COLD

COKE

COKE PURGE

HP STEAM

GENERATION

DRY COKE

FINES

WET COKE

FINES

SOUR

WATER

AIR + STEAM

REACTOR

FEED

RICH FLEXSORB

TO REGENERATION

™

Flexicoking Process

cracking reaction. The excess coke in the heater is

transferred to the gasifier, where it reacts with air and

steam to produce a gas. The gasifier products, consisting

of a gas and coke mixture, return to the heater to heat up

the coke. The gas exits the heater overhead and goes to

steam generation, to dry/wet particulate removal, and to

desulfurization in the integrated FLEXSORB™ process.

The clean flexigas is then ready for use as fuel inrefinery boilers and furnaces and/or for steam and

power generation.

Approximately 95 percent of the coke generated in the

reactor is converted in the process. Only a small amount

of product coke is collected as fines from the flexigas and

purged from the heater to extract feed metals.


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Full-Range Products SlateFLEXICOKING technology produces a full range of

products, from a C4- reactor gas to C5/975°F (525°C)

liquid products, the multi-purpose flexigas, and lastly a

small stream of low-sulfur coke that is purged to extract

feed metals.

Guaranteed Performance

The first FLEXICOKING unit began operation in 1976, andsince then five others have come online, the most recent

one in 2012. Since 2010, we have also licensed three new

units with a combined capacity of 114kbd/6.3 MTA. These

are currently in different stages of construction.

COKER GASC2 Fuel Gas, C3/C4’S for Alkylation,

Chemicals, LPG Sales

LPG

To Hydrotreating

To FCC, Hydrocracker & Chemicals

To Refinery Fuel, Power GenerationH2, N2, CO2 Production

COKECoke Sales & Metals Reclamation

H In Operation

Athens, Greece Houston, Texas Amuay, Venezuela Kawasaki, Japan Rotterdam, The Netherlands Martinez, California

H In Construction

Moscow, Russia Tuapse, Russia Talara, Peru China

ExxonMobil has licensed fluidized bed coking technology since the 1950s, including the largest fluid coker, which is

located in Syncrude, Fort McMurray, Canada. Our experience ranges from 5 to 105 kbd (60 to 750 mtons/hr) unit

capacities and a variety of difficult feeds with CCR values ranging between 17 and 37.

ExxonMobil has equally extensive experience supporting its licensees, and this is particularly true of the FLEXICOKING

technology, because ExxonMobil owns and operates FLEXICOKING units in two of its largest refineries: Rotterdam in the

Netherlands and Baytown, Texas, in the United States.

We see an increasing market interest in FLEXICOKING technology worldwide. We expect the trend to continue well into the

future, particularly in parts of the world where natural gas is limited and/or expensive, and in environmentally sensitive areas.


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FLEXICOKING™ Technology Highlights

• Produces a clean and valuable flexigas fuel

• Achieves superior environmental performance

• Offers maximum flexibility in terms of processedfeeds, product utilization, and operating modes

• Requires lower capital investment


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FLEXICOKING Technology at ESSO Nederland refinery in Rotterdam,The Netherlands. Commissioned in 1986.


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