flexicoking™ resid. upgrading technology · exxonmobil texas 42 helpe greece 21 petroperu perú...

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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


FLEXICOKING Schematic

Steam


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


Steam


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


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

7


FLEXIGAS AS AREFINERY FUELFLEXIGAS AS A

REFINERY FUEL


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


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


Rotterdam Refinery Fuel Gas & Energy Grid Details


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


FLEXIGAS FOR POWERGENERATION USING

STEAM CYCLE


STEAM CYCLE


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%


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



COMBINED CYCLE


COMBINED CYCLE


FLEXICOKING and GTCC: A Case Study

Material reproduced with permission from Mitsubishi Heavy Industries (MHI). All rights reserved


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


CAPEX FOR POWERGENERATION USING

STEAM OR COMBINEDCYCLE

CAPEX FOR POWERGENERATION USING

STEAM OR COMBINEDCYCLE


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


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


FLEXIGAS FOR H2, N2, CO2, AMMONIA ANDUREA PRODUCTION

FLEXIGAS FOR H2, N2, CO2, AMMONIA ANDUREA PRODUCTION


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


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


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

25 Research and Engineering25 Sunset at TOA Oil, Keihin Refinery ( Mizue )

FLEXICOKINGCoking and Integrated Steam / Air Gasification

Questions

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