FLEXICOKING Resid Upgrading Technology Dr. Paul Kamienski Dr. Xinjin Zhao Dr. Alberto Ravella Dr. Girish Chitnis 11 th International BBTC Conference May 16-17, 2013 Dubrovnik
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 Crudes Resids Delayed Coking (several providers) FLEXICOKING TM (ExxonMobil) Product: (a) Yield (wt%) Fuel Gas & LPG 10 C5+ Liquids 55 Coke 35 Total 100 1 FLEXICOKING Eliminates the Coke!
FLEXICOKING Technology: Simple Air + Steam Integrated Gasifier Design Products to Fractionator Feed FLEXIGAS to Coke-Fines, Water & Sour Component Removal Heater Reactor Hot Coke Gasifier FLEXIGAS Cold Coke Purge coke Air from Blower Steam 2
FLEXICOKING: Reactor Product / Yields Similar to Other Coking Processes - Thermal Conversion Feed and Recycle Cut point Differences can complicate Comparisons Gas & Liquids Feed Products FLEXIGAS Wt% FF C2 Fuel Gas 6.7 C3 / C4 LPG 4.4 LV% FF Type VR Total C4-11.1 Nominal cut point, C 565 C5-220 c 15.3 20.8 Feed Properties Sp. Gr. 1.022 R H G 220-340 C 11.0 12.6 340-525 C 32.2 33.2 Sulfur, wt% 4.6 Conradson Carbon, wt% 26 Nickel, wppm 18 Vanadium, wppm 108 Air & Steam Total C5+ 58.6 66.6 Coke, Wt% Net Product Coke 1.7 Gasified Coke 28.6 Total 30.3 3 3
FLEXICOKING: Produces a Significant Quantity of Valuable Clean Fuel Gas GAS: 23 mtons/hr LIQUIDS: 122 mtons/hr FEED: 208 mtons/hr (31 kb/d) Bold the font in the text boxes FLEXIGAS FLEXIGAS Clean Fuel Gas Composition mol% CO/H 2 40 N 2 48 Other 12 Total 100 Rates Metric English Coke Gasified, mtons / hr 60 FLEXIGAS, mtons / hr 351 Heating Value, kj / kg (BTU / SCF) 4,800 128 Heat Rate, MW (th) (MBTU / hr) 460 158 R H G Air & Steam COKE: 3. mtons/hr FLEXIGAS Users: Pipestill Furnaces Hydrogen Plant Furnaces Reformer Furnaces Steam Super heaters Waste Heat Boilers Power Plant Boilers Third Party Consumers 4
FLEXIGAS AS A REFINERY FUEL 5
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 2 ExxonMobil Baytown 3 ExxonMobil Rotterdam 4 Shell California 5 Showa Shell Japan 600 28 Large boiler / power plant consumes majority of Flexigas 430 100 FLEXIGAS used on site Very large/ complex refinery with large number of on site fuel users 450 82 Burn majority of FLEXIGAS onsite Sell ~270 MW high BTU fuel gas offsite ~300 ~100 Primarily use FLEXIGAS in refinery 300 50 Large nearby power plant consumes ~50% of FLEXIGAS in boilers 6 6
FLEXICOKING Low Joule Gas Firing Dual Fuel Burner Assembly RHJG Burner LJG Burner Pilot Burner (HNJG) 7 7
FLEXICOKING Rotterdam Refinery Environmental Emission Dutch Refineries XOM Refinery SO 2 kt / jr 30,3 3,0 NO x kt / jr 9,9 1,0 Dust kt / jr 2,7 0,09 Capacity mt / jr 61 10 Low Sulphur Products mt / jr 35-45 10 8
FLEXIGAS FOR POWER GENERATION USING STEAM CYCLE 9
TOA Power Generation using FLEXIGAS Operation 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 TOA OIL Keihin Refinery Products Vacuum Residue Fraction Genex (Power-Generating Plant) 37 % Steam Boiler Frac. L/E Low Calorie Gas (LCG) High Calorie Gas (C1, C2) FCC HCG Gas LPG (C3, C4) Refinery furnaces 21 % 33 % 9 % 100 % Gas Turbine Waste Heat Boiler R H G Air & Steam Gas Turbine: ~80 MW Steam Turbine: ~190 MW Total ~ 270 MW 10
FLEXIGAS FOR POWER GENERATION USING COMBINED CYCLE 11
Illustrating Commercial GTCC Operation Using Low Joule Gas 12 Material reproduced with permission from Mitsubishi Heavy Industries (MHI). All rights reserved
Layout for Combined Cycle Power Trains 13 Material reproduced with permission from Mitsubishi Heavy Industries (MHI). All rights reserved
Proven Operation with Low Joule Gas 14 Material reproduced with permission from Mitsubishi Heavy Industries (MHI). All rights reserved
Kimitsu Gas Turbine for 300 MW Train Kimitsu Gas Turbine 15 Material reproduced with permission from Mitsubishi Heavy Industries (MHI). All rights reserved
COMPARISON WITH OTHER TECHNOLOGIES 16
Natural Gas Prices are Not Same Everywhere Source: Washington Post Article, April 2, 2013 by Michael Birnbaum, Staff Reporter 17
Comparison Basis SFA Pacific, Inc. SFA Phase 8 Study, October 2009 Conducted on Various Resids: Arab Light, Arab Heavy, Maya, Urals, Zuata and Canadian Oil Sands Compares Various Upgrading Technologies: Delayed Coking, FLEXICOKING, Slurry and Ebullated Bed Hydroconversion Base Pricing as 1X $6.50/Million Btu Natural Gas Price $30/ton Coke $13/bbl of Ebullated Bed or Slurry Pitch Flexigas at 90% Parity with Natural Gas EMRE Analyzed Price Sensitivity by increasing Base Price by 2X and 3X EMRE Results are shown for Canadian Oil Sands, but Conclusions Apply to All Resids 18
HIGH NATURAL GAS PRICES FAVOR FLEXICOKING Delayed Coking Can Be Attractive at Low Natural Gas Prices Fuel Coke Prices and Markets Coke Transportation Logistics FLEXICOKING More Attractive When Natural Gas is Expensive or Unavailable Abundant Flexigas Canadian Athabasca Bitumen Upgrading Net Uplift, $/bbl of Bitumen $0 1X = $6.50/MMBtu 1X 2X 3X Delayed Coking FLEXICOKING 19 *Under Permission from SFA Pacific, Inc. SFA Phase 8 Study, October 2009
EVOLVING SLURRY HYDROCONVERSION TECHNOLOGIES CAN BE ATTRACTIVE AT HIGH CRUDE/LOW GAS PRICES High Crude Prices Favor Maximizing Product Liquids Low Gas Price Helps Offset High Hydrogen Consumption and Cost Additional Processing Requirements to Make Clean Products a Consideration FLEXICOKING Clearly More Attractive at Higher Gas Prices 1X = $6.50/MMBtu $0 20 *Under Permission from SFA Pacific, Inc. SFA Phase 8 Study, October 2009
EBULLATED BED DOES NOT PRODUCE POSITIVE UPLIFT EVEN AT MODERATE NATURAL GAS PRICES Relatively Low Conversion (~65%), Capex, Bottoms Disposal, Liquids Upgrading are Issues Even at Low Gas Prices FLEXICOKING Advantage Increases Rapidly with Gas Price 1X = $6.50/MMBtu $0 21 *Under Permission from SFA Pacific, Inc. SFA Phase 8 Study, October 2009
BENEFITS OF SDA INTEGRATION WITH DELAYED COKING APPEAR MARGINAL Two Conversion Steps, and High DAO Lift Needed to Offset Two Investments Ability to Upgrade high CCR DAO is a Critical Issue SDA is Energy Intensive and High Gas Prices Erode any Advantage for Integration SDA + FLEXICOKING Process and Energy Integration May be Attractive at High Gas Prices Canadian Athabasca Bitumen Upgrading Net Uplift, $/bbl of Crude $0 1X = $6.50/MMBtu 1X 2X 3X Delayed Coking SDA + Delayed Coking 22 *Under Permission from SFA Pacific, Inc. SFA Phase 8 Study, October 2009
CONTINUOUS TECHNOLOGY IMPROVEMENTS AN EXAMPLE 23
Baffle Installed in Commercial Coker Baffle fabricated and installed in commercial coker Improved operability relative to base case w/o baffle Photo above offers appreciation for commercial-scale equipment 24
FLEXIGAS FOR H 2, N 2, CO 2, AMMONIA AND UREA PRODUCTION 25
Flexibility of H 2, CO 2, NH 3, Urea and Power Production From FLEXIGAS Excess FLEXIGAS used as refinery fuel Heater Overhead and FLEXSORB FLEXIGAS Compression Hydrogen Shift CO 2 Removal PSA Offgas Hydrogen Production Purge Gas Power Generation Combined Cycle Rankine Cycle MW-hr Hydrogen Ammonia Production Ammonia Urea Production Urea CO 2 26
FLEXICOKING: Operating Commercially for 35+ Years TOA Oil - First Commercial Unit S/U in 1976, Expanded in 2002 Currently 6 Units Operating With a Total Capacity of ~200 kb/d Hellenic Petroleum Unit Started up in 3Q2012 PetroPeru Unit Deferred Rosneft is latest unit and also under design COMPANY LOCATION FEED RATE, kb/d TOA Oil Japan 27 PDVSA Venezuela 65 Shell California 22 ExxonMobil Netherlands 42 ExxonMobil Texas 42 Hellenic Greece 21 PetroPeru* Peru 22 Rosneft Russia 50 27 * Basic Design completed. Project on hold
SUMMARY Well Proven Technology Coke Upgraded into a Clean FLEXIGAS by Gasification FLEXIGAS is Suitable as a Cheap Refinery Fuel Excellent Fit for Locations with High Natural Gas Prices Continuous Technology Improvement Start-up of latest Unit in 3Q2012 28
FLEXICOKING More Value Less Coke. Are you getting the most out of the bottom of the barrel? 29
Stripper Shed Fouling in Fluid Coking Units Stripper sheds Foulant Effect of Reactor Temperature T Base Liquid Mass Fraction on Solids T Base + T Three major contributors drive stripper shed coke deposition Focus on wet/sticky coke to assess reactor performance Key factor from CFD analysis was liquid carry-under Red volumes indicate regions with greater than 1% liquid mass fraction. Higher bed temperature reduces liquid in stripper, reactor yield Can internals provide similar benefit without yield debit? 30
Internals for Stripper Fouling Mitigation Coker yield limited by stripper fouling Liquid to stripper identified as fouling mechanism CFD used to simulate present coker performance, modification alternatives Filtered model used to simulate commercialscale gas-solid flow Wet solids modeled without explicit liquid phase Added staging baffles reduced liquid carryunder to stripper Minimal performance benefit for three stages over two-stage reactor Red indicates > 1% liquid mass fraction Base Case Three Stages Two Stages US Patent Application: US 2011/0206563 Liquid to stripper 1.6 1.3 1 0.7 0.4 31