0 Research and Engineering Economically Attractive and Environmentally Friendly FLEXICOKING Resid Upgrading Technology Dr. Girish Chitnis Ms. Marie Wright

1

Research and EngineeringEconomically Attractive and Environmentally Friendly FLEXICOKING™ Resid Upgrading TechnologyDr. Girish Chitnis Ms. Marie WrightMr. Glen Phillips

International Conference on “Refining Challenges - Way Forward'

16-17 April, 2012New Delhi

2 Research and Engineering2

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: (a) Yield (wt%)Fuel Gas & LPG 10

C5+ Liquids 55

Coke 35Total 100

FLEXICOKING Eliminates the Coke!

33 Research and Engineering

ColdCoke

FLEXICOKING Technology: Simple Air + Steam Integrated Gasifier Design

Feed

Reactor

Heater

Gasifier

Steam

Purge coke

FLEXIGAS to Coke Fines, ‑Water & Sour Component Removal

Products to Fractionator

HotCoke

Air fromBlower

FLEXIGAS


FLEXICOKING Schematic

REACTOR HEATER

GASIFIER

TO FRACTIONATOR

PURGE COKEAIR FROM

BLOWER

FEED

DRY COKE FINES

WET COKE FINES

SOUR WATER

RICH FLEXSORB TO REGENERATION

SWEET FLEXIGAS

HP STEAM

GENERATION

HOT

COKE

COLD

COKE

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

REACTOR HEATER

GASIFIER

TO FRACTIONATOR

PURGE COKEAIR FROM

BLOWER

FEED

DRY COKE FINES

WET COKE FINES

SOUR WATER

RICH FLEXSORB TO REGENERATION

SWEET FLEXIGAS

HP STEAM

GENERATION

HOT

COKE

COLD

COKE

Research and Engineering

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

FL

EX

IGA

S M

arg

in o

ver

Del

ayed

Co

ke

M$/

Yea

r

FLEXIGAS Gives Positive Margin Over Delayed Coke as Fuel

Delayed Coke Price

$20 / tonne

$100 / tonne

Achieve Higher Margins over Delayed Coking

Shaded Region: FLEXICOKING becomes

More Attractive

Delayed Coking Becomes Less Attractive


FLEXICOKINGGasification

Partial OxidationGasification

Product Fuel Gas Syngas / H2 / Fuel Gas

Components 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 Avoid formation Disposal is an Issue

Materials

Refractory 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


FLEXIGAS 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 on site fuel users

3 ExxonMobil Rotterdam

450 82 • Burn majority of FLEXIGAS onsite• Sell ~270 MW high BTU fuel gas offsite

4 ShellCalifornia

~300 ~100 • Primarily use FLEXIGAS in refinery

5 Showa ShellJapan

300 50 • Large nearby power plant consumes ~50% of FLEXIGAS in boilers


FLEXICOKING Low Joule Gas Firing

Dual Fuel Burner

Assembly

LJG Burner

RHJG Burner

Pilot Burner (HNJG)

10

1111 Research and Engineering 11

Rotterdam Refinery Fuel Gas & Energy Grid Details


FLEXICOKINGRotterdam Refinery Environmental

Dutch Refineries

XOM Refinery

Emission

SO2 kt/jr 30,3 3,0

NOx kt/jr 9,9 1,0

Dust kt/jr 2,7 0,09

Capacity mt/jr 61 10

Low Sulphur Products kt/jr 35-45 10

13


FLEXIGAS FOR POWER GENERATION USING

STEAM CYCLE


TOA Oil FLEXICOKING Unit

FLEXICOKING UnitStarted up in 1976 (21 kb/SD)Current Capacity: 27 kb/SDFluid Solids Vessels:

•Gasifier on Left •Heater in Center•Reactor on Right

Earthquake-Proof Structure

FLEXIGAS Users

• Refinery Furnaces 50%

• Power Plant Boilers 50%


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

Vacuum Residue Fraction

Low Calorie Gas

High Calorie Gas

LPG (C3, C4)

Genex (Power-Generating Plant)

Gas Turbine

Waste Heat Boiler

Steam Boiler

GR H

Air & Steam

Refinery furnaces

TOA OIL Keihin Refinery

Frac.L/E

Products

(LCG)

(C1, C2)

Gas Turbine: ~80 MW

Steam Turbine:~190 MW

Total ~ 270 MW

37 %

21 %

33 %

9 %100 %

FCC HCG Gas

16


FLEXIGAS FOR POWER GENERATION USING

COMBINED CYCLE


FLEXICOKING and GTCC: A Case Study

FLEXICOKING Unit

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


Approx. 200 m

Ap

pro

x. 6

0 m

Gas Cooler

Gas Compressor

BFG

Gas Mixer

COG

E.P.

Steam Turbine

Generator

Gas Turbine

HRSG

Stack

Inlet Air Filter Transformer

MHI’s Equipment Layout

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

19


CAPEX FOR POWER GENERATION USING

STEAM OR COMBINED CYCLE


Relative Total Investment Cost (TIC)

Delay

ed C

oker

FLEXICOKER

FXK+Ste

am C

ycle

FXK+GTCC

DC+CFBB

DC+IGCC

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

0.040 0.060 0.080 0.100 0.1202.0

4.0

6.0

8.0

10.0

FXK+GTCC

DC+IGCC

$/Kw-h

Pay

ou

t, Y

ears

Shorter Payout with FLEXICOKING and Power Generation

22


FLEXIGAS FOR H2, N2, CO2, AMMONIA AND

UREA PRODUCTION


Flexibility of H2, CO2, NH3, Urea and Power Production From FLEXIGAS

Ammonia

Urea

Heater Overhead

and FLEXSORB®

FLEXIGAS Compression

Hydrogen Shift

CO2 Removal

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

• TOA Oil - First Commercial Unit S/U in 1976, Expanded in 2002• Currently 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 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


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 Delayed

Coking Route Power Generation Schemes are Commercially Proven FLEXIGAS is suitable for ammonia/urea production or for

production of H2, N2 and CO2

26 Research and Engineering26 Sunset at TOA Oil, Keihin Refinery ( Mizue )

FLEXICOKING

Coking and Integrated Steam / Air Gasification

Questions


FLEXIGAS + GTCC Gives Higher Cash Flow

FXK+GTCCLinear (FXK+GTCC)DC+IGCCLinear (DC+IGCC)

$/Kw-h

M$

120+M$ Higher Annual Cash Flow than Delayed Coking + IGCC Power Generation


FLEXICOKING Advantages Versus Other Options• Milder Conditions and Significantly Lower Capital Cost than POx

• No issues such as Disposal of Slag, UCO• No Air Separation Unit Needed

Competing Options Delayed Coking

Ebullating BedSDA

Conversion Step

Partial Oxidation

Gasification

Gasification Step CO / H2

SynGas

Air Separation Oxygen

SEPARATE PROCESS

Fluid BedCoke

Gasification

FLEXICOKING CO / H2 / N2

Fuel Gas Fluid BedCoking

Conversion Step Gasification Step

FULLY INTEGRATED

Steam/Air

Documents

0 Research and Engineering Economically Attractive and Environmentally Friendly FLEXICOKING Resid Upgrading Technology Dr. Girish Chitnis Ms. Marie Wright