geoscan.nrcan.gc.ca · Global total 4-7 trillion barrels in place. 5th NCUT Upgrading and Refining Conference Edmonton, Alberta, Canada. ... N A T U R A L G A S SW E E T G A S T O

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Research and Engineering

FLEXICOKINGFLEXICOKING™™Coking and Integrated Steam / Air GasificationCoking and Integrated Steam / Air Gasification

ExxonMobil Research & Engineering Company

Paul Kamienski

Presented at the 5th NCUT

Upgrading and Refining Conference 2009,

Edm onton, Alberta, Canada. Septem ber 14!16, 2009.

5thNCUT Upgrading and Refining Conference

Edmonton, Alberta, Canada. September 14-16, 2009Research and Engineering

OverviewOverview

2

•Heavy Crudes / Tar Sands Upgrading

Technologies

•FLUID COKING Technology

•SyncrudeTar Sands Upgraderand 8-1, 8-2,

8-3 FLUID COKING Units

•FLEXICOKING Produces Clean Fuel Gas

Instead of Coke

Research and Engineering 5thNCUT Upgrading and Refining Conference

Edmonton, Alberta, Canada. September 14-16, 2009

Global Heavy CrudeGlobal Heavy Crude

3

USA (165)

Canada(3,700)

Mexico

Ecuador

Colombia

Venezuela(2,200)

Trinidad

Brazil

Nigeria

Kazakhstan

Uzbekistan

China (114)

Malaysia

Indonesia

India

Madagascar

Russia (960)

Middle East(324)

(Units: billion barrels in place)

Global total 4-7 trillion barrels in place

5th NCUT Upgrading and Refining Conference


Heavy Crude CharacteristicsHeavy Crude Characteristics

4

Source: Gerald W . Bruce -Jacobs Consultancy-Presented at the 4th Conference on the Upgrading and Refining of Heavy Oil, Bitumen, and Synthetic Crude OilEdmonton, Alberta, Canada September 25-27, 2006



Tar Sands Extraction ApproachesTar Sands Extraction Approaches

5

Mining:

SAGD:

Research and Engineering 5th NCUT Upgrading and Refining Conference


W hat Does It Take to Get a Barrel of SCO from Tar W hat Does It Take to Get a Barrel of SCO from Tar Sands?Sands?

4.3 tonneMaterial 2.0 tonneOil Sand(1.29 barrel bitumen)

1.16 barrel Bitumen

Mining Extraction

1 barrel SCO

(Synthetic Crude Oil)

OR ~ 10~ 10--15 Nm315 Nm3Natural GasNatural Gas+

DLK/FLKDLK/FLK

6

FLEXIFLEXI



FLUID COKING TechnologyFLUID COKING Technology

• Developed by ExxonMobil Research and Engineering Company (EMRE) as an Extension of FCC Fluid Solids Technology– Heavy feed injected into fluidized coke bed with feed rings / nozzles– Partial combustion of coke in heater and coke circulation provides heat for

reaction– Scrubber preheats feed, separates coke fines, and sets recycle cut point– Liquid products split in down stream fractionators– Coke pneumatically convey and stored in silos for fuel coke market

7

Reactor Products

to Fractionators

Hot

CokeCold

Coke

ScrubberHeavy

Feed

Air

ProductCoke

Flue Gas to

CO Boiler

ReactorReactor BurnerBurner



FLUID/FLEXICOKING vs. Delayed CokingFLUID/FLEXICOKING vs. Delayed Coking

• Liquid Product Yields Slightly Higher Than in Delayed Coking

• Continuous Process– Staffing requirements low– Steady state operations– Avoids process & equipment thermal

cycles

• Handles Virtually Any PumpableHydrocarbon Feed

• Coke Has Multiple Roles– Heat transfer medium– Low value coke supplies process heat– Low value coke produces low cost gas

for refinery fuel (FLEXICOKING)

8

• Liquid Product Quality Higher Than Fluid Bed Coker

• Cyclic Process– Staffing requirements high– Short drum cycles (12-18 hours)– Fractionator performance from

“unsteady operations”– Drum stressing from temperature cycles

• High CCR Feeds Can Coke Furnace

– More frequent spalling/decoking– Feed “dilution,”derating thru-put

• Coke Is Only a Reaction Product– High cost fuel gas supplies process

heat

FLUID COKING/FLEXICOKING DELAYED COKING (DLK)



FLUID/FLEXICOKING vs. Delayed CokingFLUID/FLEXICOKING vs. Delayed Coking

• Coke Product– FLUID COKING produces less than

Delayed Coking– FLEXICOKING produces only ~1

wt%FFcoke at 30% higher capital cost (Estimate: $4800/Bbl Feed/SD)

• Utilities– Little or no fuel gas use– High net steam generation

• Environmental– FLUID COKING offgasscrubbed to

meet sulfur emissions– FLEXICOKING coke gas desulfurized to

make low sulfur fuel for refinery use

9

• Coke Product– Produces significant amount of coke– Different kinds of coke (shot vs.

sponge) depending on properties of feedstock

• Utilities– Large amount of fuel gas use for

furnace– Almost zero net steam generation

• Environmental– Open coke piles becoming problematic– Require low sulfur fuel gas to meet

sulfur emission limits

FLUID COKING/FLEXICOKING DELAYED COKING (DLK)



FLUID COKING:FLUID COKING:A Proven Commercial TechnologyA Proven Commercial Technology

• First Commercial Application in Billings, Montana in 1954 Over 50 years Ago– Over 350 Cumulative Years of Operating Experience

• Significant Improvements in Capacity, Reliability and Run Length

• Currently 7 Operating Units Process >420 kb/D of Heavy Feeds

10

CO M PAN Y LO CATIO N CURRENT FEED RATE, kb/D

ExxonMobil Montana 10

Valero Delaware 52

Imperial Oil Canada 21

Valero California 28

Syncrude 8-1 Canada 110



New Large Syncrude Unit Started Up in 2006



• Located in Fort McMurray, Alberta

SyncrudeSyncrude UpgraderUpgrader

11



• Ownership:

• Size: Design of 129 million barrels per year – Produces High Quality Synthetic Crude (33 API)

– Transported to market via Pembina Syncrude Pipeline

SyncrudeSyncrude UpgradeUpgrade

12



Syncrude Operating Commercially 31 Years!Syncrude Operating Commercially 31 Years!

13

Synthetic CrudeOil

FLUID

COKERS (2)

DILUENT

RECOVERY (2)

HYDROTREATERS (4)D iluted B itum en

A ll

D is tilla tesA tm o s p heric

B o tto m s

1978

2009

B o tto m s

SyncrudeSw eet

P rem ium

FLUID

COKERS (3)

DILUENT

RECOVERY (3)

HYDROPROCESSOR (1)

VACUUM

DISTILLATION (1)

HYDROTREATERS (6)

D iluted

B itum en A ll

D is tilla tes

A tm o s p heric

& V a cuum

B o tto m s



Syncrude Processing ConfigurationSyncrude Processing Configuration

SU L P HU R

H2

M IN IN G

R E CL A IM

SY ST E M

OIL SA N D

T R A N SF E RE X T R A CT ION

F E E D SY ST E M

OIL SA N DT A IL IN G S

T A IL IN G S

D ISP OSA L

SIT E S

D IL U E N T

B OT T OM S

N A T U R A L G A S

SW E E T G A S

T O U T IL IT IE S

B IT U M E N F R OT H

A CID

G A S

SOU R G A S

D IL U T E D

B IT U M E N

H2

H2SY N T HE T IC

CR U D E OIL

H2

T A IL IN G S

3 9 5 -B

F L U ID

COK E R

HY D R OCR A CK E R

R E F OR M E R

N A P HT HA

HY D R OT R E A T IN G

U N IT

L IG HT G A S-OIL


U N IT

HE A V Y G A S-OIL


U N IT

A M IN E

P L A N TSU L P HU R

P L A N T S

E X T R A CT ION

P L A N T

B IT U M E N

F R OT H

T R E A T M E N T

P L A N T

D IL U E N T

R E COV E R Y

U N IT

14



Syncrude Achieve Significant Quality ImprovementSyncrude Achieve Significant Quality Improvement

15



FLEXICOKING:FLEXICOKING:Coke Gasified in Integrated Steam Air Gasifier Coke Gasified in Integrated Steam Air Gasifier

• Produces Clean CO/H2 Fuel Gas 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 or Third Party Furnaces / Boilers

Steam

Generation

FLEXIGASFLEXIGAS

Clean FuelClean Fuel

Reactor Products

to Fractionators

Air

Hot

CokeCold

Coke

Scrubber

GasifierGasifier

Coke

Fines

Fines

Recovery

Tertiary

Cyclones

TO FLEXSORB

Gas Treating

Direct

Contact

CoolerSour

Water

Steam

ReactorReactor

Heavy

Feed

Coke Withdrawal

FLEXIGAS Users:

Pipestill Furnaces

Hydrogen Plant Furnaces

Reformer Furnaces

Steam Superheaters

Waste Heat Boilers

Power Plant Boilers

Third Party Consumers

HeaterHeater

Air Blower

16



Bold the font in the text boxes

FLEXICOKING Produces a Significant Quantity of FLEXICOKING Produces a Significant Quantity of Valuable Clean Fuel GasValuable Clean Fuel Gas

17

COKE: 3. mtons/hr

FEED: 208 mtons/hr

(31 kb/D)

GAS: 23 mtons/hr

LIQUIDS: 122 mtons/hr

GGRR HH

Air &

Steam

FLEXIGAS

FLEXIGAS Users: Pipestill Furnaces

Hydrogen Plant Furnaces

Reformer Furnaces

Steam Superheaters

Waste Heat Boilers

Power Plant Boilers

Third Party Consumers

FLEXIGAS Clean Fuel GasFLEXIGAS Clean Fuel Gas

Composition, mol% Metric English

CO/H2 40

N2 48

Other 12

Total 100

Rates Metric English

Coke Gassified, mtons / hr 60

Flexigas, mtons / hr 351

Heating Value, kj / kg (BTU / SCF) 4,800 128

Heat Rate, MW (th) (MBTU / hr) 460 158



FLEXICOKINGFLEXICOKINGOperating Commercially for 30 YearsOperating Commercially for 30 Years

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

• Currently 5 Units Operating W ith a Total Capacity of ~200 kb/D

• New Unit for Hellenic Petroleum in Greece– Currently under construction at Elefsina Refinery site

18

CO M PAN Y LO CATIO N FEED RATE, kb/D

TOA Oil Japan 27

PDVSA Venezuela 65

Shell California 22

ExxonMobil Netherlands 42

ExxonMobil Texas 42

Hellenic Greece 21



FLEXICOKING Unit FLEXICOKING Unit –– ExxonMobil RotterdamExxonMobil Rotterdam

• Started Up in 1986

• Currently 42 kb/D

• Gasifier in Center (green)

• Coke Silos on Left

• Heater and Reactor / Scrubber on Right

19



Rotterdam Refinery Fuel Gas GridRotterdam Refinery Fuel Gas Grid

20

EuroGen

Flare

Furnaces

Power

Grid

Refinery

Power

Consumers

Electric

Drivers

Steam Steam

DriversDrivers

Dump

CondensorTreat Gas

Consumers

Rotterdam Site Outside

Parties

WSP

Power

former

Air

Products

Air

Liquid

Gas Terra

Sales

Gas

TreatingFLEXICOKERFLEXICOKER

Co

Generation

ERTO

Driver Switch Program

Steam Steam

GenerationGeneration

FlareLJG LJG

GridGridRHJGRHJG

GridGrid

Treat Gas Grid

HJNG Grid

LPG Vaporizer

Offgas

HNJG

Steam

UHJG Treated

UHJG Untreated

RHJG

Hydrogen

Min Possible Flow

LJG

Electric Power



TOA Oil FLEXICOKING Unit, JapanTOA Oil FLEXICOKING Unit, Japan

21

FLEXICOKING UnitFLEXICOKING Unit

Started up in 1976 (21 kb/SD)Started up in 1976 (21 kb/SD)

Current Capacity: 27 kb/SDCurrent Capacity: 27 kb/SD

Fluid Solids Vessels: Fluid Solids Vessels:

•• Gasifier on Left, Gasifier on Left,

•• Heater in CenterHeater in Center

•• Reactor on RightReactor on Right

EarthquakeEarthquake--Proof StructureProof Structure

FLEXIGAS Users:FLEXIGAS Users:

•• Refinery FurnacesRefinery Furnaces 50%50%

•• Power Plant BoilersPower Plant Boilers 50%50%

TO A O IL CO . LTD. Keihin Refinery

FLEXICOKING UnitFLEXICOKING Unit

Started up in 1976 (21 kb/SD)Started up in 1976 (21 kb/SD)

Current Capacity: 27 kb/SDCurrent Capacity: 27 kb/SD

Fluid Solids Vessels: Fluid Solids Vessels:

•• Gasifier on Left, Gasifier on Left,

•• Heater in CenterHeater in Center

•• Reactor on RightReactor on Right

EarthquakeEarthquake--Proof StructureProof Structure



Keihin Refinery Participates in W holesale Electricity Keihin Refinery Participates in W holesale Electricity BusinessBusiness

• Operation Began in 2003 in Co-operation with Other 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

22

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

TO A O IL CO . LTD. Keihin Refinery



SummarySummary

• Significant Oil Sands Reserves in W estern Canada

– Remote location and requires significant upgrade for downstream processing

• FLUID COKING Commercially Proven Heavy Feed Upgrading Technology

– Continuous Fluid Bed Process similar to FCC, heat of reaction provided by partial coke and coke circulation

– Produces similar products to other coking processes

• Syncrude summary points messages

– Includes three large Fluid Coking units

– Produces high quality pipelineable synthetic crude

– Recent start up of new 8-3 unit significantly added to processing capability

• FLEXICOKING Offers Another Option for Oil Sands Upgrading

– Produces large quantity of clean fuel gas product instead of coke

– Fuel gas can be used to meet energy requirements of complex

• Mine or SAGD resources recovery

• Upgrade furnaces and boilers or power production

23

Documents

geoscan.nrcan.gc.ca · Global total 4-7 trillion barrels in place. 5th NCUT Upgrading and Refining Conference Edmonton, Alberta, Canada. ... N A T U R A L G A S SW E E T G A S T O