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

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Presentation on theme: "0 Research and Engineering Economically Attractive and Environmentally Friendly FLEXICOKING Resid Upgrading Technology Dr. Girish Chitnis Ms. Marie Wright."— Presentation transcript:

1 0 Research and Engineering Economically Attractive and Environmentally Friendly FLEXICOKING Resid Upgrading Technology Dr. Girish Chitnis Ms. Marie Wright Mr. Glen Phillips International Conference on Refining Challenges - Way Forward' April, 2012 New Delhi

2 1 Research and Engineering 1 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 & LPG10 C5+ Liquids55 Coke 35 Total100 FLEXICOKING Eliminates the Coke!

3 22 Research and Engineering Cold Coke 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 Hot Coke Air from Blower FLEXIGAS

4 33 Research and Engineering FLEXICOKING Schematic Steam

5 4 Research and Engineering 4 FLEXICOKING Products Same Liquid Yields as Delayed Coking Coke Gasified in a Simple Integrated Steam + Air Gasifier Produces Clean CO/H 2 Fuel Gas (FLEXIGAS) Product Instead of Coke FLEXSORB® Hindered Amine Reduces H 2 S to Low Level Low SO X Nitrogen Diluent Reduces BTU Content, But Low NO X FLEXIGAS Burned in Refinery, Third Party Furnaces / Boilers or for Power Research and Engineering Steam

6 55 Research and Engineering FLEXIGAS at Parity with NG Price, $/mm Btu FLEXIGAS Margin over Delayed Coke M$/Year 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

7 66 Research and Engineering FLEXICOKINGGasification Partial Oxidation Gasification ProductFuel GasSyngas / H 2 / Fuel Gas ComponentsCO/ H 2 / N 2 CO / H 2 Heat Content, kJ/kg Process GasesSteam / AirOxygen (a) Temperature, °C Pressure, barg2 – 420 – 70 SlagAvoid formationDisposal is an Issue Materials Refractory Lined Carbon Steel Simple Inlet Distributor Brick Lined Complex Alloy Nozzles Cycle Length, months36-48<6 (b) Capex$$$$ FLEXICOKING Gasification & PO X Comparison a. Typically Requires air separation plant b. Per Gasifier. Overall reliability improves with spares

8 7 Research and Engineering FLEXIGAS AS A REFINERY FUEL

9 8 Research and Engineering 8 8 F LEXIGAS 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 SITEFLEXIGAS (MW) FLEXIGAS Used in Refinery (%) Off Site Consumers 1PDVSA, Venezuela 60028Large boiler / power plant consumes majority of Flexigas 2ExxonMobil Baytown Flexigas used on site Very large/ complex refinery with large number of on site fuel users 3ExxonMobil Rotterdam 45082Burn majority of FLEXIGAS onsite Sell ~270 MW high BTU fuel gas offsite 4Shell California ~300~100Primarily use FLEXIGAS in refinery 5Showa Shell Japan 30050Large nearby power plant consumes ~50% of FLEXIGAS in boilers

10 99 Research and Engineering FLEXICOKING Low Joule Gas Firing Dual Fuel Burner Assembly LJG Burner RHJG Burner Pilot Burner (HNJG) 9

11 10 Research and Engineering 10 Rotterdam Refinery Fuel Gas & Energy Grid Details

12 11 Research and Engineering FLEXICOKING Rotterdam Refinery Environmental Dutch Refineries XOM Refinery Emission SO 2 kt / jr 30,33,0 NO x kt / jr 9,91,0 Dust kt / jr 2,70,09 Capacity mt / jr 6110 Low Sulphur Products kt / jr

13 12 Research and Engineering FLEXIGAS FOR P OWER G ENERATION U SING S TEAM C YCLE

14 13 Research and Engineering TOA Oil FLEXICOKING Unit FLEXICOKING Unit Started up in 1976 (21 kb/SD) Current Capacity: 27 kb/SD Fluid Solids Vessels: Gasifier on LeftGasifier on Left Heater in CenterHeater in Center Reactor on RightReactor on Right Earthquake-Proof Structure FLEXIGAS Users Refinery Furnaces50%Refinery Furnaces50% Power Plant Boilers50%Power Plant Boilers50%

15 14 Research and Engineering 14 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 G RH 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 15 Research and Engineering FLEXIGAS FOR P OWER G ENERATION U SING C OMBINED C YCLE

17 16 Research and Engineering 16 FLEXICOKING and GTCC: A Case Study FLEXICOKING Unit Material reproduced with permission from Mitsubishi Heavy Industries (MHI). All rights reserved

18 17 Research and Engineering Approx. 200 m Approx. 60 m Gas Cooler Gas Compressor BFG Gas Mixer COG E.P. Steam Turbine Generator Gas Turbine HRSG Stack Inlet Air Filter Transformer MHIs Equipment Layout Material reproduced with permission from Mitsubishi Heavy Industries (MHI). All rights reserved

19 18 Research and Engineering C APEX FOR P OWER G ENERATION U SING S TEAM OR C OMBINED C YCLE

20 19 Research and Engineering Relative Total Investment Cost (TIC) Add a Simple Gasifier for Only 30% More Capex than Delayed Coker

21 20 Research and Engineering Simple Payout versus Electricity Price Shorter Payout with FLEXICOKING and Power Generation Shorter Payout with FLEXICOKING and Power Generation

22 21 Research and Engineering FLEXIGAS FOR H 2, N 2, CO 2, A MMONIA AND U REA P RODUCTION

23 22 Research and Engineering Flexibility of H 2, CO 2, NH 3, Urea and Power Production From FLEXIGAS Ammonia Urea Heater Overhead and FLEXSORB® FLEXIGAS Compression Hydrogen Shift CO 2 Removal Ammonia Production Power Generation Combined Cycle Rankine Cycle Power Generation Combined Cycle Rankine Cycle Excess FLEXIGAS used as refinery fuel Urea Production Hydrogen Hydrogen Production CO 2 MW-hr Purge Gas PSA Offgas

24 23 Research and Engineering 23 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 COMPANYLOCATIONFEED RATE, kB/D TOA OilJapan 27 PDVSAVenezuela 65 ShellCalifornia 22 ExxonMobilNetherlands 42 ExxonMobilTexas 42 HellenicGreece 21 PetroPeruPeru 22 RosneftRussia 50

25 24 Research and Engineering 24 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 PO x 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 H 2, N 2 and CO 2

26 25 Research and Engineering 25 Sunset at TOA Oil, Keihin Refinery ( Mizue ) FLEXICOKING Coking and Integrated Steam / Air Gasification Questions

27 26 Research and Engineering FLEXIGAS + GTCC Gives Higher Cash Flow 120+M$ Higher Annual Cash Flow than Delayed Coking + IGCC Power Generation

28 27 Research and Engineering 27 FLEXICOKING Advantages Versus Other Options FLEXICOKING Advantages Versus Other Options Milder Conditions and Significantly Lower Capital Cost than PO x No issues such as Disposal of Slag, UCO No Air Separation Unit Needed Competing Options Delayed Coking Ebullating Bed SDA Conversion Step Partial Oxidation Gasification Gasification Step CO / H 2 SynGas Air Separation Oxygen SEPARATE PROCESS Fluid Bed Coke Gasification FLEXICOKING CO / H 2 / N 2 Fuel Gas Fluid Bed Coking Conversion Step Gasification Step FULLY INTEGRATED Steam/Air


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