0 research and engineering economically attractive and environmentally friendly flexicoking resid...
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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
44 Research and Engineering
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
5 Research and Engineering5
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
66 Research and Engineering
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
77 Research and Engineering
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
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Research and Engineering
FLEXIGAS AS A REFINERY FUEL
9 Research and Engineering99
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
1010 Research and Engineering
FLEXICOKING Low Joule Gas Firing
Dual Fuel Burner
Assembly
LJG Burner
RHJG Burner
Pilot Burner (HNJG)
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Rotterdam Refinery Fuel Gas & Energy Grid Details
1212 Research and Engineering
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
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Research and Engineering
FLEXIGAS FOR POWER GENERATION USING
STEAM CYCLE
1414 Research and Engineering
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%
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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
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Research and Engineering
FLEXIGAS FOR POWER GENERATION USING
COMBINED CYCLE
17 Research and Engineering17
FLEXICOKING and GTCC: A Case Study
FLEXICOKING Unit
Material reproduced with permission from Mitsubishi Heavy Industries (MHI). All rights reserved
1818 Research and Engineering
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
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Research and Engineering
CAPEX FOR POWER GENERATION USING
STEAM OR COMBINED CYCLE
2020 Research and Engineering
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
2121 Research and Engineering
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
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Research and Engineering
FLEXIGAS FOR H2, N2, CO2, AMMONIA AND
UREA PRODUCTION
2323 Research and Engineering
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
24 Research and Engineering24
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
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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
2727 Research and Engineering
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
28 Research and Engineering28
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