UpgradingofHeavyOilswith

FLEXICOKING
ExxonMobil Research & Engineering Company
Tim Hilbert

FLEXICOKING:
Integrated Coking and Gasification

FLEXICOKINGTM Integrated Coke Gasification

Key features of technology
Commercial experience

FLEXIGAS Utilization - Clean Fuel Gas

Utilization in refinery or for power production

Rotterdam and TOA Oil FLEXICOKING Experience

Commercial operations
Expansion and joint venture for power production

Coking Process

Coking is the Most Widely Used Resid Conversion Approach Worldwide!

Delayed Coking Furnace & Drum, Batch Process, Coke Pits
FLUID COKING 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
Product: (a)
Heavy
Crudes
Resids

Delayed Coking (several providers)

FLUID COKINGTM (ExxonMobil)

Yield (wt%)

Fuel Gas & LPG

10

C5+ Liquids

55

Coke (b)

35

Total

100

Coke Dispositions Can Have A Major Impact on Project Economics!

FLUID COKING
Technology and Commercial Experience
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 burner 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 conveyed and stored in silos for fuel coke market
Reactor Products
to Fractionators
Heavy
Feed

Flue Gas to
CO Boiler

Scrubber

Reactor

First commercialized
in ExxonMobils
Billings, Montana
Refinery in 1954!

Burner
Product Coke

Cold
Coke

Hot
Coke

Over 420 kB/D of Operating

Capacity Worldwide

Air

7 Units with last S/U in 06

- Unit Rates from 10 110 kB/D
3

FLEXICOKING

Same Liquid Yields as Fluid or Delayed Coking

Coke Gasified in Integrated Steam Air Gasifier
Produces Clean CO/H2 Fuel Gas Product Instead of Coke

Low SOX
FLEXSORB Hindered Amine Reduces H2S to Low Level
Nitrogen Diluent Reduces BTU Content, But
Low NOX
FLEXIGAS Burned in Refinery or Third Party Furnaces / Boilers
Tertiary
Cyclones
Steam
Generation

Reactor Products
to Fractionators
Heavy
Feed

TO FLEXSORB
Gas Treating

Fines
Recovery

Scrubber

Reactor

Heater

Coke
Fines

Gasifier

Sour
Water

Direct
Contact
Cooler

FLEXIGAS
Clean Fuel

Steam Air Blower

Cold
Coke

FLEXIGAS Users:
Refinery
Third Party Consumers

Hot
Coke
Coke Withdrawal

Air

FLEXICOKING: Reactor Product / Yields

Similar to Other Coking Processes - Thermal Conversion
Feed and Recycle Cut point Differences can complicate Comparisons
Gas & Liquids
Wt%
FF

Products
FLEXIGAS

LV%
FF

C2 Fuel Gas

6.7

C3 / C4 LPG

4.4

VR

Total C4-

11.1

Nominal cut point, C

565

C5 / 430 F

15.3

20.8

Nominal cut point, F

1050

430 / 650 F

11.0

12.6

650 / 975 F

32.2

33.2

Total C5+

58.6

66.6

Feed
Type

Feed Properties
Gravity, API

6.9

Sulfur, wt%

4.6

Conradson Carbon, wt%

26

Nickel, wppm

18

Vanadium, wppm

108

Air &
Steam

Coke, Wt%
Net Product Coke

1.7

Gasified Coke

28.6

Total

30.3

FLEXICOKING:
Produces a Significant Quantity of Valuable Clean Fuel Gas
FLEXIGAS Clean Fuel Gas
mol%
40

Composition
CO/H2

GAS: 23 mtons/hr
LIQUIDS: 122 mtons/hr

FLEXIGAS

FEED: 208 mtons/hr

(31 kb/D)

N2

48

Other

12

Total

100

Rates
Coke Gasified, mtons / hr
FLEXIGAS, mtons / hr

Boldthefontinthetextboxes

Heating Value, kj / kg (BTU / SCF)

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

Metric
60

English

351
4,800

128

460

158

FLEXIGAS Users:
Air &
Steam

COKE: 3. mtons/hr

Pipe still Furnaces

Hydrogen Plant Furnaces
Reformer Furnaces
Steam Superheaters
Waste Heat Boilers
Power Plant Boilers
Third Party Consumers

FLEXICOKING:
Operating Commercially for 30 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
New Unit for Hellenic Petroleum in Greece under construction
New Unit for PetroPeru most recent Licensee
COMPANY

LOCATION

FEEDRATE,kB/D

TOA Oil

Japan

27

PDVSA

Venezuela

65

Shell

California

22

ExxonMobil

Netherlands

42

ExxonMobil

Texas

42

Hellenic

Greece

21

PetroPeru

Peru

22

2010 Middle East Petrotech, Bahrain May 23-26, 2010

Processing Configurations Comparable to

FLEXICOKING

FLEXICOKING Commercially Proven With Integrated Steam / Air

Gasification
Milder Conditions and Lower Capital Cost than POX
FULLY INTEGRATED
Conversion Step

Gasification Step

Fluid Bed
Coking

Fluid Bed
Coke
Gasification

FLEXICOKING

CO / H2 / N2
Fuel Gas

Steam/Air
SEPARATE PROCESS
Competing
Options

Conversion Step

Gasification Step

Delayed Coking
Ebullating Bed
SDA

Partial
Oxidation
Gasification

Air

Separation

CO / H2
SynGas

Oxygen
8

FLEXIGAS Utilization

FLEXIGAS Fuel is Rich in CO and H2

Heating value reduced by nitrogen diluents

FLEXSORB Amine Gas Treating Reduces Sulfur to Very Low Levels (< 10
ppm H2S)
Burns very cleanly ultra-low SOx and NOx
Burns with constant heating value (unlike refinery fuel gas)

FLEXIGAS Burns Very Readily in a Wider Range of Services in a Variety of

Commercially Available Burners
Process heaters (pipe stills, naphtha reformers, hydrogen plant furnaces)
Utility boilers (steam generation, steam super heaters)
Over-the-fence sales to power plants or other nearby consumers

Burner Conversion and Fuel Distribution Costs Are Low

Burners commercially available at same cost as conventional burners
Low pressure pipes / ducts

Refinery Fuel Balance Planning Important

Overall fuel requirements in conversion project
Location and size of refinery consumers
Third party fuel consumers

FLEXICOKING Commercial Experience

ExxonMobil Rotterdam

Started Up in 1986
Currently 42 kB/D
Gasifier in Center (green)
Coke Silos on Left
Heater and Reactor /
Scrubber on Right

FLEXICOKING Unit Added in Major Upgrade to Hydroskimming Refinery

Refinery has high degree of integration / efficiency

Refinery is Entirely Gas Fired

Refinery fuel gas
FLEXIGAS
Supplemental natural gas

Real Time Optimization (RTO) Control System Used to Manage Fuel Gas
Sources / Balance
10

Rotterdam FLEXIGAS Consumers

Large number of Furnaces, Fired Heaters & Boiler On Site Consumers

Primary Users

Furnace / Heaters / Burners

Boilers (2)

Grass Roots

Atmospheric Pipe still Furnace (2)

Revamp

Vacuum Pipe still Furnace

Grass Roots

Naphtha Reformer Furnace

Grass Roots

Steam Reforming H2 Plant Furnace

Grass Roots

Stabilizer Reboiler

Revamp

Splitter Reboiler

Revamp

Steam Super Heater

Grass Roots

11

Considerations for Use of FLEXIGAS

Overall Refinery Fuel Balance and Design of FLEXIGAS
Distribution System
Consider Refinery Consumers that are Large and Close to
FLEXICOKING First
Secondary Refinery Consumers Selected Based upon Fuel Savings
versus Cost of Burners and Ducts
Refinery Scenario Planning to Identify:
Source of alternate fuel gas for consumers and dual fired burners for added
flexibility
Disposition of FLEXIGAS when selected consumers are down

Large Nearby Consumer Helps Fuel Balance and Provides Flexibility

12

TOA Oil Refinery FLEXICOKING Unit

TOA Oil Keihin

186 kB/D

Mizue

65 kB/D

Ohgimachi

120 kB/D

Ohgimachi and Mizue Plants ~

1.2 km Apart
KPL (Kawasaki Underground
Pipeline (5)) Enables Two Sites
to Operate as Integrated Refinery

2010 Middle East Petrotech, Bahrain May 23-26, 2010

13

TOA Keihin Refinery: Process Configuration

Vacuum Distillation Unit at Mizue Processes Long Residue from

Both Sites and Provides Feed to FLEXICOKING Unit

Intermediate / Finished Products Transported Between Plants

Through Underground Pipelines
Crude

Atmospheric Distillation (120,000)

Atmospheric
Distillation

Crude

Ohgimachi Refinery

Units: BPSD
Underground Pipeline
Propylene

(65,000)
(58,000)
Vacuum
Fractionation
Unit

Vacuum
Residue
Mizue Refinery

HDS Unit
(Light Oil)

Gasoline
(42,000)

HDS Unit
(Vac. Gas Oil)

FLEXICOKING Unit

FCC Unit

Solvent
Kerosene
Light Oil

Polymerization

Heavy Oil
Coke

(27,000)

14

TOA Oil FLEXICOKING Unit

FLEXICOKING Unit
Started up in 1976 (21 kb/SD)
Current Capacity: 27 kb/SD
Fluid Solids Vessels:
Gasifier on Left
Heater in Center
Reactor on Right
Earthquake-Proof Structure

FLEXIGAS Users
Refinery Furnaces

50%

Power Plant Boilers

50%

15

TOA Oil FLEXICOKING

Reactor Products / Yields
GasandLiquids

Process Long Residue from Both

Ohgimachi and Mizue

Yield(wt%) Disposition

Also process H-Oil Bottoms from nearby

Tonen Kawasaki refinery

C2

8.5 10.0

C3C4

4.8 6.5

Naphtha

PRODUCTS
FLEXIGAS

Feed(VacuumResidue)
Density
Sulfur(wt%)
CCR(wt%)
Ni+V(wtppm)

1.01 1.03
4.0 4.7
19 22
<230

GasOil
R

Light:Caustic
TreatmentforMogas
19.0 21.0
Heavy:Hydrotreated
forPlatformerFeed
Light:Hydrotreated
tobeDieselOil
36.0 39.0 Product
Heavy:Hydrotreated
tobeFCCFeed

ProductCoke
Air &
Steam

Purge
Coke

GasTurbineFuelfor
PowerPlant
C3H8,C3H6 recovery
FeedforPoly
NaphthaPlant

Yield(wt%) Disposition
Total

26 28

Gasified

23 27

NetProduct

2 4

Convertedto
LowCalorieGas
SalestoCement
Company

16

Keihin Refinery Participates in Wholesale Electricity Business

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 Refineries
Stable Supply of Electricity and Steam

TOA OIL Keihin Refinery

Vacuum
Residue
Fraction

Products

Genex (Power-Generating Plant)

Steam Boiler

37 %

Low Calorie Gas

(LCG)

Frac.
L/E

High Calorie Gas

(C1, C2)

FCC HCG Gas

LPG (C3, C4)
Refinery furnaces
R

21 %

Waste Heat
Boiler

33 %
Gas Turbine
9%
100 %

G
Air & Steam

Gas Turbine:
~80 MW
Steam Turbine: ~190 MW
Total
~ 270 MW

17

Major Advantages of FLEXICOKING Technology

FLEXICOKING Produces a Large Quantity of Valuable Clean Fuel Gas
FLEXIGAS is primarily CO / H2, with N2
Sulfur content < 10 ppm H2S and burns cleanly with very low SOx and NOx

FLEXICOKING Produces Valuable Liquids Like Other Conversion

Processes
Yields are similar to other coking processes

FLEXICOKING Minimizes Product Coke with Integrated Air Gasification

Approx. 1-4% compared with approx. 30% for other coking processes

FLEXIGAS Burns Readily in a Wide Range of Consumers

Process heaters, Utilities, Power Plants or over-the-fence sales

FLEXICOKING Fits Best in Locations with Large Demand for Clean Fuel

18

Upgrading of Heavy Oils with

FLEXICOKING

Questions

Sunset at TOA Oil, Keihin Refinery ( Mizue )