geoscan.nrcan.gc.ca · Global total 4-7 trillion barrels in place. 5th NCUT Upgrading and Refining...
Transcript of geoscan.nrcan.gc.ca · Global total 4-7 trillion barrels in place. 5th NCUT Upgrading and Refining...
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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
Edmonton, Alberta, Canada. September 14-16, 2009Research and Engineering
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
5th NCUT Upgrading and Refining Conference
Edmonton, Alberta, Canada. September 14-16, 2009Research and Engineering
Tar Sands Extraction ApproachesTar Sands Extraction Approaches
5
Mining:
SAGD:
Research and Engineering 5th NCUT Upgrading and Refining Conference
Edmonton, Alberta, Canada. September 14-16, 2009
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
5th NCUT Upgrading and Refining Conference
Edmonton, Alberta, Canada. September 14-16, 2009Research and Engineering
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
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Reactor Products
to Fractionators
Hot
CokeCold
Coke
ScrubberHeavy
Feed
Air
ProductCoke
Flue Gas to
CO Boiler
ReactorReactor BurnerBurner
5th NCUT Upgrading and Refining Conference
Edmonton, Alberta, Canada. September 14-16, 2009Research and Engineering
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)
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• 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)
5th NCUT Upgrading and Refining Conference
Edmonton, Alberta, Canada. September 14-16, 2009Research and Engineering
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
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• 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)
5th NCUT Upgrading and Refining Conference
Edmonton, Alberta, Canada. September 14-16, 2009Research and Engineering
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
Syncrude 8-2 Canada 110
Syncrude 8-3 Canada 95
New Large Syncrude Unit Started Up in 2006
5th NCUT Upgrading and Refining Conference
Edmonton, Alberta, Canada. September 14-16, 2009Research and Engineering
• Located in Fort McMurray, Alberta
SyncrudeSyncrude UpgraderUpgrader
11
5th NCUT Upgrading and Refining Conference
Edmonton, Alberta, Canada. September 14-16, 2009Research and Engineering
• 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
5th NCUT Upgrading and Refining Conference
Edmonton, Alberta, Canada. September 14-16, 2009Research and Engineering
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
Research and Engineering 5th NCUT Upgrading and Refining Conference
Edmonton, Alberta, Canada. September 14-16, 2009
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
HY D R OT R E A T IN G
U N IT
HE A V Y G A S-OIL
HY D R OT R E A T IN G
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
5th NCUT Upgrading and Refining Conference
Edmonton, Alberta, Canada. September 14-16, 2009Research and Engineering
Syncrude Achieve Significant Quality ImprovementSyncrude Achieve Significant Quality Improvement
15
5th NCUT Upgrading and Refining Conference
Edmonton, Alberta, Canada. September 14-16, 2009Research and Engineering
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
Research and Engineering 5th NCUT Upgrading and Refining Conference
Edmonton, Alberta, Canada. September 14-16, 2009
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
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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
5th NCUT Upgrading and Refining Conference
Edmonton, Alberta, Canada. September 14-16, 2009Research and Engineering
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
5th NCUT Upgrading and Refining Conference
Edmonton, Alberta, Canada. September 14-16, 2009Research and Engineering
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
Research and Engineering 5th NCUT Upgrading and Refining Conference
Edmonton, Alberta, Canada. September 14-16, 2009
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
Research and Engineering 5th NCUT Upgrading and Refining Conference
Edmonton, Alberta, Canada. September 14-16, 2009
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
5th NCUT Upgrading and Refining Conference
Edmonton, Alberta, Canada. September 14-16, 2009Research and Engineering
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
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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
5th NCUT Upgrading and Refining Conference
Edmonton, Alberta, Canada. September 14-16, 2009Research and Engineering
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