delayed coking 09
TRANSCRIPT
SYDECSM DELAYED COKINGMaximize profit from the bottom of the barrel
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Delayed coking is a keytechnology for residue upgradingor zero fuel oil production.
Advantages• Refiners can process heavier, cheaper
crudes to increase their refinery margins
• Converts low-value residues to high-value fuels with moderate capital investment
• Easy integration into existing refinery
• Delayed coking is a safe, reliable andWELL-PROVEN technology, meeting allregulatory requirements
DELAYED COKING- the key benefits
In today’s environment, refiners recognize the need for delayed coking to keep pacewith the growing demand for transportation fuels, more stringent legislation and theopportunity for improvement in refinery profit margins.
Valero’s $350 million investment in a 45,000barrel per day coker (complex) at its Texas Cityrefinery increased the plant’s ability to processheavy, sour Maya crude. As a result, the cokergenerated nearly $200 million in operatingincome in one year alone!
Typical yield from a barrel of coker feedstock
Resid
Coke
Coker Gas
LPG
Naphtha
LCGO toDiesel
HCGO toHDS, HCor FCC
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Delayed coking is a cyclicprocess that thermally cracksvacuum residue or otherresidue feedstocks into gas, light products and petroleum coke.
Key process steps:
• heat residue to about 930°F(500°C) in coker furnace
• transfer the hot residue to cokedrum before it has formed coke
• fill the drum and allow theheavy tars to coke
• switch the drums on timed cycle(12 to 24 hours)
• decoke the full drumhydraulically
• recover the cut coke, crush and prepare for shipment
• recycle water to eliminate waste
• fractionate cracked productsinto gas, coker naphtha, light coker gasoil and heavy coker gasoil
• further process fractionatedproducts in downstream units
What is
THE SYDECSM
PROCESS?
AtmosphericDistillation
Vacuum Distillation Unit
Delayed Coking Unit
Coke
Fractionator
CokeDrum
Gas Plant
Gas Fuels
Liquid Fuels
CokeBy-products
LighterGases
andLiquids
Residue
Foster Wheeler offers SYDECSM (Selective Yield Delayed Coking) under license
BEST-IN-CLASSTECHNOLOGY Foster Wheeler has designed andengineered more delayed cokersworld-wide than any other technologyprovider or engineering contractor.
• Over 2.4 million bpsd installedusing our technology
• Over 70 revamps designed in thelast 10 years
• Almost 40 new units designed inthe last 5 years
• Our mechanical design expertiseand extensive EPC experienceenables successful technologytransfer
• Proprietary equipment design andsupply – drum unheading systemsand the all-important coker heater
• Proprietary specification of othercritical equipment
• Maximum liquid yields whilemaximizing operating efficiency
RIGHT PEOPLE, RIGHT EXPERTISEOur people have in-depth technicalknowledge and expertise. We have the largest team of coking experts in the industry, many of them with over 30 years’ experience in all aspects ofcoker design and project execution.
SEAMLESS EPC EXECUTIONAs a world-class EPC contractor with a long track record of executingsuccessful major projects andrevamps, our clients benefit from ourexperience of meeting aggressive costand schedule targets.
FOSTER
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Our coking capabilityfor new plants andrevamps
• Feasibility, planning andeconomic studies
• Process design packages
• EPC
• Commissioning, start-up and operations assistance
• Operator training
• Design and supply of:- drum unheading devices- coker heaters
• Capacity increases/revamps:- coke drum replacement- safety improvement
• API fitness-for-serviceevaluation
• Fatigue life evaluation oncoke drum support skirts
- taking
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WHEELERtechnology further
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PROJECT
VALEROTexas City Refinery, USAEPC in less than 28 months, underbudget, from process design to ‘oilin’. Coker process 45,000 bpsd infour drums.
PETRONORSomorrostro, SpainProcess design, FEED and EPC for36,000 bpsd delayed coker, plus cokehandling and storage facilities, and a gas concentration unit.
PETROXTalcahuano, ChileWe designed, supplied and built anew 12,000 bpsd delayed cokingplant at this innovative PetropowerTM
combined coker/cogeneration facility.
SINCORJose, VenezuelaEPCm for debottlenecking andshutdown. One of four Orinocoupgraders; we provided delayedcoking technology for three.
MOLSzázhalombatta, HungaryWe have worked with MOL for morethan 20 years. Our recent revampand expansion increased capacity by27% to 26,400 bpsd.
RELIANCE INDUSTRIESJamnagar Export Refinery, IndiaHuge new eight-drum 160,000 bpsddelayed coking unit, one of the largestin the world, and four Terrace-WallTM
delayed coker heaters.
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highlights
BPCastellón, SpainFEED and EPC for new 20,000 bpsdcoker and design, engineering,procurement and supply of 43.5 MWdouble-fired Terrace-WallTM heater.
ENERCONENAP’s Aconcagua Refinery,ChileFeasibility study, basic design and EPCof a 20,000 bpsd coking facility,including amine regeneration unit,sour water stripping and cokehandling facilities.
INDIAN OIL CORPORATIONGujarat, IndiaLicense and basic engineering for new 3.7 mtpa delayed coker, part ofIOCL’s residue upgrading program.
REPSOL YPFCartagena, SpainOur relationship with Repsol started in 1966 and recently included thelicense, process design package andEPCs for a 53,000 bpsd delayedcoker unit, gas concentration unit and90,000 bpsd vacuum distillation unit.
BPWhiting Refinery, USLicense, process design package andEPCm for coker project to increaserefinery’s ability to process Canadianheavy crude.
SAUDI ARAMCO/TOTALJubail Export Refinery, Saudi ArabiaProcess design package for a newdelayed coker, part of the JubailExport Refinery, a grassroots full-conversion refinery designed toprocess Arabian heavy crude.
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The fired heater is the heartof the delayed coker, and we can offer: • Terrace-WallTM double-fired,
sloped wall type
• single-fired cabin-or box-type withhorizontal tubes and bridge wall
Foster Wheeler fired heaters are anintegral part of our technology, andensure economic operation with long on-stream factors.
Our in-house team provides fullprocess, thermal and mechanicaldesign to our stringent specificationsand standards, leaving no criticaldetails open to misinterpretation by a third-party designer.
The key advantages of Foster Wheeler’s Terrace-WallTM
delayed coker heaters:
• Sloped walls provide an extremelyuniform heat flux from top tobottom of the radiant coil
• The burners firing up the slopedwalls stabilize the coker off-gas fueland spread the flame evenly alongthe length of the tube and up thewall
• Grade access permits 360-degreeviewing access and easier burnermaintenance
• Completely isolated cells allowindividual pass firing controls for on-line spalling and turndownabilities, which result in cost savingsfrom increased run length
SYDECSM - the heart
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of the process
Key features of the SYDECSM
process are reliability andefficiency:
• Terrace-WallTM double-firedfurnace
• Advanced coke drum design
• Fractionator zone sprays andfines removal
• Low pressure, ultra-low recycle
• On-line spalling/pigging
• Can achieve successful run lengths of five years ormore between turnarounds
Safety:
• Unheading systemimprovements
• Safety interlocks
Environmental advantages:
• SYDECSM is an environmentally friendly process
• There is low-sulfur fuel gas production
• Enclosed blowdown recovery systems
• Unique clean coke handling systems
Although cokingtechnology is‘mature’, we arealways looking forways to make ourSYDECSM technologyeven safer andmore reliable forour clients.
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The SYDECSM
difference
Due to the stringent environmental regulations atENAP’s Aconcagua refinery in Chile, the petroleumcoke produced is milled in a coke crusher andconveyed in belts installed in a closed gallery anddriven into a hemispherical storage facility (‘domo’).
success
GAS-TO-LIQUIDS
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Did you know?
• Commercial coking first started in 1929
• Since 1994, all residue upgrading in the USA has been based on delayed coking
• Foster Wheeler cokers have the flexibilityto produce fuel-grade coke or morevaluable anode coke depending onfeedstock
• We can integrate delayed coking with
- solvent deasphalting (SDA) to increaseresidue conversion
- circulating fluidized-bed (CFB)technology to produce electricityand/or steam
- gasification to produce electricity,steam and hydrogen
Turning visioninto reality
