successful start-up of delayed ... - amec foster · pdf file8 why refiners select amec foster...

Maximising return on investmentThree Big Questions & Three Big Answers

Pre-Conference Workshop at ME-TECH 2015, DubaiMonday, 16 February 2015, 12.30pm – 6.00pm

Steve Beeston: Vice President, Technology,Amec Foster Wheeler

Successful Start-Up of Delayed Coking UnitPetron RMP-2 Project

Effective Project DeliveryThe 4 Rights

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Petron Corporation► Petron is a private Philippine refiner and retail

station operator► Largest refiner and marketer in the Philippines

► Supplies over one third of the country’s oil requirements

► Owned by San Miguel since Dec 2008► Operates a 180,000 BPSD refinery in Limay,

Bataan► Originally an Exxon refinery► Refinery built by Foster Wheeler over 50 years ago

3 © Amec Foster Wheeler 2015. All rights reserved.

Petron’s Bataan Refinery

Petron RMP-2 Project: The Right Project► Project vision

► Make the Bataan Refinery one of the most modern integrated oil refining and petrochemical complexes in Asia

► Help Filipino nation-building► Existing refinery constraints

► Throughput constrained by fuel oil production► Limited petrochemicals production

► Project objectives► Install residue conversion to increase white oils

production► Increase petrochemicals production► Increase the refinery’s competitiveness in S.E. Asia


Petron’s Bataan Refinery

Petron Approach: The Right Execution► Aim

► Utilize best technology► Fast track project implementation► Meet aggressive budget


Petron Execution Approach► Technology Selection

► Review of technology market► Focused ITB► Rapid evaluation of licensor proposals


Petron RMP-2 Project Licensor signing ceremony

RMP-2 Major Units: The Right Technology


Sources: Licensor press releases

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Why Refiners Select Amec Foster Wheeler for Delayed CokingExperience

► Most installed units (> 60%)► Wide range of feedstocks► Extensive heavy crude experience► All coke types► Full range of unit sizes► Multiple repeat clients

Technical Resources► In-house experience & expertise► Vendor and 3rd party support► Operations support

High on stream factors and reliability► Safe operation► Long run lengths► Over 5 years between turnarounds► Minimal environmental impact

Innovative design► Proprietary double fired heater► Forged ring coke drum design► Total automation concept► Modular construction► Process integration

© Amec Foster Wheeler 2015. All rights reserved.

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Amec Foster Wheeler DCU Experience2005 - 2014

Number of units awarded Capacity (BPSD)


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Amec Foster Wheeler DCU Experience2005 - 2014


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Recent DCU AwardsClient Location Capacity

(BPSD)Award Date

Petrourica Venezuela 109,415 2014

Bashneft Russia 36,300 2014

Petrobicentenario Venezuela 172,464 2014

DRPIC Oman 52,000 2014

Omsk Russia 34,500 2013

Axion Argentina 35,000 2012

Petromiranda Venezuela 103,700 2012

Confidential Europe 50,000 2012

Client Location Capacity (BPSD)

Award Date

Takreer Abu Dhabi 29,500 2011

PDVSA Venezuela 50,000 2011

Petrochina (2) China 52,500 2011

Petrobras (3) Brazil 65,000 2010

Antipinsky Russia 24,000 2010

RDP Ecuador 93,000 2010

Petron Philippines 45,000 2010

STRAS Turkey 40,000 2010


PetrocedeñoUpgraderDelayed Coker

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Foster Wheeler SYDECSM Process► Leading Delayed Coking technology► Proprietary Terrace WallTM double-fired

furnace► Maximum liquid product yields

► Low pressure► Ultra low recycle

► Designed in safety and reliability► Large coke drums► Unique fractionator design► Environmentally friendly► Total automation capability► Operations support

Innovative

design leads to

superior technology

and operations


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Terrace-Wall Double Fired HeaterFeatures► High average heat flux► Reduced coil volume► High in-tube velocities► Independent pass control► Sloped wall design for even flux► On-line spalling & piggingBenefits► Process difficult feeds► Provides feedstock flexibility► Longer run lengths► More profitable operations

The Terrace-Wall heater provides true management of the heat flux for optimal performance


Terrace-Wall Heater


Coke Drum Design► Single thickness wall► Skirt-shell connection

► Hot box► Weld build up / Forged ring

► 1¼ Chrome steel with cladding ► Proprietary FW plate chemistry,

welding and finishing specifications ► Long life (>8,000 cycles) with

forged ring design

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Better design for longer life


Large Coke Drums► Amec Foster Wheeler pioneered large coke drum designs► First to commercialize 9.8 m diameter drums► Ability to optimize unit costs


Amec Foster Wheeler Coke Drum Life Monitoring Program


Petron Delayed Coking Unit

► Install additional thermocouples on drum

► Monitor temperature gradients► Optimize quench and heat up

rates► Coke drum life estimation► Proactive maintenance

prevents costly shutdowns

Amec Foster Wheeler DCU Training ServicesProtecting the investment► Conventional classroom training► KnowledgeWeb and KnowledgeWeb+

► Web based training can be combined with simulator

► 24/7 real time access anywhere, anytime with the internet and a browser

► Customized: unit / site specific► Helps to maximize yields by applying the

knowledge of the unit designers► Helps to improve reliability by incorporating the

knowledge and maintenance procedures of the different process equipment.

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Petron DCU Overview► 45,000 BPSD Arab Medium VR► 4 drums

► 7.4 m diameter, 30.1 m F-F

► 2 x 3 pass Terrace-Wall heaters► Low pressure► Ultra low recycle► Max liquid yields



Petron Project Execution► The DCU contains very specialized equipment

► Amec Foster Wheeler proprietary heaters► Coke drums► Unheading devices► Coke cutting system

► Petron preselected key equipment items


Coke Drums► Sumitomo

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Petron Delayed Coking UnitSumitomo’s Saijo fabrication facilities

Unheading Devices► Zimmerman & Jansen

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Petron was the first to buy an electric actuated BUD


Petron Delayed Coking Unit TUD

Motiva Port Arthur Delayed Coking Unit BUD

Remote & Automated Coke Cutting► Flowserve

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Safety First: Coke cutting from remote shelter, off the structure



RMP-2 Major Units


Sources: Licensor press releases

RMP-2 Project IntegrationPetron engaged Axens Performance Programs (P2) to:

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► Optimize and integrate the units► Determine offsite and utilities

requirements► Provide a basis for basic

engineering► Enable fast track execution


View of RMP-2 Project

RMP-2 Project Timeline

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“Projects of similar magnitude usually take about 60 months to complete but Petron was able to complete the project in just 44 months, from inception to completion. The construction phase was completed in just 21 months” Lubin Nepomuceno, President Petron (Petron Media Release)

Fast track project


Petron Project Execution► EPC

► Project management by Petron► Utilized known contractor for EPC – Daelim

► Reimbursable conversion to lump sum

► Foster Wheeler awarded lump sum EPs (detailed engineering & procurement services) scope for the DCU► Experienced in detail design of Delayed Coking Units► Schedule advantage► Ensure operable and maintainable unit


Why EPs by Amec Foster Wheeler?► Recent start-ups of Foster Wheeler DCUs, where Foster Wheeler

was not the EPC contractor, have shown significant issues relating to:► Safety► Operability► Ergonomics► Maintainability


Design / Construction Issues Seen► Coke drums

► Coke chute size: 1m x 1m► 3 sided coke chutes► No allowance for drum expansion

► Coker structure► Insufficient egress in an emergency► Vibration

► Coke fines filters undersized► Minimum distances not followed► And many more………

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Why EPs by Amec Foster Wheeler?► Recent start-ups of Amec Foster Wheeler DCUs, where Amec Foster Wheeler

was not the EPC contractor, have shown significant issues relating to:► Safety► Operability► Ergonomics► Maintainability

► Amec Foster Wheeler’s Solution:► Offer EPs to ensure a correctly designed DCU (Coker Island & Gas Plant)


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DCU Detailed Design Issues► The DCU is a highly complex unit; more

so than the average refinery unit due to:► Vertical design► High loads► Hot systems► Cyclic operations► Density of steel and piping

► As a result, estimating hours based on standard equipment count metrics do not apply to the complex DCU

► Metrics show that the DCU requires approximately 30% more effort than the average refinery unit.


BP Whiting Delayed Coking Unit: 3D model

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Why Amec Foster Wheeler EPs?► Experience and track record

► FW has performed EPC scope services for over 50% of it’s licensed Cokers since 1995, more than any other EPC

► Close relationships with key equipment suppliers

► Templated designs resulting in significant cost savings and schedule improvement


Amec Foster Wheeler switch deck layout

EPs Scope► Detailed engineering and procurement services for Coker

Island and Gas Plant► Deliverables:

► Detailed design► Technical procurement activities including technical bid

tabulation preparation (vendor selection and actual procurement by EPC)

► Amec Foster Wheeler scope stops at IFC documentation

► Foster Wheeler and Daelim produced a comprehensive DOR to ensure project integrity and smooth execution

► Foster Wheeler also provided construction support



EPs Execution► Optimal use of Amec Foster Wheeler’s

High Value Engineering Center in India► Coker Island – Houston (with India

support)► Gas Plant – India (with Houston

supervision) to control costs and ensure execution efficiency

► Houston DCU design experts design the key elements of the DCU


Petron Delayed Coking Unit; fired heaters

Amec Foster Wheeler EPs for Cokers► Amec Foster Wheeler’s EPs

approach provides clients with a show case, state of the art DCU incorporating:► Safe and ergonomic layouts► Enhanced operability and

maintainability► Amec Foster Wheeler experience

and lessons learned

► Petron DCU recently started-up



Petcoke Disposal Options► Coke sales

► Coke sells for about $80 / MT

► Are there other options?

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Generate powerProduce hydrogenProduce Synthetic Natural Gas (SNG)Produce chemicals


Local Power GenerationAnother option for coke

► For new refineries and complexes consider burning coke for on-site power generation

► Saves purchasing power and generation is local► Attractive for remote locations► Attractive for areas with unreliable electric power

► Excess power can be exported to the grid► Attractive for developing areas

► Additional revenue source for the refiner

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The solution is PetroPowerSM


PetroPowerSM

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An integrated solution to generate liquid fuels and power from residue feedstocks


ENAP Refinery, Chile

PetroPower

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► Proven integration of a DCU with power generation

► Utilizes a Circulating Fluid Bed Boiler (CFB) for HP steam production

► Potential for complete petcoke disposal► PetroPower can be a third party operation



CFB Advantages► Widest fuel flexibility

► Flameless low temperature burning technology► Wide variety of fuels

► Very clean burning► Sulfur captured in furnace using limestone► Dry process: no water► High combustion efficiency► Low burning temperature reduces NOx

► Low maintenance► No ash slagging► Minimal corrosion and fouling

► Highly reliable


PetroPower – ENAP, Chile► Integrated DCU/CFB/Power production

► 12,000 BPSD Coker► 700 MTD coke production► 59 MW net power production

► Started-up in 1998► Original ownership

► 85% Foster Wheeler► 7.5% ENAP► 7.5% Petrox

► Still operating today



PetroPower - Petron► Petron has previously installed 4 Foster Wheeler CFBs to produce

power from coal and petcoke► Each CFB can produce 35 MW of power

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CFBs


Petron power plant Petron: view from DCU cutting deck

The PetroPower Advantage

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Exploits the cost advantage of solid fuels


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PetroPower Case Study Basis► Middle East location► 100,000 BPSD DCU► 5,750 MTD coke production► 7.4 wt% sulfur in petcoke

► Sulfur stack emissions 200 mg/Nm3

► Supercritical CFB► 2 x 50% steam turbines► No steam export

► Petcoke value $60/t► Limestone $40/t► Lime $75/t


This information is from an internal Amec Foster Wheeler study

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PetroPower Economics► Power block TIC $1.6 bn

► Power output 890 MW

► Cost of electricity $80 / MWh



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Cost Of Electric Power Production

PetroPower produces electricity from petcoke at less than half the cost of a

HFO boiler

HFO valued at $80/bblPetcoke valued at $60/tonne



PetroHyPowerSM

Generate both power and hydrogen from petcoke

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Can balance power / hydrogen

requirements


PetroHyPower Case Study► Refinery

► Location: Middle East► Configuration: 100,000 BPSD DCU ► 5,750MTD petcoke

► Power production options► HFO (base case)► PetroPower► IGCC► IGCC with Hydrogen production► PetroHyPower

► Pricing basis► HFO $80/bbl► Petcoke $60/tonne► Hydrogen $2,000/tonne



Heavy Fuel Oil Savings Through PetcokeUtilization



Economic Comparison

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Significant incentive to utilize PetroXXXPower



PetroSNGTM

► Production of Synthetic Natural Gas from petroleum coke► SNG production attractive where no cheap gas is readily available (e.g. China)► PetroSNG has been developed in conjunction with Clariant utilizing the new

Vesta Process► PetroSNGPower is an option

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DelayedCoker Gasification

Vesta Process

Acid Gas Removal

SNG


Coke Utilization Options


Petron RMP-2 Project Highlights: The Right Result► 44 months from inception to completion► Over 75,000,000 man-hours without a lost

time incident► 17,000 skilled workers at peak► Enables gasoline production to double to

36,000 BPSD► 47,000 BPSD of negative margin fuel oil

converted to valuable products► The Foster Wheeler DCU is a key component

of the Bataan Refinery Modernization Project


Source: Petron media release

Summary► Delayed Coking remains the residue upgrading technology of choice► Amec Foster Wheeler is the leading supplier of Delayed Coking technology► Amec Foster Wheeler has leading DCU detailed design capability

► Enhanced safety, operability and maintainability► Schedule improvement through experience and templated designs

► Amec Foster Wheeler has PetroPower options to enhance margins► Power and steam generation► Hydrogen production► SNG and chemicals

► Petron’s RMP-2 project demonstrates the features and benefits of AmecFoster Wheeler’s DCU and PetroPower technologies and execution services


Effective Project Delivery

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Amec Foster Wheelercan help you

deliver

The 4 Rights

connected excellence in all we do

Thank You

successful start-up of delayed ... - amec foster · pdf file8 why refiners select amec foster...

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