SYDECSM DELAYED COKINGMaximize profit from the bottom of the barrel

SYDEC DELAYED COKING

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Foster Wheeler’s SYDEC delayedcoking technology is the leader inresidue upgrading for zero fuel oilproduction.

• Improved profitability by maximizingproduction of transportation fuels

• Yield selectivity to maximize distillateproduction

• Options for calcinable grade cokeproduction

• Feedstock flexibility to process residue,pitch, or partially converted material

• Extended run-lengths between spallingand turnarounds for more on streamtime and lower maintenance costs

• Designed to maximize operator safetywith better layout, improved egress,sophisticated interlocks and slide valve unheading

- the key benefits

In today’s market, refiners need to improve profitability by maximizing the productionof transportation fuels with residue upgrading technology that is commercially provenwith strong economic impact, provides feedstock and product flexibility, and is highlyreliable with long periods between turnarounds.

Guaranteed performance and proven safety with SYDEC

Typical yield from a barrel of coker feedstock

Resid

Coke

Coker Gas

LPG

Naphtha

LCGO toDiesel

HCGO toHDS, HCor FCC

Foster Wheeler offers SYDECSM (Selective Yield Delayed Coking) under license

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THE SYDECPROCESS

AtmosphericDistillation

Vacuum Distillation Unit

Delayed Coking Unit Fractionator

CokeDrum

Gas Plant

Gas Fuels

Liquid Fuels

Coke

LighterGases

andLiquids

Residue

Delayed coking is a cyclicprocess that thermally cracksvacuum residue or otherresidue feedstocks into gas, light products and petroleum coke.

Key process steps:

• heat feedstock 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 convert

• 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

Our coking capabilityfor new plants and revamps

• Feasibility, planning andeconomic studies

• Process design packages

• EPC

• Commissioning, start-up and operations assistance

• Comprehensive training and knowledge transfer with KnowledgeWebTM

• Design and supply of cokerheaters

• Capacity increases/revamps:- coke drum replacement- safety improvement

• API fitness-for-service evaluation

• Fatigue life evaluation on cokedrums

• Ongoing licensor supportservices

BEST TECHNOLOGY VALUE Foster Wheeler has designed andengineered more delayed cokersworld-wide than any other technologyprovider or engineering contractor.

• Over 4 million bpsd installed

• Over 33 revamps designed in thelast 10 years

• Almost 40 new units designed inthe last 5 years

• Most accurate yield and productquality prediction with 50+ yearsof operating data, proprietarymodels and pilot plant research

• Designs for extended coke drumlife while reducing cycle times forprofitable operations

• State-of-the-art unit operations andfull coker automation on our mostrecently constructed units

• Comprehensive operator trainingwith our proprietary KnowledgeWebsystem designed to reduce errors

• Dedicated operations support forcommissioning and start-up

• Proven designs for long run lengthcoker heaters, including sloped-wall, double-fired designs for veryheavy feeds

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.

Coker units are complex, and wealways recommend Foster Wheelerdetailed engineering and criticalprocurement to realize the fulloperational benefits of our well-designed, well-constructeddelayed coking unit.

FOSTER

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- 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 ‘oil in’.Designed to process 45,000 bpsd infour drums.

REPSOL/PETRONORCartagena and Somorrostro,SpainOur relationship with Repsol started in1966 and recently included thelicense, process design package andEPCm for a 53,000 bpsd delayedcoker unit, and 90,000 bpsd vacuumdistillation unit at Cartagena, andlicense process design package andEPCm for a 35,500 bpsd delayedcoking unit at Somorrostro.

ENAP BIOBIOTalcahuano, ChileWe designed, supplied and built a new 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.

TUPRASIzmit, TurkeyLicense, basic design and heatersupply for 52,000 bpsd grassrootsdelayed coker enabling the refinery toreduce fuel oil production andincrease diesel production.

MOLSzázhalombatta, HungaryWe have worked with MOL for morethan 15 years. Our recent revamp ofthe original SYDEC unit increasedcapacity by 27% to 26,400 bpsd.

BPCastellón, SpainFEED and EPC for new 20,000 bpsdcoker and design, engineering,procurement and supply of 43.5 MWdouble-fired Terrace-WallTM heater.

CNOOCHuizhou, ChinaLicense package, FEED and heater fora 77,000 bpsd anode coker with theworld’s largest coke drums in operation(32 feet or 9.78 metres diameter).

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highlights

PETRON CORPORATIONBataan, Philippines Part of Petron’s Refinery Master Plan-2Project, detailed engineering andprocurement services for a 37,500bpsd delayed coker unit includingengineering and material supply oftwo double-fired Terrace-Wall coker heaters.

ENERCONENAP’s Aconcagua Refinery,ChileFeasibility study, basic design and EPC of a 20,000 bpsd coking facility,including amine regeneration unit,sour water stripping and cokehandling facilities.

INDIAN OIL CORPORATIONGujarat and Paradip, IndiaLicense and basic engineering for new3.7 mtpa delayed coking units.

TOTAL Port Arthur, Texas, USALicense, basic design and Terrace-Wall heater supply for a grassroots 50,000 bpsd delayedcoking unit allowing Total to processheavier crudes.

CONFIDENTIAL CLIENT USALicense, basic design and Terrace-Wall heater supply for 15,000 bpsd delayed coking unit.The unit includes the world’s only pass coker heater.

BPWhiting Refinery, USALicense, process design package,EPCm and KnowledgeWeb for a 102,000 bpsd delayed coker unit.The unit is fully automated andconstructed on a modular basis.

YPFLa Plata, ArgentinaEngineering, equipment supply andassistance with construction and start-up for a delayed coker heater for thenew delayed coking unit at YPF’sComplejo Industrial La Plata.

SAUDI ARAMCO/TOTALJubail Export Refinery, Saudi ArabiaProcess design package for a new103,000 bpsd delayed coker, part of the Jubail Export Refinery, a grassroots full-conversion refinerydesigned to process Arabian heavy crude.

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The fired heater is the heart ofthe delayed coker, and we can offer:

• Terrace-Wall double-fired, sloped wall type

• Single-fired cabin- or box-type withhorizontal tubes and bridge wall

The heater is an integral part of ourcoking technology. It incorporates keydesign features which are pivotal toour cokers’ excellent performance andreliability ensuring economic operationwith extended run lengths anddurations between turnarounds of up to seven years.

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-Walldelayed 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 fuel and spread the flame evenly along the length of the tube and up the wall

• Grade access permits 360-degreeviewing access and easier burnermaintenance

• Completely isolated cells allowindividual pass firing controls for on-line spalling, pigging andturndown abilities, which result in cost savings from increased run length

• Unique 3-pass heaters for smallercapacity units

The heater -

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the heart of the process

Key features of the SYDECprocess to improve reliability,operability and efficiency:

• Terrace-Wall double-firedheater

• Advanced coke drum design

• Fractionator zone sprays andfines removal

• Low pressure, ultra-low recycle

• On-line spalling/pigging

• Run lengths of five years ormore between turnarounds

Safety in design:

• Slide valve unheading system

• Sophisticated extensive safetyinterlocks

• Improved deck layout andbetter safety egress

• Full coker automation available

• Coke drum life monitoringprogram

Environmentally friendlyprocess:

• Low-sulfur fuel gas production

• Enclosed coke transport andstorage

• Enclosed blowdown recoverysystems

• Unique clean coke handlingsystems

• Waste by-product processing

• Water minimization

• Improved heat integration

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The SYDECevolution

Due to the stringent environmentalregulations at ENAP’s Aconcaguarefinery in Chile, the petroleum cokeproduced is milled in a coke crusherand conveyed in belts installed in a closed gallery and driven into a domed storage facility.

Although our coking technology is well-proven, we are always looking for ways to make the SYDECtechnology even safer, more reliable and moreprofitable for our clients.

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success

Did you know?

• Commercial coking first started in 1929

• Since 1994, almost all residueupgrading in the USA has been basedon delayed coking

• Foster Wheeler cokers have the flexibilityto produce fuel-grade coke or morevaluable anode or needle cokedepending on feedstock

• We can integrate delayed coking with

- solvent deasphalting to increase residue conversion

- circulating fluidized-bed technology to produce electricity and/or steam

- gasification to produce electricity, steam and hydrogen

- other hydroprocessing technologies

• 24 grassroots SYDEC units havesuccessfully started operation since 1955

Turning visioninto reality

contact us at:refining@fwc.com www.fwc.com

LEADERS IN REFINING