Petcoke Process - Foster Wheeler PDF
Petcoke Process - Foster Wheeler PDF
Petcoke Process - Foster Wheeler PDF
Miguel I. Londono
Principal Process Engineer
Residue
Upgrading
& Conversion
Catalytic Non-Catalytic
RFCC Coking
Ebullated Bed Hydrocracking Visbreaking
Slurry Phase Hydrocracking Solvent Deasphalting
Fluid/ Flexicoking
Partial Oxidation
Typical SYDECSM Yields
HCGO
Gravity, ºAPI 16.56 16.55 14.27 13.86
Ni + V, ppmw 0.5 0.7 0.6 0.4
CCR, wt% 0.31 0.53 0.55 0.41
Coke
Sulfur, wt% 4.65 3.96 6.02 6.39
Advantages and Benefits of Delayed Coking
Full conversion of resid to valuable products
Full range of lighter products
Complete decarbonization of residue feed and metals removal
Maximum yield of clean liquid products
Low pressure coking / ultra-low recycle coking
Marketable Coke Product
High Sulfur coke (>4%) priced for its heating value in power plants,
cement kilns & gasification
Low/medium sulfur coke (1 – 3%) priced for heating value and carbon
content in calcining & metallurgical coke making
Relatively low CAPEX & OPEX
Proven, Safe & Reliable
First Unit Built in 1929
Some 150 Units Built Since Then – 56 in the US Alone
Five Years Between Turnarounds Common
Supported by Vendors, Contractors & Operators
A Cash Generator
Examples of Cash Generation
MOL
Asphalt Upgrading
Budapest, Hungary
Started Up in 2003
Added $100 Million
per Year to
Operating Profit
FW Experience - Delayed Cokers
• SYDECSM Technology
• Market Leader
– Over 2.5 Million BPSD Capacity
– 52 new units built (5k to 122k
BPSD)
– 24 new units in last 5 years
– 62 major projects since 1990
• Strong Execution
– The Standard for execution,
schedule and operation;
independent benchmarking
– Currently have 15+ projects in-
house: new and revamp
– Continuous work, strong
execution teams
– Operations Support
Foster Wheeler SYDECSM
Experience recent years
Client Location Capacity Date Client Location Capacity Date
PetroCanad Alberta Can 141,000 2010 Flint Hills Corpus Christ 15,500 R 2008
Pemex Salina Cruz 76,362 2010 Confid US 102,000 R 2008
Repsol YPF Argentina 28,000 2009 Confid US 73,000 R 2008
Naftan Belarus 23,000 2009 Sincor Venezuela 120,000 R 2007
United Pennsylvania 14,400 2009 BP Spain 20,000 R 2007
Petronor Spain 35,500 2009 FHR Texas 15,500 R 2007
Idemitsu Japan 35,000 2009 ExxonMobil Beaumont 45,000 2006
Cosmo Japan 25,000 2009 Pemex Minatitlan 55,794 2005
Petropower Chile 18,200 R 2008 Emerol Turkmenistan 17598 R 2004
CNOOC China 77,000 R 2008 Premcor, 843 Port Arthur 105,000 R 2004
FHR Minnnesota 38,000 R 2008 Reliance India 150,000 R 2004
Rompetrol Romania 18,100 2008 RPC Chile 20,000 R 2003
Reliance#2 India 160,000 2008 Citgo Corpus Christ 43,000 R 2003
CHS Montana 15,000 2008 Citgo Coker II Lake Charles 69,300 R 2003
Advantage FW – Experience
New FW Units Built
Client Location Date Client Location Date
•Single-Fired Heater
– Firebox dimensions
– In-tube velocity
– Burner selection and spacing
– Coil spacing
Peak heat flux is
– Separate flow pass control
80% above average
– Independent firing controls
heat flux.
Latest Advances on SYDECSM Delayed Coking
Operability Features – FW Furnace
Double-Fired Furnace
Latest Advances on SYDECSM Delayed Coking
Operability Features – FW Furnace
• Double-Fired Furnace
Peak heat flux is
– For Difficult Feeds
– Feedstock Flexibility only 20% above
– Longer Runlength average heat flux.
FW Design Features
* High average heat flux to maintain film temperature
* Reduced coil volume
* High in-tube velocity
* Independent pass control
* Sloped heater wall for even flux
Latest Advances on SYDECSM Delayed Coking
Operability Features – FW Furnace
Latest Advances on SYDECSM Delayed Coking
Operability Features – FW Furnace
The Variables
Temperature – Higher is better
Pressure – Lower is better
Recycle – Lower is better, but . . .
Fresh
Feed
On-Line
Heater Fines
Charge Removal
Latest Advances on SYDECSM Delayed Coking
MCGO
or
Wash HCGO
HCGO
or
XHCGO
Coker
Feed
Latest Advances on SYDECSM Delayed Coking
Operability Features – Overhead Quench
QUENCH OIL
STRAINER
TCV PC
MEDIUM HCGO
PRESSURE QUENCH
FO PI
STEAM From
Fractionator
FC
Blowdown
Oil from
Blowdown
FULL CONE Tower
SPRAY NOZZLE
TI
VAPORS
OVHD
COKE DRUM
VAPOR OUTLET
Latest Advances on SYDECSM Delayed Coking
Operability Features – Fractionator Bottoms Fines
Removal
Coke Drum
OVHD Vapor
Heat
Shield
Fresh
Feed
On-Line
Heater Fines
Charge Removal
Latest Advances on SYDECSM Delayed Coking
Recovery of Blowdown Vent Vapors
Blowdown Vent
Vapors
to Recovery
Lt. Gas Oil Compressor
Makeup Blowdown Condenser
Blowdown
Settling
Drum
Blowdown
Drum
Blowdown
Oil
Circulating
Oil Cooler
Blowdown
Sour water
Steam
Wax
Tailing
Latest Advances on SYDECSM Delayed Coking
Large Coke Drums
DeltaValve Systems
Twenty Installations Done / In Progress
Latest Advances on SYDECSM Delayed Coking
Safety Features – FW Unheading
Semi-
Automatic
Bottom
Device
Latest Advances on SYDECSM Delayed Coking
Semi-
Automatic
Bottom
Device
Latest Advances on SYDECSM Delayed Coking
Fully
Automatic
Bottom
Device
Latest Advances on SYDECSM Delayed Coking
FW – Safety Features
Drum Switch
Advance Drum Interlocks Heater
Unheading Interlocks
Cutting
Shelter
Latest Advances on SYDECSM Delayed Coking
Deep
Pit
CHUTE
CHUTE
System
PIT
PIT
CLEAR
CLEAR
WATER
WATER
SUMP
SUMP
FINES
FINES
SETTLING
SETTLING
MAZE
MAZE
Latest Advances on SYDECSM Delayed Coking
Pad FINES
SETTLING
System COKE BASIN
PAD
CLEAR WATER
SUMP
• Operations Support
– Startup Planning Cadereyta Madero
System Definition
System Sequence
Unit Sequencing
Startup Procedures
Coordination of Vendors
– Training
Home Office
Site
Host Site
On The Job
FW – Training & Operations
Miguel I. Londono
Principal Process Engineer
Professional Experience
Lead engineer for the Process design of a new 15,000 BPSD / 2 Drum Delayed-coker
unit to process Western Canadian Vacuum Residue.
2002 - 2004 Foster Wheeler USA Corporation – Houston
y The new field facilities included Remote Manifolds, three Flow Stations, two Main Process
Stations, and pipelines between stations.
y Upstream New Processing Facilities for LASMO. Dacion Field, Venezuela. Dacion
Management Team (DMT).
2000 Foster Wheeler USA Corporation – Venezuela
Senior Process Engineer
Upstream New Processing Facilities for LASMO - Dacion Field, Venezuela
y Participation in the conceptual design and optimization study for the development of major
new heavy oil production facilities in Dacion Field, Venezuela.
y Responsible for the design of utility systems for the new facilities. Development, review,
and issue of heat and material balances, process flow diagrams and engineering flow
diagrams, equipment and instrument specifications.
y The new field facilities included Remote Manifolds, three Flow Stations, two Main Process
Stations and pipelines between stations.
1999 - 2000 Foster Wheeler USA Corporation - Houston
Process Advisor
Reliance Petroleum Limited Jamnagar Refinery, India - Delayed Coker Unit
Participation as a process advisor in the commissioning, start-up, and operation of a 122,400
BPSD/8 Drum Delayed coker Unit in India, (four months continuous experience).
Process Engineer
Phillips Petroleum Company, Sweeny, TX
Proposal for a 54,000 BPSD Delayed Coker Lump Sum - Responsibilities included sizing and
specification of equipment and line sizing.
Phillips Petroleum Company, Delayed Coker Unit, Sweeny, TX
Responsible for the PRO-II simulation for an existing FCCU Absorber-Stripper Gas Plant,
TSWEET simulation of existing FCCU Acid Gas and LPG Treatment Systems, checking of
existing equipment for new operating conditions, preliminary sizing and specification of new
equipment required.
FCCU Absorber Stripper Gas Plant FCCU Acid Gas and LPG Treatment Systems for Clark
Refining & Marketing, Inc., Port Arthur, TX. Responsible for checking existing pressure safety
valves (PSVs), sizing, and specification of new PSVs required for an Isomerization unit.
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