Pre-Conference Workshop at ME-TECH 2015, Dubai Monday, 16 February 2015, 12.30pm – 6.00pm
Maximising return on investment
Three Big Questions & Three Big Answers
Successful Start-Up of Delayed Coking Unit Petron RMP-2 Project
Steve Beeston:
Vice President, Technology, Amec Foster Wheeler
Effective Project Delivery The 4 Rights
2
Petron Corporation ►
Petron is a private Philippine refiner and retail station operator
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Largest refiner and marketer in the Philippines ►
Supplies over one third of the country’s oil requirements
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Owned by San Miguel since Dec 2008
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Operates a 180,000 BPSD refinery in Limay, Bataan ►
Originally an Exxon refinery
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Refinery built by Foster Wheeler over 50 years ago Petron’s Bataan Refinery
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© Amec Foster Wheeler 2015. All rights reserved.
Petron RMP-2 Project: The Right Project ►
Project vision ►
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Throughput constrained by fuel oil production Limited petrochemicals production
Project objectives ► ► ►
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Petron’s Bataan Refinery
Existing refinery constraints ►
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Make the Bataan Refinery one of the most modern integrated oil refining and petrochemical complexes in Asia Help Filipino nation-building
Install residue conversion to increase white oils production Increase petrochemicals production Increase the refinery’s competitiveness in S.E. Asia © Amec Foster Wheeler 2015. All rights reserved.
Petron Approach: The Right Execution ►
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Aim ►
Utilize best technology
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Fast track project implementation
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Meet aggressive budget
© Amec Foster Wheeler 2015. All rights reserved.
Petron Execution Approach ►
Technology Selection ►
Review of technology market
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Focused ITB
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Rapid evaluation of licensor proposals
Petron RMP-2 Project Licensor signing ceremony 6
© Amec Foster Wheeler 2015. All rights reserved.
RMP-2 Major Units: The Right Technology
Sources: Licensor press releases
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© Amec Foster Wheeler 2015. All rights reserved.
Why Refiners Select Amec Foster Wheeler for Delayed Coking Experience ►
Most installed units (> 60%)
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Safe operation
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Wide range of feedstocks
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Long run lengths
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Extensive heavy crude experience
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Over 5 years between turnarounds
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All coke types
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Minimal environmental impact
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Full range of unit sizes
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Multiple repeat clients
Technical Resources
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High on stream factors and reliability
Innovative design ►
Proprietary double fired heater
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Forged ring coke drum design
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Total automation concept
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In-house experience & expertise
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Modular construction
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Vendor and 3rd party support
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Process integration
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Operations support © Amec Foster Wheeler 2015. All rights reserved.
Amec Foster Wheeler DCU Experience 2005 - 2014
Number of units awarded 9
Capacity (BPSD) © Amec Foster Wheeler 2015. All rights reserved.
Amec Foster Wheeler DCU Experience 2005 - 2014
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© Amec Foster Wheeler 2015. All rights reserved.
Recent DCU Awards Client
Location
Capacity (BPSD)
Award Date
Client
Location
Capacity (BPSD)
Award Date
Petrourica
Venezuela
109,415
2014
Takreer
Abu Dhabi
29,500
2011
Bashneft
Russia
36,300
2014
PDVSA
Venezuela
50,000
2011
Petrobicentenario
Venezuela
172,464
2014
Petrochina (2)
China
52,500
2011
DRPIC
Oman
52,000
2014
Petrobras (3)
Brazil
65,000
2010
Omsk
Russia
34,500
2013
Antipinsky
Russia
24,000
2010
Axion
Argentina
35,000
2012
RDP
Ecuador
93,000
2010
Petromiranda
Venezuela
103,700
2012
Petron
Philippines
45,000
2010
Confidential
Europe
50,000
2012
STRAS
Turkey
40,000
2010
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© Amec Foster Wheeler 2015. All rights reserved.
Foster Wheeler SYDECSM Process ►
Leading Delayed Coking technology
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Proprietary Terrace WallTM double-fired furnace
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Maximum liquid product yields ►
Low pressure
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Ultra low recycle
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Designed in safety and reliability
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Large coke drums
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Unique fractionator design
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Environmentally friendly
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Total automation capability
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Operations support
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Innovative Petrocedeño Upgrader Delayed Coker
design leads to superior technology and operations © Amec Foster Wheeler 2015. All rights reserved.
Terrace-Wall Double Fired Heater
The Terrace-Wall heater provides true management of the heat flux for optimal performance
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Features ► High average heat flux ► Reduced coil volume ► High in-tube velocities ► Independent pass control ► Sloped wall design for even flux ► On-line spalling & pigging Benefits ► Process difficult feeds ► Provides feedstock flexibility ► Longer run lengths ► More profitable operations © Amec Foster Wheeler 2015. All rights reserved.
Terrace-Wall Heater
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© Amec Foster Wheeler 2015. All rights reserved.
Terrace-Wall Heater
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© Amec Foster Wheeler 2015. All rights reserved.
Coke Drum Design ►
Single thickness wall
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Skirt-shell connection ►
Hot box
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Weld build up / Forged ring
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1¼ Chrome steel with cladding
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Proprietary FW plate chemistry, welding and finishing specifications
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Long life (>8,000 cycles) with forged ring design
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Better design for longer life
© Amec Foster Wheeler 2015. All rights reserved.
Large Coke Drums
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Amec Foster Wheeler pioneered large coke drum designs
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First to commercialize 9.8 m diameter drums
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Ability to optimize unit costs
© Amec Foster Wheeler 2015. All rights reserved.
Amec Foster Wheeler Coke Drum Life Monitoring Program ►
Install additional thermocouples on drum
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Monitor temperature gradients
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Optimize quench and heat up rates
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Coke drum life estimation
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Proactive maintenance prevents costly shutdowns
Petron Delayed Coking Unit 18
© Amec Foster Wheeler 2015. All rights reserved.
Amec Foster Wheeler DCU Training Services Protecting the investment ► Conventional classroom training ► KnowledgeWeb and KnowledgeWeb+ ► ► ► ► ►
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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.
Petron DCU Overview ►
45,000 BPSD Arab Medium VR
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4 drums ►
7.4 m diameter, 30.1 m F-F
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2 x 3 pass Terrace-Wall heaters
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Low pressure
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Ultra low recycle
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Max liquid yields Petron Delayed Coking Unit
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© Amec Foster Wheeler 2015. All rights reserved.
Petron Project Execution ►
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The DCU contains very specialized equipment ►
Amec Foster Wheeler proprietary heaters
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Coke drums
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Unheading devices
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Coke cutting system
Petron preselected key equipment items
© Amec Foster Wheeler 2015. All rights reserved.
Coke Drums ►
Sumitomo
Sumitomo’s Saijo fabrication facilities 22
Petron Delayed Coking Unit
Unheading Devices ►
Zimmerman & Jansen
Motiva Port Arthur Delayed Coking Unit BUD
Petron Delayed Coking Unit TUD
Petron was the first to buy an electric actuated BUD 23
© Amec Foster Wheeler 2015. All rights reserved.
Remote & Automated Coke Cutting ►
Flowserve Petron Delayed Coking Unit
Safety First: Coke cutting from remote shelter, off the structure
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© Amec Foster Wheeler 2015. All rights reserved.
RMP-2 Major Units
Sources: Licensor press releases
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© Amec Foster Wheeler 2015. All rights reserved.
RMP-2 Project Integration Petron engaged Axens Performance Programs (P2) to: ►
Optimize and integrate the units
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Determine offsite and utilities requirements
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Provide a basis for basic engineering
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Enable fast track execution
View of RMP-2 Project 26
© Amec Foster Wheeler 2015. All rights reserved.
RMP-2 Project Timeline
Fast track project “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) 27
© Amec Foster Wheeler 2015. All rights reserved.
Petron Project Execution ►
EPC ►
Project management by Petron
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Utilized known contractor for EPC – Daelim ►
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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
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Schedule advantage
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Ensure operable and maintainable unit
© Amec Foster Wheeler 2015. All rights reserved.
Why EPs by Amec Foster Wheeler? ►
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Recent start-ups of Foster Wheeler DCUs, where Foster Wheeler was not the EPC contractor, have shown significant issues relating to: ►
Safety
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Operability
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Ergonomics
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Maintainability
© Amec Foster Wheeler 2015. All rights reserved.
Design / Construction Issues Seen ►
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Coke drums ►
Coke chute size: 1m x 1m
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3 sided coke chutes
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No allowance for drum expansion
Coker structure ►
Insufficient egress in an emergency
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Vibration
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Coke fines filters undersized
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Minimum distances not followed
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And many more………
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Why EPs by Amec Foster Wheeler? ►
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Recent start-ups of Amec Foster Wheeler DCUs, where Amec Foster Wheeler was not the EPC contractor, have shown significant issues relating to: ►
Safety
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Operability
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Ergonomics
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Maintainability
Amec Foster Wheeler’s Solution: ►
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Offer EPs to ensure a correctly designed DCU (Coker Island & Gas Plant)
© Amec Foster Wheeler 2015. All rights reserved.
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. ►
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BP Whiting Delayed Coking Unit: 3D model
© Amec Foster Wheeler 2015. All rights reserved.
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
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Close relationships with key equipment suppliers
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Templated designs resulting in significant cost savings and schedule improvement Amec Foster Wheeler switch deck layout
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© Amec Foster Wheeler 2015. All rights reserved.
EPs Scope ►
Detailed engineering and procurement services for Coker Island and Gas Plant
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Deliverables: ►
Detailed design
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Technical procurement activities including technical bid tabulation preparation (vendor selection and actual procurement by EPC)
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Amec Foster Wheeler scope stops at IFC documentation
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Foster Wheeler and Daelim produced a comprehensive DOR to ensure project integrity and smooth execution
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Foster Wheeler also provided construction support
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Petron Delayed Coking Unit
© Amec Foster Wheeler 2015. All rights reserved.
EPs Execution ►
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Optimal use of Amec Foster Wheeler’s High Value Engineering Center in India ►
Coker Island – Houston (with India support)
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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 2015. All rights reserved.
Amec Foster Wheeler EPs for Cokers ►
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Amec Foster Wheeler’s EPs approach provides clients with a show case, state of the art DCU incorporating: ►
Safe and ergonomic layouts
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Enhanced operability and maintainability
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Amec Foster Wheeler experience and lessons learned
Petron DCU recently started-up Petron Delayed Coking Unit
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© Amec Foster Wheeler 2015. All rights reserved.
Petcoke Disposal Options ►
Coke sales
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Coke sells for about $80 / MT
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Are there other options?
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Generate power Produce hydrogen Produce Synthetic Natural Gas (SNG) Produce chemicals
© Amec Foster Wheeler 2015. All rights reserved.
Local Power Generation Another option for coke ►
For new refineries and complexes consider burning coke for on-site power generation
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Saves purchasing power and generation is local
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Attractive for remote locations
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Attractive for areas with unreliable electric power
Excess power can be exported to the grid ►
► 38
The solution is PetroPowerSM
Attractive for developing areas
Additional revenue source for the refiner © Amec Foster Wheeler 2015. All rights reserved.
PetroPowerSM An integrated solution to generate liquid fuels and power from residue feedstocks
ENAP Refinery, Chile 39
© Amec Foster Wheeler 2015. All rights reserved.
PetroPower ►
Proven integration of a DCU with power generation
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Utilizes a Circulating Fluid Bed Boiler (CFB) for HP steam production
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Potential for complete petcoke disposal
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PetroPower can be a third party operation
ENAP Refinery, Chile
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© Amec Foster Wheeler 2015. All rights reserved.
CFB Advantages ►
Widest fuel flexibility ► ►
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Very clean burning ► ► ► ►
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Sulfur captured in furnace using limestone Dry process: no water High combustion efficiency Low burning temperature reduces NOx
Low maintenance ►
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Flameless low temperature burning technology Wide variety of fuels
No ash slagging Minimal corrosion and fouling
Highly reliable © Amec Foster Wheeler 2015. All rights reserved.
PetroPower – ENAP, Chile ►
Integrated DCU/CFB/Power production ►
12,000 BPSD Coker
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700 MTD coke production
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59 MW net power production
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Started-up in 1998
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Original ownership
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85% Foster Wheeler
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7.5% ENAP
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7.5% Petrox
Still operating today ENAP Refinery, Chile
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© Amec Foster Wheeler 2015. All rights reserved.
PetroPower - Petron ►
Petron has previously installed 4 Foster Wheeler CFBs to produce power from coal and petcoke
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Each CFB can produce 35 MW of power
CFBs
Petron power plant 43
Petron: view from DCU cutting deck © Amec Foster Wheeler 2015. All rights reserved.
The PetroPower Advantage Exploits the cost advantage of solid fuels
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© Amec Foster Wheeler 2015. All rights reserved.
PetroPower Case Study Basis ►
Middle East location
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Petcoke value $60/t
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100,000 BPSD DCU
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Limestone
$40/t
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5,750 MTD coke production
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Lime
$75/t
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7.4 wt% sulfur in petcoke
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Sulfur stack emissions
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Supercritical CFB
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2 x 50% steam turbines
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No steam export
200 mg/Nm3
This information is from an internal Amec Foster Wheeler study 45
© Amec Foster Wheeler 2015. All rights reserved.
PetroPower Economics ►
Power block TIC
$1.6 bn
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Power output
890 MW
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Cost of electricity
$80 / MWh
This information is from an internal Amec Foster Wheeler study 46
© Amec Foster Wheeler 2015. All rights reserved.
Cost Of Electric Power Production
PetroPower produces electricity from petcoke at less than half the cost of a HFO boiler HFO valued at $80/bbl Petcoke valued at $60/tonne
This information is from an internal Amec Foster Wheeler study 47
© Amec Foster Wheeler 2015. All rights reserved.
PetroHyPowerSM Generate both power and hydrogen from petcoke
Can balance power / hydrogen requirements
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© Amec Foster Wheeler 2015. All rights reserved.
PetroHyPower Case Study ►
Refinery ► ► ►
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Power production options ► ► ► ► ►
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Location: Middle East Configuration: 100,000 BPSD DCU 5,750MTD petcoke HFO (base case) PetroPower IGCC IGCC with Hydrogen production PetroHyPower
Pricing basis ► ► ►
HFO Petcoke Hydrogen
$80/bbl $60/tonne $2,000/tonne This information is from an internal Amec Foster Wheeler study
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© Amec Foster Wheeler 2015. All rights reserved.
Heavy Fuel Oil Savings Through Petcoke Utilization
This information is from an internal Amec Foster Wheeler study 50
© Amec Foster Wheeler 2015. All rights reserved.
Economic Comparison
Significant incentive to utilize PetroXXXPower
This information is from an internal Amec Foster Wheeler study 51
© Amec Foster Wheeler 2015. All rights reserved.
PetroSNGTM ►
Production of Synthetic Natural Gas from petroleum coke
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SNG production attractive where no cheap gas is readily available (e.g. China)
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PetroSNG has been developed in conjunction with Clariant utilizing the new Vesta Process
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PetroSNGPower is an option
Delayed Coker
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Gasification
Acid Gas Removal
Vesta Process
SNG
© Amec Foster Wheeler 2015. All rights reserved.
Coke Utilization Options
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© Amec Foster Wheeler 2015. All rights reserved.
Petron RMP-2 Project Highlights: The Right Result ►
44 months from inception to completion
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Over 75,000,000 man-hours without a lost time incident
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17,000 skilled workers at peak
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Enables gasoline production to double to 36,000 BPSD
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47,000 BPSD of negative margin fuel oil converted to valuable products
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The Foster Wheeler DCU is a key component of the Bataan Refinery Modernization Project
Source: Petron media release
54
© Amec Foster Wheeler 2015. All rights reserved.
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 ►
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Amec Foster Wheeler has PetroPower options to enhance margins ► ► ►
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Enhanced safety, operability and maintainability Schedule improvement through experience and templated designs Power and steam generation Hydrogen production SNG and chemicals
Petron’s RMP-2 project demonstrates the features and benefits of Amec Foster Wheeler’s DCU and PetroPower technologies and execution services © Amec Foster Wheeler 2015. All rights reserved.
Effective Project Delivery
Amec Foster Wheeler can help you deliver
The 4 Rights 56
Thank You
connected excellence in all we do
