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Successful ThruPlus® Delayed Coker Start-up in an Environmentally Sensitive Area Vincent Leung - Sr. Process

Successful ThruPlus® Delayed Coker Start-up in an Environmentally Sensitive Area

Vincent Leung - Sr. Process Engineer, ConocoPhillips Tim Old - Technology Licensing Director, ConocoPhillips Jack Follick - Engineering Project Development Manager, Tesoro

Presentation Outline

Performing today. Preparing for tomorrow.

Overview

Project Details

Environmental and Other Improvements

Project Highlights

Summary

Questions

Preparing for tomorrow. Overview Project Details Environmental and Other Improvements Project Highlights Summary Questions
Preparing for tomorrow. Overview Project Details Environmental and Other Improvements Project Highlights Summary Questions

Presentation Outline

Performing today. Preparing for tomorrow.

Overview

Project Details

Environmental and Other Improvements

Project Highlights

Summary

Questions

Preparing for tomorrow. Overview Project Details Environmental and Other Improvements Project Highlights Summary Questions
Preparing for tomorrow. Overview Project Details Environmental and Other Improvements Project Highlights Summary Questions

Tesoro is an Independent Refining/Marketing Company

Performing today. Preparing for tomorrow.

No upstream assets

Kenai, Alaska

72,000 bpd

Key products:

Jet & Gasoline

• • • • • • • • Auburn Office
Auburn Office

Headquartered in San Antonio, Texas

Seven Refineries

660,000 bpd total crude capacity

Retail network of over 850 sites

Martinez, California

166,000 bpd

Key products:

CARB Gasoline

&

CARB Diesel

5,500 Employees

Traded on NYSE: symbol TSO

Anacortes, Washington

115,000 bpd

Key products:

Gasoline & Diesel

Salt Lake City, Utah

58,000 bpd

Key products:

Gasoline & Diesel

Mandan,

North Dakota

58,000 bpd

Key products:

Gasoline & Diesel

Wilmington,

California

100,000 bpd

Key products:

CARB Gasoline

&

CARB Diesel

Calgary Office Kapolei, Hawaii • 94,000 bpd Denver Office • Key products: Jet& Gasoline Long
Calgary
Office
Kapolei, Hawaii
• 94,000 bpd
Denver Office
• Key products:
Jet& Gasoline
Long
Corporate Office
Beach
Office
Singapore
Office
94,000 bpd Denver Office • Key products: Jet& Gasoline Long Corporate Office Beach Office Singapore Office
94,000 bpd Denver Office • Key products: Jet& Gasoline Long Corporate Office Beach Office Singapore Office

Tesoro Golden Eagle Refinery Martinez, CA

Performing today. Preparing for tomorrow.

Martinez, CA Performing today. Preparing for tomorrow. • Located on 900 hectares (2,200 acres) site about

Located on 900 hectares (2,200 acres) site about 30 miles east of San Francisco, CA

Located in Contra Costa County, CA which has a strict Industrial Safety Ordinance

Largest Tesoro Corporation refinery, started operation in 1913

Crude capacity = 166,000 barrels per day California/Alaska/Non-US crudes

Conversion units = FCC, Hydrocracker, Alkylation unit, and previously Fluid Coker – now Delayed Coker

crudes • Conversion units = FCC, Hydrocracker, Alkylation unit, and previously Fluid Coker – now Delayed
crudes • Conversion units = FCC, Hydrocracker, Alkylation unit, and previously Fluid Coker – now Delayed

Environmental Awareness in California

Performing today. Preparing for tomorrow.

Refinery located in San Francisco Bay area

Large population of almost 7 million

Over past two decades, California has led the way on stricter air quality regulations

Environmental regulations generally ahead of the rest of the U.S. and much of Europe e.g. has had tighter gasoline and diesel specs

Informed and active public participation in air quality and health and safety matters

gasoline and diesel specs • Informed and active public participation in air quality and health and
gasoline and diesel specs • Informed and active public participation in air quality and health and

Environmental Stewardship

Performing today. Preparing for tomorrow.

Environmental Stewardship Performing today. Preparing for tomorrow.
Environmental Stewardship Performing today. Preparing for tomorrow.
Environmental Stewardship Performing today. Preparing for tomorrow.

Environmental Stewardship

Performing today. Preparing for tomorrow.

Refinery located in highly environmentally conscious area

Environmental stewardship is one of Tesoro’s top priorities

Tesoro wanted to significantly reduce air emissions

Tesoro determined that switching to a Delayed Coker was the most appropriate solution

reduce air emissions • Tesoro determined that switching to a Delayed Coker was the most appropriate
reduce air emissions • Tesoro determined that switching to a Delayed Coker was the most appropriate

Presentation Outline

Performing today. Preparing for tomorrow.

Overview

Project Details

Environmental and Other Improvements

Project Highlights

Summary

Questions

Preparing for tomorrow. Overview Project Details Environmental and Other Improvements Project Highlights Summary Questions
Preparing for tomorrow. Overview Project Details Environmental and Other Improvements Project Highlights Summary Questions

Coker Modification Project

Performing today. Preparing for tomorrow.

Project Aims

Significantly reduce air emissions

Extend duration between major turnarounds

Reduce fuel gas production to provide flexibility for future energy conservation projects

Incorporate recent advances in Delayed Coker technology and lessons learned throughout the industry to provide a very safe unit

recent advances in Delayed Coker technology and lessons learned throughout the industry to provide a very
recent advances in Delayed Coker technology and lessons learned throughout the industry to provide a very

Coker Modification Project

Performing today. Preparing for tomorrow.

Project Overview

Modify Fluid Coker to Delayed Coker

ConocoPhillips ThruPlus® Delayed Coker license signed December 2005

Feed rate of 50,000 barrels per day of vacuum residue

Maximum coke production rate of 3,500 short ton per day (1) wet basis

Fluid Coker shut down March 2008

ThruPlus® Delayed Coker start-up April 2008

Conducted successful Acceptance Test August 2008

Fast-trackFast-track projectproject toto meetmeet regulatoryregulatory deadlinedeadline

(1) Equivalent to 3,175 metric tons per day

project to to meet meet regulatory regulatory deadline deadline ( 1 ) Equivalent to 3,175 metric
project to to meet meet regulatory regulatory deadline deadline ( 1 ) Equivalent to 3,175 metric

Coker Modification Project

Performing today. Preparing for tomorrow.

ConocoPhillips Delivered Unique Expertise

Licensor and owner/operator of cokers

Operates 16 units and 42 external licenses

Responded to extremely tight time constraint imposed by regulatory deadline

Assigned “A” team to Tesoro project as for all projects

Lead Process and Mechanical Engineer each:

Had 30+ years experience

Had concentrated on Delayed Coker (DC) for 10+ years

Had Extensive experience in DC operations and maintenance

Could lead the design and answered arising questions quickly

Had access to ConocoPhillips expertise network

 Could lead the design and answered arising questions quickly  Had access to ConocoPhillips expertise
 Could lead the design and answered arising questions quickly  Had access to ConocoPhillips expertise

Presentation Outline

Performing today. Preparing for tomorrow.

Overview

Project Details

Environmental and Other Improvements

Project Highlights

Summary

Questions

Preparing for tomorrow. Overview Project Details Environmental and Other Improvements Project Highlights Summary Questions
Preparing for tomorrow. Overview Project Details Environmental and Other Improvements Project Highlights Summary Questions

Coker Modification Project

Performing today. Preparing for tomorrow.

Environmental Improvements

No release of particulates during upsets or start-up

Large reductions in NOx, SOx, and greenhouse gases

With the new DC, cleaner RFG or NG can be burnt to provide process heat rather than burning high sulfur coke/ gas

Safety Improvement

Switch from anhydrous ammonia used in SNCR system on Fluid Coker CO Boiler to aqueous ammonia used in SCR on Delayed Coker heaters

anhydrous ammonia used in SNCR system on Fluid Coker CO Boiler to aqueous ammonia used in
anhydrous ammonia used in SNCR system on Fluid Coker CO Boiler to aqueous ammonia used in

Coker Modification Project

Performing today. Preparing for tomorrow.

Environmental Impact Minimization – VOC’s

Closed Blowdown System (CBS)

Condenses and recovers steam and hydrocarbon vapors from off-line coke drums

Minimizes air, water, and noise pollution

 Minimizes coke drum relief impact on the flare (Tesoro agreed to no routine flaring)
 Minimizes coke drum relief impact on the flare (Tesoro agreed to no routine
flaring)
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Coker Modification Project

Performing today. Preparing for tomorrow.

Environmental Impact Minimization: NOx, SOx, and CO2

NOx & SOx: Eliminated flare emissions during drum quench and back- warming

COP has worked in conjunction with EPA to significantly reduce NOx and SOx emissions

COP licensor and owner/operator of cokers

NOx: Reduced heater stack emissions

Low NOx burners

Selective Catalytic Reduction

SOx: Reduced heater stack emissions

Operation at low excess air and air pre-heater systems for maximum efficiency

Burning natural gas or clean refinery fuel gas rather than high sulfur gas/coke

CO2: Reduced by:

Eliminating burning of coke to generate process heat

Including an air pre-heater on each of Delayed Coker Heaters

CO and PM: Some reduction compared to Fluid Coker

 Including an air pre-heater on each of Delayed Coker Heaters  CO and PM: Some
 Including an air pre-heater on each of Delayed Coker Heaters  CO and PM: Some

Coker Modification Project

Performing today. Preparing for tomorrow.

Emissions Reductions

NO X : 93.3%

SO 2 : 99.7%

NH 3 : 98.6%

GHG: 70%

for tomorrow. • Emissions Reductions  NO X : 93.3%  SO 2 : 99.7% 
for tomorrow. • Emissions Reductions  NO X : 93.3%  SO 2 : 99.7% 

Coker Modification Project

Performing today. Preparing for tomorrow.

Environmental Impact Minimization: PM10

for tomorrow. • Environmental Impact Minimization: PM10  Dust emissions are minimized through efficient pit-pad

Dust emissions are minimized through efficient pit-pad design

Time coke spends on pad achieves better coke dewatering/moisture control (8-10%wt)

Typically prevents top layer of coke becoming drying enough to form dust

Water sprays available to add water as required to prevent dry out

Avoids excessive water on coke draining from trucks leaving coke dust on roads

Avoids coke handling system equipment reliability problems

Lower coke water content than alternative Coke Crusher/Pumped Coke-Water Slurry/Solids Separation System

problems  Lower coke water content than alternative Coke Crusher/Pumped Coke-Water Slurry/Solids Separation System
problems  Lower coke water content than alternative Coke Crusher/Pumped Coke-Water Slurry/Solids Separation System

Coker Modification Project

Performing today. Preparing for tomorrow.

Environmental Impact Minimization: PM10 cont.

High pit-pad perimeter wall (1.5 meters above maximum normal coke pile height) reduces wind erosion of retained coke

Overhead cranes with large buckets not front end loaders to minimize coke size degradation

Water spray dust control available on pit-pad, crusher inlet, belt conveyer transfer points, and load-out facilities

Enclosed coke transfer system (conveyer belts and associated drop points)

Trucks are covered

Truck wheels are washed when leaving load-out station

belts and associated drop points)  Trucks are covered  Truck wheels are washed when leaving
belts and associated drop points)  Trucks are covered  Truck wheels are washed when leaving
belts and associated drop points)  Trucks are covered  Truck wheels are washed when leaving

Coker Modification Project

Performing today. Preparing for tomorrow.

Safety Advantages of COP Coke Handling System

Structure sloped wall

Greater barrier protection against drum drain events

Provides excellent energy dissipation for blowouts and coke falls

Stabilizes coke drum structure

Pit-pad

Crane operator moving coke from safe location

Operator can cut coke for all drums without needing to move any coke – gives time for crane repairs while operator is out of harm’s way

coke for all drums without needing to move any coke – gives time for crane repairs
coke for all drums without needing to move any coke – gives time for crane repairs
coke for all drums without needing to move any coke – gives time for crane repairs

Coker Modification Project

Performing today. Preparing for tomorrow.

Capex Advantages of COP Coke Handling System

Lower than alternative Coke Crusher/Pumped Coke-Water Slurry/Solids Separation system

Sloped wall/pit-pad design can reduce the required switch deck elevation versus metal chutes by more than 3 meters (10 ft) results in CAPEX saving of USD 500,000 - $1,000,000 per drum

elevation versus metal chutes by more than 3 meters (10 ft) results in CAPEX saving of
elevation versus metal chutes by more than 3 meters (10 ft) results in CAPEX saving of
elevation versus metal chutes by more than 3 meters (10 ft) results in CAPEX saving of

Coker Modification Project

Performing today. Preparing for tomorrow.

Reliability Advantages of COP Coke Handling System

Very robust and simple equipment in simple systems

Pit-pad provides adequate surge

Failure of any particular piece of equipment and consequent repair time does not result in process unit operation being affected by coke handling system

Very high stream factor

Nature of pit-pad crane system allows incorporation of daily maintenance schedule into operations

Other Advantages of COP Coke Handling System

All of the circulating water used to quench and cut coke is fully re-used except for moisture content of coke export

 All of the circulating water used to quench and cut coke is fully re-used except
 All of the circulating water used to quench and cut coke is fully re-used except

Presentation Outline

Performing today. Preparing for tomorrow.

Overview

Project Details

Environmental and Other Improvements

Project Highlights

Summary

Questions

Preparing for tomorrow. Overview Project Details Environmental and Other Improvements Project Highlights Summary Questions
Preparing for tomorrow. Overview Project Details Environmental and Other Improvements Project Highlights Summary Questions

Coker Modification Project

Performing today. Preparing for tomorrow.

Very Quick And Smooth Start-up

Thorough operator training

Tesoro personnel visited COP’s Borger Refinery to observe coker operations and talk directly to Borger operators

Tesoro conducted their own operator training, with consultation from COP’s Coke Technology group

Tested all the interlocks before start-up

COP standard design requires safety interlocks to prevent release of hydrocarbons to the atmosphere

COP recommends additional interlocks to prevent mistakes that, while not unsafe, will result in operational upsets

COP’s practice is to assist licensee in testing all interlocks on new units

Interlocks are tested to prove they will allow proper operation and prevent improper operation

Stepping through the interlock system has also proved to be valuable operator training as it gives “hands-on” practice

Ongoing post start-up support

has also proved to be valuable operator training as it gives “hands-on” practice  Ongoing post
has also proved to be valuable operator training as it gives “hands-on” practice  Ongoing post

Coker Modification Project

Performing today. Preparing for tomorrow.

Other Highlights

Extended duration between major turnarounds

Increased stream factor

Reduced maintenance costs

Improved safety

Reduced fuel gas production to provide flexibility for future energy conservation projects

costs  Improved safety  Reduced fuel gas production to provide flexibility for future energy conservation
costs  Improved safety  Reduced fuel gas production to provide flexibility for future energy conservation

Coker Modification Project

Performing today. Preparing for tomorrow.

On-Stream Factor

On-stream factor affected by

Operating duration between major turnarounds

Coke handling system

Furnace design

Coke drum life

Flash zone design

Learning from experienced designers, equipment suppliers, and operations personnel

Operation of 50,000 barrels per day – Delayed Coker can be worth millions of dollars per day

operations personnel  Operation of 50,000 barrels per day – Delayed Coker can be worth millions
operations personnel  Operation of 50,000 barrels per day – Delayed Coker can be worth millions

Coker Modification Project

Performing today. Preparing for tomorrow.

High Efficiency, Low Fouling Rate Furnace Design

Good double fired furnace

Minimize fouling

Low peak to average flux

High velocity

Short residence time

On-stream spalling capability

Pigging capability

Proper instrumentation

velocity  Short residence time  On-stream spalling capability  Pigging capability  Proper instrumentation
velocity  Short residence time  On-stream spalling capability  Pigging capability  Proper instrumentation
velocity  Short residence time  On-stream spalling capability  Pigging capability  Proper instrumentation

Coker Modification Project

Performing today. Preparing for tomorrow.

High Efficiency, Low Fouling Rate Furnace Design

Radiant tube support design

Correct metallurgy

Return bend design

GoodGood designdesign minimizesminimizes downtime,downtime, GetsGets moremore throughputthroughput

design Good Good design design minimizes minimizes downtime, downtime, Gets Gets more more throughput throughput
design Good Good design design minimizes minimizes downtime, downtime, Gets Gets more more throughput throughput
design Good Good design design minimizes minimizes downtime, downtime, Gets Gets more more throughput throughput

Coker Modification Project

Performing today. Preparing for tomorrow.

Coke Drum Design

Achieve long drum life

Design for 7,000 drum cycles

Expect 9,000+

Consider drum fatigue

Stress due to drum cycle

Circumferential weld

Skirt attachment

Achieve bulge resistance

Minimize maintenance cost

to drum cycle  Circumferential weld  Skirt attachment  Achieve bulge resistance  Minimize maintenance
to drum cycle  Circumferential weld  Skirt attachment  Achieve bulge resistance  Minimize maintenance
to drum cycle  Circumferential weld  Skirt attachment  Achieve bulge resistance  Minimize maintenance

Presentation Outline

Performing today. Preparing for tomorrow.

Overview

Project Details

Environmental and Other Improvements

Project Highlights

Summary

Questions

Preparing for tomorrow. Overview Project Details Environmental and Other Improvements Project Highlights Summary Questions
Preparing for tomorrow. Overview Project Details Environmental and Other Improvements Project Highlights Summary Questions

Coker Modification Project

Performing today. Preparing for tomorrow.

Project Accomplishments

Modified Fluid Coker to a modern Delayed Coker Unit

Significantly reduced air emissions

Improved overall environmental conditions

Reduced fuel gas production and provided flexibility for future energy conservation projects

Improved safety and reduced emissions by eliminating the Fluid Coker Atmospheric Blowdown Tower

conservation projects  Improved safety and reduced emissions by eliminating the Fluid Coker Atmospheric Blowdown Tower
conservation projects  Improved safety and reduced emissions by eliminating the Fluid Coker Atmospheric Blowdown Tower

Coker Modification Project

Performing today. Preparing for tomorrow.

Looking for an example of a new Delayed Coker operating in an environmentally sensitive area?

ThenThen looklook nono furtherfurther thanthan thethe ConocoPhillipsConocoPhillips LicensedLicensed ThruPlusThruPlus®® DelayedDelayed CokerCoker atat Tesoro’sTesoro’s Martinez,Martinez, CaliforniaCalifornia USUS refineryrefinery

Delayed Coker Coker at at Tesoro’s Tesoro’s Martinez, Martinez, California California US US refinery refinery
Delayed Coker Coker at at Tesoro’s Tesoro’s Martinez, Martinez, California California US US refinery refinery
Delayed Coker Coker at at Tesoro’s Tesoro’s Martinez, Martinez, California California US US refinery refinery

Presentation Outline

Performing today. Preparing for tomorrow.

Overview

Project Details

Environmental and Other Improvements

Project Highlights

Summary

Questions

Preparing for tomorrow. Overview Project Details Environmental and Other Improvements Project Highlights Summary Questions
Preparing for tomorrow. Overview Project Details Environmental and Other Improvements Project Highlights Summary Questions