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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

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 countrys 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


Petrons Bataan Refinery

Amec Foster Wheeler 2015. All rights reserved.

Petron RMP-2 Project: The Right Project

Project vision

Throughput constrained by fuel oil production


Limited petrochemicals production

Project objectives

Petrons Bataan Refinery

Existing refinery constraints

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 refinerys competitiveness in S.E. Asia
Amec Foster Wheeler 2015. All rights reserved.

Petron Approach: The Right Execution

Aim

Utilize best technology

Fast track project implementation

Meet aggressive budget

Amec Foster Wheeler 2015. All rights reserved.

Petron Execution Approach

Technology Selection

Review of technology market

Focused ITB

Rapid evaluation of licensor proposals

Petron RMP-2 Project Licensor signing ceremony


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Amec Foster Wheeler 2015. All rights reserved.

RMP-2 Major Units: The Right Technology

Sources:
Licensor press releases

Amec Foster Wheeler 2015. All rights reserved.

Why Refiners Select


Amec Foster Wheeler for Delayed Coking
Experience

Most installed units (> 60%)

Safe operation

Wide range of feedstocks

Long run lengths

Extensive heavy crude experience

Over 5 years between turnarounds

All coke types

Minimal environmental impact

Full range of unit sizes

Multiple repeat clients

Technical Resources

High on stream factors and reliability

Innovative design

Proprietary double fired heater

Forged ring coke drum design

Total automation concept

In-house experience & expertise

Modular construction

Vendor and 3rd party support

Process integration

Operations support
Amec Foster Wheeler 2015. All rights reserved.

Amec Foster Wheeler DCU Experience


2005 - 2014

Number of units awarded


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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

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

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Innovative
Petrocedeo
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

Skirt-shell connection

Hot box

Weld build up / Forged ring

1 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

Amec Foster Wheeler 2015. All rights reserved.

Large Coke Drums

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Amec Foster Wheeler pioneered large coke drum designs

First to commercialize 9.8 m diameter drums

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

Monitor temperature gradients

Optimize quench and heat up


rates

Coke drum life estimation

Proactive maintenance
prevents costly shutdowns

Petron Delayed Coking Unit


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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

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 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

Coke drums

Unheading devices

Coke cutting system

Petron preselected key equipment items

Amec Foster Wheeler 2015. All rights reserved.

Coke Drums

Sumitomo

Sumitomos Saijo fabrication facilities


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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
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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

Determine offsite and utilities


requirements

Provide a basis for basic


engineering

Enable fast track execution

View of RMP-2 Project


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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)
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Amec Foster Wheeler 2015. All rights reserved.

Petron Project Execution

EPC

Project management by Petron

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

Schedule advantage

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

Operability

Ergonomics

Maintainability

Amec Foster Wheeler 2015. All rights reserved.

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 Wheelers 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 its
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

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Amec Foster Wheeler 2015. All rights reserved.

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

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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 Wheelers


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 2015. All rights reserved.

Amec Foster Wheeler EPs for Cokers

Amec Foster Wheelers 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


Petron Delayed Coking Unit

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Amec Foster Wheeler 2015. All rights reserved.

Petcoke Disposal Options

Coke sales

Coke sells for about $80 / MT

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

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

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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


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Amec Foster Wheeler 2015. All rights reserved.

PetroPower

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

ENAP Refinery, Chile

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Amec Foster Wheeler 2015. All rights reserved.

CFB Advantages

Widest fuel flexibility

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

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

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


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

Each CFB can produce 35 MW of power

CFBs

Petron power plant


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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

Petcoke value $60/t

100,000 BPSD DCU

Limestone

$40/t

5,750 MTD coke production

Lime

$75/t

7.4 wt% sulfur in petcoke

Sulfur stack emissions

Supercritical CFB

2 x 50% steam turbines

No steam export

200 mg/Nm3

This information is from an internal Amec Foster Wheeler study


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Amec Foster Wheeler 2015. All rights reserved.

PetroPower Economics

Power block TIC

$1.6 bn

Power output

890 MW

Cost of electricity

$80 / MWh

This information is from an internal Amec Foster Wheeler study


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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


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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

Power production options

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


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Amec Foster Wheeler 2015. All rights reserved.

Economic Comparison

Significant incentive to
utilize PetroXXXPower

This information is from an internal Amec Foster Wheeler study


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Amec Foster Wheeler 2015. All rights reserved.

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

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

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

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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

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

Petrons RMP-2 project demonstrates the features and benefits of Amec


Foster Wheelers 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
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Thank You

connected
excellence
in all we do

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