0. Dr. Girish Chitnis Ms. Marie Wright Mr. Glen Phillips
Economically Attractive and Environmentally Friendly FLEXICOKING™ Resid Upgrading Technology
Dr. Girish Chitnis
Ms. Marie Wright
Mr. Glen Phillips
International Conference on
“Refining Challenges - Way Forward'
16-17 April, 2012
New Delhi

1. Coking Process
Coking is the Most Widely Used Resid Conversion Approach Worldwide!
Delayed Coking – Furnace & Drum, Batch Process, Coke Pits
FLEXICOKING™ – Fluidized Bed, Continuous, Coke Silos and Closed System
– Environmental considerations important for both
Coke by-product Yield Typically 1/3 of Feed
Similar amount for other resid conversion processes
Product: (a)
Yield (wt%)
Fuel Gas & LPG 10
C5+ Liquids 55
Coke 35
Total
100
Delayed Coking (several providers)
FLEXICOKINGTM (ExxonMobil)
Heavy Crudes
Resids
FLEXICOKING Eliminates the Coke!

2. FLEXICOKING Technology: Simple Air + Steam Integrated Gasifier Design
Products to Fractionator
Feed
FLEXIGAS to Coke‑Fines,
Water & Sour Component Removal
Heater
Hot
Coke
FLEXIGAS
Gasifier
Reactor
Air from
Blower
Cold
Coke
Steam
Purge coke

3. FLEXICOKING Schematic
Steam

4. FLEXICOKING Products Same Liquid Yields as Delayed Coking
Coke Gasified in a Simple Integrated Steam + Air Gasifier
Produces Clean CO/H2 Fuel Gas (FLEXIGAS) Product Instead of Coke
FLEXSORB® Hindered Amine Reduces H2S to Low Level Low SOX
Nitrogen Diluent Reduces BTU Content, But Low NOX
FLEXIGAS Burned in Refinery, Third Party Furnaces / Boilers or for Power
Steam
Research and Engineering 4

5. FLEXIGAS Gives Positive Margin Over Delayed Coke as Fuel
Shaded Region: FLEXICOKING becomes More Attractive
Delayed Coking Becomes Less Attractive
Delayed Coke Price 3 4 5 6 7
150.0
90.0
60.0
30.0
0.0
-30.0
120.0
FLEXIGAS at Parity with NG Price, $/mm Btu
$20 / tonne
FLEXIGAS Margin over Delayed Coke
M$/Year
$100 / tonne
Achieve Higher Margins over Delayed Coking

6. FLEXICOKING Gasification & POX Comparison
Partial Oxidation
Product
Fuel Gas
Syngas / H2 / Fuel Gas
Components
CO/ H2 / N2
CO / H2
Heat Content, kJ/kg
5250
9375
Process Gases
Steam / Air
Oxygen (a)
Temperature, °C
Pressure, barg
2 – 4
20 – 70
Slag
Avoid formation
Disposal is an Issue
Materials
Refractory Lined Carbon Steel
Simple Inlet Distributor
Brick Lined
Complex Alloy Nozzles
Cycle Length, months
36-48
<6 (b)
Capex $
$$$
a. Typically Requires air separation plant
b. Per Gasifier. Overall reliability improves with spares

7. FLEXIGAS as a REFINERY FUEL

8. FLEXIGAS Use in Commercial FLEXICOKING Units
Significant Fraction of FLEXIGAS Consumed within Refineries
Excess FLEXIGAS Used for Fuel in Nearby Power Plants
Rotterdam Exports Higher BTU Content Fuel Gas
SITE
FLEXIGAS
(MW)
FLEXIGAS Used in Refinery (%)
Off Site Consumers 1
PDVSA,
Venezuela
600 28
Large boiler / power plant consumes majority of Flexigas 2
ExxonMobil
Baytown
430
100
Flexigas used on site
Very large/ complex refinery with large number of on site fuel users 3
ExxonMobil Rotterdam
450 82
Burn majority of FLEXIGAS onsite
Sell ~270 MW high BTU fuel gas offsite 4
Shell
California
~300
~100
Primarily use FLEXIGAS in refinery 5
Showa Shell
Japan
300 50
Large nearby power plant consumes ~50% of FLEXIGAS in boilers

9. FLEXICOKING Low Joule Gas Firing
RHJG Burner
Dual Fuel Burner Assembly
LJG Burner
Pilot Burner (HNJG)

10. Rotterdam Refinery Fuel Gas & Energy Grid Details

11. FLEXICOKING Rotterdam Refinery Environmental
Dutch Refineries
XOM Refinery
Emission
SO2 kt/jr
30,3
3,0
NOx kt/jr
9,9
1,0
Dust kt/jr
2,7
0,09
Capacity mt/jr 61 10
Low Sulphur Products kt/jr
35-45

12. FLEXIGAS for Power Generation Using Steam Cycle

13. TOA Oil FLEXICOKING Unit
Started up in 1976 (21 kb/SD)
Current Capacity: 27 kb/SD
Fluid Solids Vessels:
Gasifier on Left
Heater in Center
Reactor on Right
Earthquake-Proof Structure
FLEXIGAS Users
Refinery Furnaces 50%
Power Plant Boilers 50%

14. TOA Power Generation using FLEXIGAS
Operation Began in 2003 in Cooperation with Electric Power Company
LCG is Supplied as Fuel for Steam-Generating Boiler
Steam is Used for Power Generation and also by Refineries
Stable Supply of Electricity and Steam
Power Plant Demand Outpaces FLEXIGAS Production
TOA OIL Keihin Refinery
Genex (Power-Generating Plant)
Vacuum Residue Fraction
Products
Steam Boiler
37 %
Low Calorie Gas
(LCG)
21 %
Frac.
L/E
High Calorie Gas
Waste Heat Boiler
(C1, C2)
33 %
FCC HCG Gas
LPG (C3, C4)
Gas Turbine
9 %
Refinery furnaces
100 % G R H
Gas Turbine: ~80 MW
Steam Turbine: ~190 MW
Total ~ 270 MW
Air & Steam

15. FLEXIGAS for Power Generation Using Combined Cycle

16. FLEXICOKING and GTCC: A Case Study
FLEXICOKING Unit
Material reproduced with permission from Mitsubishi Heavy Industries (MHI). All rights reserved

17. MHI’s Equipment Layout
Approx. 200 m
Approx. 60 m
Gas Cooler
Gas Compressor
BFG
Gas
Mixer CO G
E.P.
Steam Turbine
Generator
Gas Turbine
HRSG
Stack
Inlet Air Filter
Transformer
Material reproduced with permission from Mitsubishi Heavy Industries (MHI). All rights reserved 17

18. Capex for Power Generation Using Steam or Combined Cycle

19. Relative Total Investment Cost (TIC)
Add a Simple Gasifier for Only 30% More Capex than Delayed Coker

20. Simple Payout versus Electricity Price
Shorter Payout with FLEXICOKING and Power Generation

21. FLEXIGAS for H2, N2, CO2, Ammonia and Urea Production

22. Flexibility of H2, CO2, NH3, Urea and Power Production From FLEXIGAS
Excess FLEXIGAS used as refinery fuel
Power Generation
Combined Cycle
Rankine Cycle
MW-hr
PSA Offgas
Purge Gas
Heater Overhead and FLEXSORB®
FLEXIGAS Compression
Hydrogen Shift
CO2 Removal
Hydrogen Production
Hydrogen
Ammonia Production
Ammonia
Urea Production
Urea
CO2

23. FLEXICOKING: Operating Commercially for 35+ Years
TOA Oil - First Commercial Unit S/U in 1976, Expanded in 2002
Currently 5 Units Operating With a Total Capacity of ~200 kB/D
Hellenic Petroleum Unit under construction
PetroPeru Unit under design
Rosneft is latest unit and also under design
COMPANY
LOCATION
FEED RATE, kB/D
TOA Oil
Japan 27
PDVSA
Venezuela 65
Shell
California 22
ExxonMobil
Netherlands 42
Texas
Hellenic
Greece 21
PetroPeru
Peru
Rosneft
Russia 50 23

24. SUMMARY FLEXICOKING Technology is Well Proven
Eliminates Coke Production
Coke Upgraded into a Clean FLEXIGAS by Gasification
Gasification using Steam +Air is Cheaper, More Reliable and Simpler than POx
FLEXIGAS is Suitable as a Cheap Refinery Fuel
No Limitations in Using FLEXIGAS for Power Generation
Power generation Payout is More Attractive than Delayed Coking Route
Power Generation Schemes are Commercially Proven
FLEXIGAS is suitable for ammonia/urea production or for production of H2, N2 and CO2 24

25. Coking and Integrated Steam / Air Gasification
FLEXICOKING
Coking and Integrated Steam / Air Gasification
Questions
Sunset at TOA Oil, Keihin Refinery ( Mizue )

26. FLEXIGAS + GTCC Gives Higher Cash Flow
120+M$ Higher Annual Cash Flow than Delayed Coking + IGCC Power Generation

27. FLEXICOKING Advantages Versus Other Options
Milder Conditions and Significantly Lower Capital Cost than POx
No issues such as Disposal of Slag, UCO
No Air Separation Unit Needed
Fluid Bed
Coke
Gasification
FLEXICOKING
CO / H2 / N2
Fuel Gas
Coking
Conversion Step
Gasification Step
FULLY INTEGRATED
Steam/Air
Competing Options
Delayed Coking
Ebullating Bed
SDA
Conversion Step
Partial
Oxidation
Gasification
Gasification Step
CO / H2
SynGas
Air
Separation
Oxygen
SEPARATE PROCESS