Conocophillips Tim Old

7/31/2019 Conocophillips Tim Old

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Successful ThruPlus Delayed

Coker Start-up in anEnvironmentally Sensitive Area

Vincent Leung - Sr. Process Engineer, ConocoPhillipsTim Old - Technology Licensing Director, ConocoPhillipsJack Follick - Engineering Project Development Manager, Tesoro


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Performing today. Preparing for tomorrow.

Presentation Outline

Overview

Project Details

Environmental and Other Improvements

Project Highlights

Summary

Questions


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Overview

Project Details


Project Highlights

Summary

Questions


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Tesoro is an Independent Refining/Marketing Company

Kenai, Alaska 72,000 bpd Key products:

Jet & Gasoline

Anacortes,Washington

115,000 bpd Key products:

Gasoline & Diesel

Mandan,North Dakota


Gasoline & Diesel

Salt Lake City, Utah 58,000 bpd

Key products:Gasoline & Diesel

Kapolei, Hawaii 94,000 bpd Key products:

Jet& Gasoline Corporate Office

Denver Office

SingaporeOffice

Auburn Office

LongBeachOffice

Martinez, California 166,000 bpd Key products:

CARB Gasoline& CARB Diesel

Wilmington,California


CARB Gasoline& CARB Diesel

CalgaryOffice

No upstream assets

Headquartered in San Antonio, Texas Seven Refineries

660,000 bpd total crude capacity Retail network of over 850 sites

5,500 Employees

Traded on NYSE: symbol TSO


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Tesoro Golden Eagle Refinery Martinez, CA

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, andpreviously Fluid Coker now Delayed Coker


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Environmental Awareness in California

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


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Environmental Stewardship


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Environmental Stewardship

Refinery located in highly environmentallyconscious area

Environmental stewardship is one of Tesoros toppriorities

Tesoro wanted to significantly reduce airemissions

Tesoro determined that switching to a Delayed

Coker was the most appropriate solution


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Overview

Project Details


Project Highlights

Summary

Questions


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Coker Modification Project

Project Aims

Significantly reduce air emissions

Extend duration between major turnarounds

Reduce fuel gas production to provide flexibility forfuture energy conservation projects

Incorporate recent advances in Delayed Cokertechnology and lessons learned throughout the industryto provide a very safe unit


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Project Overview

Modify Fluid Coker to Delayed Coker

ConocoPhillips ThruPlus Delayed Coker license signedDecember 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-track project to meet regulatory deadlineFast-track project to meet regulatory deadline

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


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ConocoPhillips Delivered Unique Expertise Licensorand 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


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Overview

Project Details


Project Highlights

Summary

Questions


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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 inSCR on Delayed Coker heaters


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Environmental Impact Minimization VOCs

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 routineflaring)

B lo w d o w nQ u e n c hT o w e r

S e tt lin gD ru m

N o n c o n d e n s e dV a p o r s

C o k e D ru m

B a c k w a r mE ff lu e n t

C o k e D ru mO v e r h e a d

B lo w d o w n

Q u e n c hW a te r S p ra y

C o n d e n s e dB lo w d o w n

W a t e r

L ig h tS lo p O il

H PS te a m

Q u e n c h T o w e rC o n d e n s e rs

H e a v y S lo p

O i l toQ u e n c h

S p ra y


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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 SOxemissions

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


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Emissions Reductions NOX: 93.3%

SO2: 99.7%

NH3: 98.6% GHG: 70%


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Environmental Impact Minimization: PM10

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/SolidsSeparation System


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Environmental Impact Minimization: PM10 cont.

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

Overhead cranes with large buckets not front end loaders to minimize cokesize 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


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Structure sloped wall Greater barrier protection against

drum drain events

Provides excellent energy dissipationfor blowouts and coke falls

Stabilizes coke drum structure

Pit-pad Crane operator moving coke from safe

location

Operator can cut coke for all drumswithout needing to move any coke gives time for crane repairs whileoperator is out of harms way

Safety Advantages of COP Coke Handling System


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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 deckelevation versus metal chutes by more than 3 meters (10 ft) results inCAPEX saving of USD 500,000 - $1,000,000 per drum


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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 repairtime does not result in process unit operation being affected by cokehandling system

Very high stream factor

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

Other Advantages of COP Coke Handling System

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


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Overview

Project Details


Project Highlights

Summary

Questions


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Very Quick And Smooth Start-up Thorough operator training

Tesoro personnel visited COPs Borger Refinery to observe coker operationsand talk directly to Borger operators

Tesoro conducted their own operator training, with consultation from COPsCoke Technology group

Tested all the interlocks before start-up

COP standard design requires safety interlocks to prevent release ofhydrocarbons to the atmosphere

COP recommends additional interlocks to prevent mistakes that, while notunsafe, will result in operational upsets

COPs practice is to assist licensee in testing all interlocks on new units

Interlocks are tested to prove they will allow proper operation and preventimproper operation

Stepping through the interlock system has also proved to be valuable operatortraining as it gives hands-on practice

Ongoing post start-up support


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Other Highlights Extended duration between major turnarounds

Increased stream factor

Reduced maintenance costs

Improved safety

Reduced fuel gas production to provide flexibility forfuture energy conservation projects


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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 canbe worth millions of dollars per day


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Good double fired furnace

Minimize fouling

Low peak to average flux

High velocity

Short residence time

On-stream spalling capability

Pigging capability

Proper instrumentation

High Efficiency, Low Fouling Rate Furnace Design


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Radiant tube support design

Correct metallurgy

Return bend design

High Efficiency, Low Fouling Rate Furnace Design

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


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Achievelong 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

Coke Drum Design


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Overview

Project Details


Project Highlights

Summary

Questions


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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 forfuture energy conservation projects

Improved safety and reduced emissions by eliminating theFluid Coker Atmospheric Blowdown Tower


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Looking for an example of a new Delayed Coker

operating in an environmentally sensitive area?

Then look no further than the ConocoPhillipsThen look no further than the ConocoPhillips

Licensed ThruPlusLicensed ThruPlus Delayed Coker at Tesoros Delayed Coker at Tesoros

Martinez, California US refineryMartinez, California US refinery


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Overview

Project Details


Project Highlights

Summary

Questions

Conocophillips Tim Old

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