BP: Refining Opportunities

BP: Refining
Opportunities
KeithZink
CherryPointRefineryCokerEngineer
2001CSMGraduate(CEPR)
AboutMe
• GraduatedfromCSMin2001(CEPR)
• ContractProcessDesignEngineer(5yr)
− BP
− Chevron
− ConocoPhillips
− Shell(Equilon,Texaco)
− PetroStar
• EnergyEngineeratBPCherryPointRefinery(3yr)
• DelayedCokerUnitProcessEngineer
AboutBP
1.SomeMobilemployeesbecamepartofBPstaffpostdissolutionofJVinEurope
2.BPacquiredsomeBelgiumassets
BP U.S. Downstream Business Units
Cherry Point Refinery
Whiting Refinery
Carson Refinery
Texas City Complex
Refining and Manufacturing
Toledo Refinery
Downstream– RefiningandMarketing
Refining receives the crude oil
Produced by E&P and upgrades
it to valuable products. Gasoline
is the largest product from refining,
but others include hydrogen,
natural gas, jet fuel, diesel fuel,
asphalt, coke, elemental sulfur, motor oil, and chemical
feedstocks. Marketing is the most visible Link between
our company and the general public (consumer) and
focuses on providing the highest quality gasoline in
conjunction with convenience retailing. BP is the second
largest marketer of gasoline in the U.S.
RawCrudevs.RefinedProduct
Percent of B a rrel
100
Fuel Gas, LPG
Gasoline
Jet Fuel
Diesel
Gasoil
Coke
80
60
40
20
0
Raw Crude
Refined Crude
CherryPointRefinery
CherryPointRefinery
• 2nd Newest Refinery in the U.S.
• Designed to run 100 kBD ANS Crude, currently capable of 230+ kBD
• ANS supply on decline, so working to diversify crude feed
capabilities
• Economies of scale in action – large, single train equipment so
reliability is critical. Industry leader in operating costs.
• A lot of exciting projects going on:
− ULSD upgrades
− ~$1B in capital investment over next 5 years
CareerPathsforEngineers
• Technical Ladder: Becomeatechnicalexpertin
oneormorefields.Leadtechnologistsassist
globallytohelpsolvethemostchallenging
problems.
• Management Track: Manyopportunitiesfor
engineerstopursuerolesatvariouslevelsof
management.
• Commercial: Opportunitiesintherealmof
productionplanningand/oroursupplyandtrading
organization(IST).
Engineer’sResponsibilities
First and Foremost License to operate:
Ensureyourunitissafe
andoperatinginan
environmentally
responsiblemanner.
Nothingisasimportantas
ensuringthateveryone
goeshomesafeattheend
oftheday.
AnEngineer’sDuties
•Serveasgeneraltechnicalresourcetooperations.
•Providetechnicalsupportandtroubleshootingtotheunits.
•Ensurethatunitoperateswithinenvironmentalpermitlimitations.
•Helpdevelopandimplementcapitalprojectsandbestpracticeprocedures
toimproveprocessoperation.
•UnderstandandcommunicateimpactsofdecisionsonCompany,Refinery,
&Operationsgoals.
•Monitortheperformanceofthefractionationtowers,catalysts,material
balances,productspecifications,reactoryields,andenergyconsumptionto
optimizeperformance.
•Provideengineeringsupportforturnarounds.
•Providetechnicaltrainingandcoachingforprocessoperationsstaff.
AboutCokers…
• Mostcrudesyieldaheavyfractioncalled:resid
− LeftoverfromCrudeunitaftereasystuffremoved.
− Madeupofheavylongchainhydrocarbonsandlargearomaticrings
− Limitedpracticalcommercialusage:asphalt,
− Asphaltdemandlimitedtoseasonalusageandroads.
− Cokingdevelopedtoupgradelowervalueresid tohighervaluedliquid
products.
• Cokingisagrowingtechnology….
− Startedinthe1930’sandstillalargepartofthefutureinrefining.
− Severaltechnologiesbutdelayedcokingmostpopular.
− Availablecrudesaregettingheavieryieldingmoreresid.
− Heavycrudesgenerallycheaperduetolimitedglobalcokingcapacity.
Howitworks– ReactionBasics
• Adelayedcokerisoperatesasasemi-batchprocess.
• Thisisaconversionunit:
− Weareconvertingmoleculesbasedontwodifferentprocesses:
− Cracking– Hydrocarbons(diesel,stove,gasoline,lpg,andfuelgas)
− Condensationorpolymerization- Coke
• Overallthisisanendothermicreactionwithneededenergyprovidedbytwolarge
firedheaters.
• Reactionsareafunctionoftemperature,pressure,andvelocityinthecokedrums.
• Unitrateislimitedprimarilybythesizeofthecokedrums.
Coker- TheBasicBuildingBlocks
• Furnaces-”theheartofthecoker”
− Runlengthlimitedbycokinginthefurnaces
• CokeDrums
• Combinationtower
− Fractionatesheavierliquidhydrocarbonsintodiesel(HCGO&
LCGO)andstove.
• Gastreating
− WetGasCompressor
− Lighterhydrocarbonsfractionatedintogasoline(Hvy/LtNaphtha),
lpg andfuelgas.
− Providesasmuchas70%oftheconsumedfuelgasinthe
refinery.
• Blowdown
− Recoverventgasandminimizeimpacttoenvironment.
Prefractionator (combination)
Dehex (gas treating)
Stabilizer
Structure
Heaters
CokerFurnaces
• Supplyheatforreaction.
• Resid heatedfrom700Fto935F(cokingtemperatures).
• Condensation/Thermallycrackingreactionsbegins.
• 1furnaceperpairofdrums.2furnacestotal
• Tubevelocityandheatinputratecritical
− Operationoutsidespecifiedconditionscouldresultincoked
furnacetubes
• Highoxygencontentinburnerboxpromotesbetterheat
distribution
• Cokemustberemovedfromafurnaceevery6monthsto1
yearbymechanicalpiggingcalled“decoke”
CokerDrums
• Wherethemajorityofthereactionoccurs.
• SeparationofCokeandliquidhydrocarbons.
• Thermalcyclinglimitsdrumlife.(amb tempto900degF)
• CPcokerapproximate27.5ftdiameterby100ftT-T
• Pieceofequipmentthatusuallylimitsunitrate.
• Drumschedule
− Drumsteam-out(45minutes)
− Coolingwater(4hours)
− Vent/Drain(1.5hours)
− Unhead(0.5hours)
− Drill(3hours)
− Head(0.5hours)
− SteamPurge&Pressuretest(3hours)
− Warm-up(2-hours)
− SwitchintodrumforCoking(16hrs)
ASemi-BatchProcess
CokerFractionation
• Heatrequiredforfractionationdeliveredbycokedrumeffluent enteringthebottomof
thefractionator.
• Productsfromheavytolightintower:
− Heaterfeed
− Heavygasoil
− Lightgasoil(diesel)
− Stove(Kero)
− Naphtha
− Fuelgas
• Fractionationinaharshenvironment
− Cokeformation
− Carry-over
• Pumparoundloopsexisttoremoveheatfromtower
− Heatintegratedforenergyefficiency
Whatcangowrong?
• Drumfoamovers
• ShotCoke
• Bottom/TopDe-Heading
• Drilling(hotspots)
• Drumoverfill
• Cokedovhdfouling
• Combinationtowerfouling
• SafetyMoment- 1998Equilon
DCUFatalities
TAR– BusiestTimeAtARefinery
TAR:AChanceToGetYourHandsDirty.
AttentionToDetailWillMakeYourJobEasier
CrudeSchedulingataGlance…
• ANSsupplyondowntrend,soworkingtodiversifyfeedbyprocessingmore
alternatecrude:
− WAF
− ArabSours
− Escalante(mostlyforcokeproperties)
− CanadianHeavies
• Schedulingrequirescarefullymanaging:
− Crudereceiptsandlogistics;constrainedbydockoutages,limited
storage,crudecompatibility,andeventheweather!
− Totalcrudeinventory– nottoolow,nottoomuch.
− Productqualityspecifications(fromdieselTANtocrudeOVHDchlorides
tocalcinedcokehardness).
− Economicoptimization/assetutilization.
• Provideinputtocrudepurchasingdecisions&strategies.
TipsForFindingaJobInRefining
• Internships- Providevaluableexperienceandinsighttoindustry
whichaidsindiscussionduringinterviews;however,notessential.
• HeatandMassTransfer,Fluids,Kinetics,ProcessControl,
PetroleumRefining,GasProcessing,ProcessDesign,Economic
Evaluation…..allthe“good” stuff!
• Communicationskills- Essentialtogetanythingdoneatarefinery
• BackgroundknowledgeaboutOilindustry.
• Willingnesstotakeonnewchallengesandworkasateamtomeet
them.
WhybuildacareerwithBP?
Excellent colleagues
World leader in trading
Pioneer in clean fuels
Strong push for innovation
Global opportunity
Challenging & rewarding
If interested, register at the CSM career center AND register
with BP at:
http://www.bp.com/uscollegecareers
Questions?