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Processing Heavy Crude

and
Bottleneck Study Program
of COSMO OIL
25th Apr. 2019
5th ASEAN Refining & Petrochemical Forum

International Cooperation Center


Fumiyoshi Matsumiya
Today’s Agenda 1

1 Overview of Cosmo Group

2 Cosmo’s Strategy to the Environmental Change

3 Revamping Delayed Coker Unit at Sakai Refinery

4 Refinery Operation Optimization


2

1 Overview of Cosmo Group

2 Cosmo’s Strategy to the Environmental Change

3 Revamping Delayed Coker Unit at Sakai Refinery

4 Refinery Operation Optimization


Cosmo’s Group Structure 3

Japanese financial Japanese Other Japanese


Foreign individuals companies and
institutions and
investors and others corporations
securities firms

20.8 % 36.5 % 20.7 % 12.8 % 9.2 %


The biggest shareholder

Listed in Tokyo Stock Exchange

Group of affiliated
Oil exploration and production Oil refining, petrochemicals Oil product sales, Retail, etc. companies

Crude production Major crude oil importing countries Domestic sales share Wind power generation capacity
(three operating companies) United Arab Emirates 20,885 thousand KL 227,000kW
(Abu Dhabi) (Gasoline, Naphtha, Jet fuel, Kerosene, Domestic market share:
Approx. 40,000 barrels/day Kingdom of Saudi Arabia Gasoil, A fuel oil, C fuel oil) Approx. 6%
Comparison with refining capacity: State of Qatar
Approx. 10% Oil refining capacity Number of service stations in Japan Ethylene production capacity
400,000 barrels/day Number of COSMO 1,290,000 tons/year
Oil exploration & production areas Domestic market share : Brand stations Domestic market share:
United Arab Emirates Approx. 11.4% 2,858 Approx. 18%
(Abu Dhabi) Car leasing business for Individuals
Para-xylene production capacity Major affiliated companies
State of Qatar 1,180,000 tons/year Cumulative total Eco Power
47,602 cars Maruzen Petrochemical
Major affiliated companies Major affiliated companies COSMO Credit Card Members COSMO Oil Lubricants
Abu Dhabi Oil COSMO Matsuyama Oil Approx. 4,400 ,000 members COSMO Engineering
CM Aromatics COSMO Trade and Service
Qatar Petroleum Development Major affiliated companies
Hyundai COSMO Petrochemical COSMO ALA
United Petroleum Development COSMO Oil Sales Gyxis
Sogo Energy
Cosmo’s Business Activities 4

COSMO GROUP is one of major energy companies in Japan.


Core Petroleum Business Petrochemical Business

<E&P>
Production Capacity
Crude Oil Production
40,000 BPD Para-Xylene 1,180
Benzene 940
Mixed Xylene 620
Ethylene 1,290
(1,000 Tons/Y)

<Refining>
CDU Capacity
363,000 BPD Renewable Energy Business

<Marketing>
Sales Volume
20,885 KKL <Wind Power> <Solar Power>
Number of Generation Capacity Generation Capacity
Gas Stations 227MW+ 88MW* 24MW
2,858 *under construction

As of March 2018
Introduction of Cosmo’s Refineries 5

COSMO OIL is operating 3 Refineries (Total CDU capa. 363,000BPD)


COSMO’s Refineries

Chiba Refinery Yokkaichi Refinery Sakai Refinery

CDU CAPA. 177,000BPD CDU CAPA. 86,000BPD CDU CAPA. 100,000BPD


- Built in 1963 - Built in 1943 - Built in 1968
- Integrated with - Operating power plant - Equipped with new
Petrochemical Complex since 2004 secondary units
- Installed Isomerization - Producing Lubricating Oil - Installed Delayed Coker
Unit (Built in 2005) (Base Oil) in 2010 to receive
heavier crude oil.

COSMO OIL is accumulating its refinery technology and know-how


through operating experience for more than 50 years.
Introduction of COSMO’s R&D center 6

①Crude oil selection / transportation/CDU


・TBP Distillation evaluation of crude oil

・Compatibility test

・Consulting on wastewater treatment

④Trouble shooting
・Analysis and cause investigation
of Filter clogging substance, scale
in piping and rust in the vessel tank.
②Secondary processing unit
・Pilot evaluation for catalyst selection

・Proposal of optimization in catalyst


operation using our simulator

③Blending/ Quality management


·
Study of optimum additives and its addition amount.
·
Fuel prescription
(Propose coping prescription against the influence of operational change)
·
Response to future regulations.
(ex. examination of prescription for IMO regulation.)
7

1 Overview of Cosmo Group

2 Cosmo’s Strategy to the Environmental Change

3 Revamping Delayed Coker Unit at Sakai Refinery

4 Refinery Operation Optimization


Petroleum Demand Decline in Japan 8

Fuel demand is decreasing year by year due to population decline and


improvement of fuel efficiency in relation to cars (EV, HV and PHV).
Petroleum product demand forecast between 2019-2023 in Japan
KKL

▲9 %

FY2017 FY2018 FY2019 FY2020 FY2021 FY2022 FY2023

Achievement Prospect Forecast


Gasoline Naphtha Jet Kerosene Gas oil A fuel oil B and C fuel oil
Source: 6th Integrated Resources and Energy Survey by Ministry of Economy, Trade and Industry
Cosmo’s Strategy to Domestic Demand Decline 9

・Securing petroleum products outlet


- The business alliance with the wholesale and retail company called
Kygnus Sekiyu K.K. with acquisition of 20% of stock share.
- Starting supply fuel to Kygnus Sekiyu by around 2020.
IMO 2020 10

- Change of IMO regulation from 2020


All sizes of ships will need to use fuel oil that meets the 0.50%
limit from 1 January 2020.
As a countermeasure, refineries may blend fuel oil with a high
(non-compliant) Sulphur content with fuel oil with a Sulphur
content lower than the required Sulphur content to achieve a
compliant fuel oil.

Source: IMO website


Cosmo’s Strategy to IMO 2020 Implementation 11

・Revamping Delayed Coker Unit at Sakai Refinery


- Increasing production of profitable products, such as diesel fuel oil
converted from the heavy oil fraction.

DCU

Jet Fuel
Vacuum Residue
Gas Oil

・ Refinery operation optimization


- Maximizing profitable products by stable operation and process
control to improve the profit.
- Minimizing the energy cost by energy conservation
12

1 Overview of Cosmo Group

2 Cosmo’s Strategy to the Environmental Change

3 Revamping Delayed Coker Unit at Sakai Refinery

4 Refinery Operation Optimization


Configuration of Sakai Refinery 13

Sakai Refinery has the state of the art units(DCU, HDS) in Japan.
・Bottomless
・Able to process reasonable Heavy Crude Oil
Effective Utilization of DCU 14

How to achieve processing heavier crude oil?

Step1 Setting target of Crude Oil API


Step2 Crude Oil selection
Step3 Effective evaluation of selected
unexperienced crude oil (Bottleneck study)
Setting target Crude Oil API 15

Gross Profit vs. API often has Inflection Points


because Crude Oil throughput decreases in case of lower API.
→Considering equipment configuration is important rather than simple
heaviness regarding setting target crude API.

Profit per BBL


($/BBL) × Crude oil
throughput (BBL) = Gross Profit
($)
Up Up Up
00 100,000 100,000

Benefit / BBL will


Throughput

00 80,000 80,000
increase in case of
Benefit

Benefit
lower API
00 60,000 Throughput will 60,000
decrease in case of
lower API
00 40,000 40,000

Down Down Down


00 20,000 20,000
20 25 30 35 40 20 25 30 35 40 20 25 30 35 40
API API API
Crude Oil Selection 16

・Crude Oil is classified by Specific Gravity and Sulfur content.


・In general, the ratio of Impurity increases in heavier Crude Oil.
・Tangible measure will be required because Impurity causes Bad Effects on
refining units
<e.g. Bad Effects>
①Viscosity ②TAN(Naphthenic Acid)③Sulfur compounds ④Mercury ⑤Salt

45 WTI
Super
40 Murban Light
Minas
35 Brent Iranian Light Arabian Light Light
API
Bonny Light Middle
30 Kuwait
Nile Blend Ural Heavy
Iranian Heavy Cold Lake
25 Super
Oriente
heavy
20 Vasconia Maya
Castilla Napo
15
0.0 1.0 2.0 3.0 4.0
Sulfur %
Effective evaluation of Selected Unexperienced Crude Oil
(Bottleneck study) 17
The following change and effect would be caused by unexperienced
Crude Oil.
Characteristics Required
Fraction Unit Effect of Equipment
change Countermeasures

Change of Semi
CDU products yield
Residue
VDU /Decrease of Pump improvement
Viscosity Fluidity

Decrease of
VR VDU
Fluidity

Salt Crude Oil CDU Corrosion Desalter unit

Naphthenic Equipment material


Crude Oil/AR CDU Corrosion
Acid change

Washed gas Increase of


Sulfur HFG/LPG SRU enhancement
unit Fuel Gas Sulfur

Corrosion Mercury
Mercury LPG/Naphtha CDU
removal unit
Catalyst Poisoning
Effective evaluation of Selected Unexperienced Crude Oil
(Bottleneck study) 18

Checking the impact to Catalysts for HDS/FCC/RF by the change of


operations by means of Pilot Plants and Optimal Operation to maximize
the benefits.

Bottleneck Study After Bottleneck study

Evaluation Confirmation Optimization


(in catalyst operation)

Checking the impact to Confirmation of catalyst Estimation of catalysts


catalysts by processing life and activation by performance by
unexperienced feedstock the result of catalysts simulator based on
by means of pilot evaluation and actual operation data
plants. simulator. and proposal of
optimal operation to
maximize the benefits.
Result of Bottleneck Study 19
・Increase removal capability
of Mercaptans in LPG
・Increase capability of
sulfur recovery
・Reposition pipeline support

LPG、Naphtha:
Crude Oil: Removal mercury unit
Increase
capability of
Desalter VGO, AR, VR:Change of the equipment
materials

AR:
Increase
capability
of the
pump

VR:
Increase
capability of
the pump, Increase capability of
Extension of Feed pump
the heat
exchangers Increase capability of product
distillate,
Increase capability of Coke Handling
(cooling, removal of moisture)
Bottleneck Study Program (Our service) 20

Studies to identify the Bottleneck Points on each aspect including


Operations, Catalysts, and Maintenance based on our knowledge and
lessons in order to prepare for unexperienced crude oils.

 Confirm the existing performance of each


Equipment equipment.
 Identify Bottleneck points of each facility.

 Suggest the optimized operation targets and


the constraints required
Operations
 Mitigate the bottlenecks by the optimized
and improved operations.

 Suggest the impact to catalysts by the


change of operations
Catalysts
 Estimate the catalyst life with our original
simulator

 Check the static equipments and piping


materials
 Review the maintenance plan and suggest
Maintenance
the points and time for inspections /
maintenance
 Support maintenance planning
21

1 Overview of Cosmo Group

2 Cosmo’s Strategy to the Environmental Change

3 Revamping Delayed Coker Unit at Sakai Refinery

4 Refinery Operation Optimization


Profit from Operation Optimization (COSMO’s Case) 22
Ref. COSMO’s Profit from Operation Optimization with APC

5.0MM$/y 0.6MM$/y
N-HDS
-Furnace REF MG
-Desalter
-Preheat -Reactor K-HDS
CDU -Stripper etc.
-Furnace 1.4MM$/y NAPH
-Fractionator LGO-
-Side-stripper HDS -Reactor
-Stabilizer -Stripper KERO
-Deethanizer VDU
VGO- -Debutanizer etc.
HDS
-Depropanizer
JET Fuel
-Amine etc.
Naph
HDS
ULS-DGO
Coker
Gas oil
0.6MM$/y HDS FCC

FUEL OIL
-Feed system
-Vacuum COKE

column 2.3MM$/y 1.0MM$/y


-Furnace -Debutanizer Reactor , Regenerator
-Fractionator -Compressor Fractionator
-Stabilizer etc. Stripper etc.

Total Profit = 11 million USD/year


What can be achieved by “Operation optimization?” 23

Level1 Level2 Level3 Level4

Profit
Target Level

Product specification: Maximum Limit

Stabilization Targeting Targeting


No Stabilization +Stabilization

Low  Operation Optimization Level  High

Improve Operation Stability


Study Flow of “Operation Optimization” 24

Cosmo conducts to achieve operation optimization status by following


procedure based on our know-how and analysis technology.

Analysis Planning Implementation

Analytics technology Optimization Database Optimization Support

Operation data analysis Improvement plan study Control System installation

Noise
Reduction <Operation Optimization> Soft sensor
□Stabilize Operation
□Improve product yield
+
Cluster Analysis

Control logic
<System Optimization>
Regression Analysis □ Stabilize operation
□ Increase of APC
utilization
Process control installation

Identify issues Improvement proposal Improvement support

Improve operation stability and profit


Ref. Increase of LCO Production by SLO Kinetic Viscosity Control 25

Background
The current situation is based on the kinetic viscosity and catalyst
content of SLO in order to reduce SLO and to increase LCO production.
The operator manually adjusts the SLO flow rate based on SLO kinetic
viscosity.

LCO deep drawing


LCO

Pump around

Monitoring items
SLO - Kinetic viscosity
- Catalyst content
FCC main fractionator
Create the Soft Sensor based on Regression Analysis 26

Good correlation was found between the created soft sensor


and the analyzer.

Analyzer
Soft sensor

Trend of SLO kinetic viscosity


Create the Soft Sensor based on Regression Analysis 27

Limit

Stabilize the fluctuation


Target

Practical use of process control

Trend of SLO kinetic viscosity

Process
OPC server DCS
Controller
Refinery Operation Optimization Program (Our Service) 28
 Check current operating condition
Site Survey  Confirm operation level & issues
- Profit evaluation method (Product・ Utility unit price)
Research & Analysis

 Collect related data


Data Gathering
- Operation data, P&ID, PFD, equipment data

 Extract improvement points through data analysis


Analysis
 Calculate potential profit

Proposal  Propose improvement points and potential profit

 Collect additional data (If any)


Preparation  Compare with design values
 Study improvement points
Implementation

 Support test operation planning


Test
 Conduct step test (change operation condition)
Operation  Analyze test results

 Propose simplified process control construction


System
(Proposal process installation will be
Development  Construct simplified process construction

 Simplified process control operation (About 10 days)


Validation - Confirm control results and profitability
 Result report
Thank you
for your attention!

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