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Key Drivers and Trends forRetrofits of
High Temperature Reaction Furnaces and
Fired Heaters
Yukong, Crude Charge & Distillate Heaters, Ulsan, South Korea
Steam Reformer, Wilmington, California
Shell Refinery
To Retrofit or Not to Retrofit!
• If William Shakespeare were alive today – and working as a refinery manager – what would he suggest you do?
That is the question.
Types of Retrofits
• Individual components
– Simple retrofit such as Low NOxburners
• Complete systems & processes
– Overhaul of idled systems
• Retrofit entire refineries
– Switch refinery to support new type of crude
Retrofit Drivers
Primary Drivers for Retrofit Decisions
• Capacity expansions
• Regulatory compliance– i.e., emissions reduction
• Refurbishment – i.e., extended life
• Efficiency improvement– Reduce operating costs
• Reliability/Maintenance
• Correct performance degradation
• Implement process changes
More Retrofit Drivers
• Improvement of operating controls
• Addition of waste heat recovery equipment
• Integration of gas turbines with equipment
And Yet More Retrofit Drivers
• Introducing new refined products
• Introducing new forms of crudeBP PLC [NYSE:BP], one of the world's largest energy companies, will spend US$3 billion to retrofit its Chicago-area refinery in order to become a primary processor of heavy Canadian oilsands crude.
--- Resource Investor
Chevron Richmond refinery (commissioned in 1902) was retrofitted to run higher volumes of sour crude and reduce emissions. US$1 billion retrofit.
--- Downstream Today
Be Aware of Hidden Costs• Judgment errors:
– Incomplete scope– miscalculated turnaround
time; – Misjudged complexity
• Cranes• Change orders
– Thorough studies and RFQs save money!!!
• Site transportation• Unrestricted access • Permits & Safety
Engineered Retrofit Approach• Evaluate Collect design and operating data Create simulation model Correct model for actual performance Simulate changes based on client
requirements Develop Recommendations
• Engineer and Procure Engineer solution based on
recommendations Develop detailed design package Procure materials
• Execute Develop detailed execution plan Execute field construction
10
Platformer Rebuild Fully Modularized
Scope of Retrofit ServicesIt begins with
the study
Strong Logistics
capability is critical
Construction services
• Studies• Engineering• Procurement• Fabrication• Inspection• Modularization• Construction• Start-up
Crude & Vacuum Heater Expansion Project
• An “epic” expansion– 275,000 bpd to
600,000 bpd
• Once complete – will be largest refinery in the US– and 12th largest in the
world
• Many contractors and equipment suppliers on site
Motiva, Port Arthur, Texas
FCCU Retrofit with SCREmissions Reduction Project
• Citgo Clean Skies Initiative
– 94% reduction of emissions of nitrogen oxide (NOx)
– 98% reduction of emissions of sulfur dioxide (SO2)
– 96% reduction of emissions of particulate matter (dust) Citgo
Lemont Refinery
More SCR Retrofits
ExxonMobilConfidential
Rebuilds
ChevronTexaco Nova Chemical
Planned Unplanned
Worst Case Scenario Planning
ConfidentialEthylene Cracker Emergency Rebuild
High Temperature Reaction Furnaces
Mega Hydrogen ReformerSteam Reformer
Reformers
Reformer Radiant Modules Modularized Reformer Penthouse
Reformers
Vertical Convection SectionPenthouse Details
Fired Heaters
Flue gas replacement Full EPC Project Management
