Refining Technology

for Improving Efficiency

Refining Operation Team &

Materials Technology Business Team

Contents
z Company Overview
z Heater On-stream Cleaning
z Process Solvent Cleaning

Source ; 2002. 01

Company Overview

1. Introduction
2. History
3. Refining processes & units
4. Solomon Index

Source ; 2002. 01

Company Overview

Introduction
z Pioneer in economic development in Korea
z Energy & Chemical Business
z Life Science
z Internet Business

Source ; 2002. 01

Company Overview

History
z 1962.10 Established
z 1999 Revenue: US $ 10 Billion
z 2000 New Vision
: Globalized Innovative Marketing Company
z Present Employees : 4,541

Source ; 2002. 01

Company Overview

Refining Process & Units

Process

No.of Unit

Capacity

Licensor

CDU

880 MB/D

MDU

182 MB/D

Reformer

61 MB/D

UOP

VDU

78 MB/D

RFCC

50 MB/D

UOP

ARDS/VRDS

102 MB/D

Chevron

Hydrocracker

37 MB/D

Unocal

Hydrogen

145 MMSCFD

HTAS

Source ; 2002. 01

Company Overview

Solomon Index
Energy Intensity Index
Japan Trend Group
95
4Q
1Q

90
85
80

SK

75

1Q

70
65
1994

1996

1998

Total Equivalent Personnel

Japan Trend Group

50

110

45

100

40

90

Per 100K EDC

US $/EDC

Maintenance Index
Japan Trend Group

35
4Q
1Q

30
25
20

SK

15

1Q

70
60

30
1998

2000

4Q
1Q

50
40

1996

SK

80

10
1994

2000

1Q
1994

1996

1998

2000

Source ; 2002. 01

Company Overview

Solomon Index
Cash Basis ROI
Japan Trend Group

70

20

60

15

50

10

40

Percent

US Cents/UEDC

Cash Operating Expenses

Japan Trend Group

4Q
1Q

30

SK

20

SK

1Q

4Q

1Q

1994

1996

1998

2000

-5

10

1994

1996

1998

2000

Source ; 2002. 01

Company Overview

Solomon Index
Maintenance Index
Asia/Pacific (excluding Japan)

Energy Intensity Index

Asia/Pacific (excluding Japan)
105

30

100
25
US $/EDC

95
2H

90
85
80
75

SK

70
1994

1996

SK

20
15

1H

2H

1H

10
1998

2000

1994

1996

1998

2000

Total Equivalent Personnel

Asia/Pacific (excluding Japan)
110

Per 100K EDC

100

SK

90
80

2H

70
60
50

1H

40

1994

1996

1998

2000

Source ; 2002. 01

Company Overview

Solomon Index
Cash Basis ROI
Asia/Pacific (excluding Japan)

Cash Operating Expenses

Asia/Pacific (excluding Japan)
20
45

15

35
30

SK

Percent

US Cents/UEDC

40

2H

1H

SK

10

25

1H

20
15

1994

1996

1998

2000

2H

0
1994

1996

1998

2000

Source ; 2002. 01

Heater On-stream Cleaning

1. Background
2. Description
3. Benefits
4. Application Cases

Source ; 2002. 01

Heater On-stream Cleaning

Background
More deposited Scale, Higher Temperature in Radiant Section
Heater Material should not exceed its own max. allowable
temperature as below

Stud Material (Extended Material)

Maximum Tip Temperature()

Carbon Steel

510

Low Alloy (11~13 Cr)

649

Stainless Steel (18Cr-8Ni)

815

Stainless Steel (25Cr-20Ni)

982

Source ; 2002. 01

Heater On-stream Cleaning

Background
Slag Compounds
Vanadium Compounds
2Na2OV2O4 11 V2O5
Na2O3V2O5
3V2O5
V2O3
...

Melting point
1071 F
1235 F
1243 F
3580 F

Complex Sulfates

Melting point

K3Fe(SO4)3
KFe(SO4)2
Na3Fe(SO4)3
NaFe(SO4)2

1145 F
1281 F
1155 F
1274 F

Source ; 2002. 01

Heater On-stream Cleaning

Background
Throughput Loss
About 6 months after T/A in CDU, crude charge rate should be
reduced not to exceed the limit of radiant temperature.
HTR
Radiant
HTR
Radiant
Temp.

175

980

170

940

165

900

160

Maximum Guideline Temp.

860

155

820

150

780

145

740

Throughput Decrease

140
996

Radiant ()

(MB/D)

CDU
Throughput

700
9911

004

DATE

Source ; 2002. 01

Heater On-stream Cleaning

Background
Energy Cost Increase
Heater efficiency gets worse gradually from SOR to EOR.

Flue Gas ()

280

Fuel FOEB/Chg 100Bbl

1.20

260

1.10

240

1.00

220

0.90

Fuel Cost Increase

200

0.80

180

0.70

996

999

9912

003

006

009

Stack
Gas ()
Stack Flue
Flue Gas
Temp.()

0012

DATE

Source ; 2002. 01

Heater On-stream Cleaning

Description
Introduction
Batch feeding into furnace box using compressed air &
or pump to clean the fire side of heater tubes
while in operation
Good distribution using all available openings, such as
peepholes & explosion doors.
Available to use solid type
or liquid type chemicals

Source ; 2002. 01

Heater On-stream Cleaning

Description
The Function of Chemical
Oxidation (Reaction Temp. > 250) :
Oxidize unburned carbon on the tubes partly disintegrated
deposits
Mechanical Action with Compressed Air :
Remove the deposits partly disintegrated
Reduction:
Reduce NOx in the flue gas

Source ; 2002. 01

Heater On-stream Cleaning

Benefits
Unit Throughput Increase
Unit throughput could be increased by removing the bottleneck
due to high temperature in the fire box of heater

175
(MB/D)

170

HTR
Radiant

HTR
Radiant
Temp.

980

Heater On-stream Cleaning application

940

165

900

160

860

155

820

150

780

Unit Throughput
Increase

145

740

140
996

Radiant ()

Throughput

700
9911

004

009

012

DATE

Source ; 2002. 01

Heater On-stream Cleaning

Benefits
Improve heater efficiency: Fuel Saving
Fuel Saving could be achieved from reduction of final stack
temperature.

Combustion Status before Cleaning

High-severity Operation; Long flame

Combustion Status after Cleaning

Reduction of heater load
Source ; 2002. 01

Heater On-stream Cleaning

Benefits
Tube surface appeared brighter after cleaning
After Cleaning

Before Cleaning
Source ; 2002. 01

Heater On-stream Cleaning

Benefits
NOx Reduction
Its a environment-friendly technology in favor of NOx reduction
The graphs below show NOx Content [ppm] during the cleaning.
500
400

Existing
Technology

300
200
100
0
18-Dec-01 11:00

18-Dec-01 12:10

18-Dec-01 13:20

18-Dec-01 14:30

18-Dec-01 15:40

18-Dec-01 16:50

150
130

SK
Technology

110
90
70
50
04-Jan-02 07:00

04-Jan-02 07:30

04-Jan-02 08:00

04-Jan-02 08:30

04-Jan-02 09:00

04-Jan-02 09:30

Source ; 2002. 01

Heater On-stream Cleaning

Application history
Unit
SK Corp.
No.3 CDU

Application Date

2001.12

Effects
Throughput Increase :
170 [MBbl/Month]
Energy Saving : 40,000 [$/Yr]

SK Corp.
No.2 CDU

2002.1

Throughput Increase
180 [MBbl/Month]

SK Corp
No.3 Platforming

2001.3

Product(BTX) Increase
1,600,000 [$/Yr]

KOC (Kyushu
Oil Corp.)
No.3 CDU / VDU

2001.4

Radiation Temp. Decrese

CDU HTR: 920 770
VDU HTR: 850 720

Source ; 2002. 01

Heater On-stream Cleaning

Application history : Kyushu Oil Company

Look at the tube hangers! You can confirm that heat duty is
dramatically reduced after cleaning.
After Cleaning

Before Cleaning
Source ; 2002. 01

Source ; 2002. 01