Delayed coking process as a way to

increase crude conversion at JSOC

Bashneft

Dmitry Maltsev

Arthur Galiakbirov

Gennady Valyavin

April 2015

History

The most important

aspects

Ecology

General conclusions

Q&A

In 2005 to increase crude conversion it was decided to build a

new 1.2 MTPY Delayed Coker with a possibility of further upgrading to

1.6 MTPY

Project background

3

The main factors of the decision to build a new DCU were:

Growing economics of the industry

A potential uninterrupted sales channel for high-sulfur coke

Favorable macroparameters

<80% <90% >95%

2006 2010 2013

About 7 MTPY

About 8,5 MTPY About 8,5 MTPY

UNKH throughput/Conversion rate

Flow chart

4

Brief description:

The first Russian

delayed coking unit

based on domestically

designed process

Possibility to produce

two grades of coke

Maximum automation,

elimination of labor-

intensive activities

involving hard manual

labor, automatic valve

systems for coke drum

opening and closing

Closed blow down system

32-hour coking cycle

in line with the best

international practices

for 4 coke drum

systems

Manufacturing of coke drums

Direct control over fabrication of coking drums exercised by

Customer and General Design Contractor played a key role in meeting

Project schedule

5

Delivery of coke drums. Final stage.

6

Delivery of coke drums was scheduled for river navigation period. The

delivery final stage was a separate project including a river bank reinforcement,

construction of a road, elimination of dimensional restrictions within the

refinery

Construction of the unit

The main success factors in project

schedule implementation:

Joint work of Refinery and Designer teams

Efficient construction management and

qualified subcontractor involvement

7

Key indicators of the unit

8

Mass balance Yield

Fuel gas About 10%

Naphtha to Diesel hydrotreatment Up to 8%

Light gasoil to Diesel

hydrotreatment Over 30%

Heavy gasoil to FCC Below 18%

Coke Below 34%

All product quality meets further

refining process requirements

A “Coking additive" product is produced

with an increased content of volatiles

(above 16%)

Targets reached

In 2010 the unit reached its design capacity of 1,2 MTPY

In 2012 the unit was revamped to improve capacity up to 1,6 MTPY

In 2013 and 2014 1,6 MTPY were processed 9

History

The most important

aspects

Ecology

General conclusions

Q&A

In 2014 to increase crude conversion it was decided to build a

new 2.0 MTPY delayed coking unit

Project background

11

2015 2019

About 19 MTPY About 19 MTPY

Total refinery throughput/Conversion rate

<90% >98%

The following are the main factors which resulted in a decision

to build a new DCU:

Imposition of fuel oil export duties

Potential uninterrupted sales channel for high-sulfur coke

12

Given the positive experience in

the construction, in 2014 a decision was

made by JSOC Bashneft to build a new delayed

coking unit at UNPZ refinery with 2 MTPY

capacity

Construction of the new unit will

allow to completely abandon fuel oil and

vacuum gas oil production

Making use of Foster Wheeler

technology and USPTU consulting effort will

integrate international licensor best

practice and researchers experience in

construction of the most effective delayed

coking unit

Key Success Factors

USPTU

13

Project targets:

Conversion improvement

to above 98%

Refinery margin

improvement

Project description:

Capacity - 2 MTPY

4 coke drums

Full automation

Foster Wheeler heaters

Fractionation section

LPG treatment section

Fuel gas treatment section

Dedicated recycle water

preparation section

Automated coke loading system

Project description

“Coking additive” specific properties

14

Coking additive – a unique product

developed in USPTU, which first allowed

sales of high-sulfur coke to metallurgy

where it can be used as an additive in

production of metallurgical coke for iron

smelting

Utilization as a coking coal substitute

in furnace charge increases

metallurgical coke output

Possibility of direct briquetting

eliminating need for any binder and

fillers

Possibility of metallurgical coke

production for blast furnaces. With 5%

or higher sulfur content such coke

makes an excellent material for

nonferrous metal smelting

Hazardous emissions at this coke grade

production are reduced by 10%

Same as of regular coke environmental

hazard

Selecting of feed composition

15

As the vacuum cracked residual increases the stable control range of

the process mode to produce the specified quality coke decreases

As the carbonization temperature rises the coking risk of transfer

and furnace coils increases, the temperature drop leads to the risk of

froth-over to the main column

Froth-over to the main column,

difficult cooling and drilling

Coking of transfer and furnace coils

VC

M c

on

ten

t, %

Reactor Inlet temperature, C

0% of cracked

residual

30% of cracked

residual

70% of cracked

residual

stable operation operative risk high risk critical risk

History

The most important

aspects

Ecology

General conclusions

Q&A

17

The unit construction according to

Foster Wheeler technology allows to

minimize the process environmental

impact through the use of modern

technical solutions:

Furnace efficiency is 90%

The use of low-toxic injection

nozzles with low NOx generation

level

Purification of the gas with the

hydrogen sulfide residue content up

to 0.01%

Minimization the coke transportation

hub

Maintenance of the coke humidity as

>7% to prevent the solid particles

entrainment

Closed cooling system of chambers

Closed drain system

Increased coke cooling cycle (24

hours instead of 16 at the existing

units)

Construction of the fuel gas pipeline

to Novoil to relief UNPZ fuel

network and compensate for the lack

of fuel gas in Novoil

0,1%

28%

The emission of sulfur

dioxide

Башнефть

УНПЗ

УЗК

16% 24%

The emission of solid

particles

Башнефть

УНПЗ

УЗК

5%

20%

The emission of nitrogen oxides

Башнефть

УНПЗ

УЗК

Mitigation

Bashnef

t UNPZ

DCU

Bashnef

t UNPZ

DCU

Bashnef

t UNPZ

DCU

18

The main environmental advantages are

achieved through the use of the improved

cooling system of coke drums and sealed

shut-off valves during the hydraulic

discharge of coke:

Increased cooling period of 9.5 hours

Unique central feed and cooling water

inlet system, which allows to

eliminate "hot spots" in the coke mass

Residual steam supply into the closed

cooling system using an ejector

System of coking chambers redundant

shut-off valves using insulating steam

flows

Ramps providing energy dissipation

during coke unloading

Covered area for coke, preventing the

blow-off of solid particles by wind

during the storage

Optimization of hydraulic discharge of coke

History

The most important

aspects

Ecology

General conclusions

Q&A

20

The unit construction according to Foster

Wheeler technology is the reliable way to

improve the oil refining depth and will allow

to increase the processing margins and

profitability of the company as a whole

Given the wealth of Bashneft employees

experience in the construction and such

process operation we are confident in the

success of the project

The unit start-up will allow to maintain the

leading position of Bashneft in refining

capacity, processing depth and light oils

output

General conclusions

History

The most important

aspects

Ecology

General conclusions

Q&A

Dmitry Maltsev

Arthur Galiakbirov

Gennady Valyavin

April 2015