Delayed Coker Heaters Experience by

Foster Wheeler
Foster Wheeler has designed and engineered more delayed cokers worldwide
than any other organization. Foster Wheeler has built approximately half of the
world's delayed cokers specifically designed for needle coke production.

All Foster Wheeler delayed cokers are built with Foster Wheeler fired heaters to
ensure economic operation with long on-stream factors. On delayed cokers, the
Fired Heater Division engineer works very closely with the Foster Wheeler
process engineer to develop an optimum design.

All Foster Wheeler delayed coker heaters, even those for proprietary needle
cokers are entirely process designed, thermally rated, and mechanically specified
by Foster Wheeler.

Foster Wheeler Delayed Coker Heaters: Technical Features

The most important piece of equipment in delayed coker plant is the fired heater.

In this demanding service carefully controlled time/temperature profiles are critical

for profitable production. Furnace residence time must be rigidly controlled to
avoid premature coke formation in the tubes resulting in premature shut down.

F:\dip154\REFERENCE LIST\ fwfhd\Delayed Cokers Heaters1006.doc Page 1 of 9

 Delayed Coker Fired Heaters Experience by Foster Wheeler

The design of the delayed coker heaters offered by Foster Wheeler is based on
the long term proven performance and experience. Foster Wheeler has provided
over 80 delayed coker heaters in 50 different Plants world-wide.

Two types of design are available for this service:

• Single fired cabin or box type with horizontal tubes and bridge wall.
• Terrace-Wall™ double fired, sloped wall type, horizontal tubes.

Specific features of FW Delayed Coker design is the following:

• Adequate and carefully experienced peak radiant heat flux.

• Each parallel pass is symmetrically arranged in the firebox to assure uniform

heat distribution to each coil and to assure equivalent flow length through
each parallel pass.

• Adequate spacing between burners and tubes is provided permitting also, if

required, the use of liquid fuels as design fuel. Special consideration is given
to the burner selection to insure that there will be no flame impingement on
the tubes resulting from faulty burner operation. Flat flame burners will be
provided so as to produce a flame which will adhere to the center of bridge
wall and have a shape similar to a gas flame.

• A hot bridge wall is provided, as applicable, in the middle of firing box. This
feature allows to providing a very uniform heat distribution to the process coil
and a separate firing control to each radiant pass. Both features are very
important to minimize coke formation.

• A sufficient number of burners is provided along the length of the heater to

assure uniform heat transfer along the length of each tube.

F:\dip154\REFERENCE LIST\ fwfhd\Delayed Cokers Heaters1006.doc Page 2 of 9

 Delayed Coker Fired Heaters Experience by Foster Wheeler

• The outlet tubes of each pass are on larger spacing to provide heat more
uniformly around the circumference of the tubes located in the critical coking
area. By arranging these last few tubes close to the coil outlet on longer tube
centers we are able to encrease the heat absorbed by a factor of
approximately 25% keeping the same peak radiant flux rate. This feature will
permit to reduce the residence time at high temperature with consequent
reduction of coke formation thus extending the operating time between steam
air decoking.

• In designing Delayed Coker Heaters it is essential that a rising temperature

gradient be maintained from heater inlet connection to heater outlet terminal
connection. Since the floor of a vertically fired heater is the coolest zone in
the heater, Foster Wheeler design foresees the location of the centerline of
the outlet terminal tubes generously above the top of the floor. This feature
coupled with the extra wide tube spacing of the last few outlet tubes achieves
this desired requirement.

• Residence time of the hydrocarbon feed above 430°C is critical to long on-
stream periods between steam air decoking. This criteria is not only critical
for the design case but also for turndown operations at various recycle ratios.
In practical terms Foster Wheeler sizes the coil to result in an appropriate
minimum linear velocity during the turndown conditions. Steam injection
connections are provided at radiant section inlet and in predetermined
location within the radiant section near the feed bubble point to maintain this
minimum linear velocity.

F:\dip154\REFERENCE LIST\ fwfhd\Delayed Cokers Heaters1006.doc Page 3 of 9

 Delayed Coker Fired Heaters Experience by Foster Wheeler

Foster Wheeler Terrace-Wall™ Delayed Coker Heaters: unique advantages

Several unique advantages are for End User benefit with the appropriate
specification and selection of Foster Wheeler Terrace-Wall™ design:

q Sloped walls provide extremely uniform heat flux from top to bottom of
the radiant coil. As the flue gas cools, the distance from the tubes to the
wall decreases;

q The burners firing up the sloped walls stabilize the coker off-gas fuel and
spreads the flame evenly along the length of the tube and up the wall;

q Grade access allows full viewing and thermal scanning the tubes the full
length of the radiant cell. Also, allows ease of burner maintenance and
tuning;

q Completely isolated cells allow individual pass firing controls for on-line
spalling and turn-down abilities.

A partial list of Delayed Coker Heaters designed and supplied world-wide by

Foster Wheeler is given hereto attached.

F:\dip154\REFERENCE LIST\ fwfhd\Delayed Cokers Heaters1006.doc Page 4 of 9

 Delayed Coker Fired Heaters Experience by Foster Wheeler

Date Company & Location Type No. Size BPD Note

2006 Petronor HTB w/BW 1 41000 APH

Bilbao (Spain) System

2006 CNOOC Terrace-Wall™ 2 76,750 APH

Huizhou (China) System

2006 Reliance Terrace-Wall™ 4 Confid. APH

Yanmangar (India) System

2006 BP Oil Terrace-Wall™ 1 28,000 APH

Castellón (Spain) System

2006 Repsol YPF HTB w/BW 1 32,700 APH

La Plata (Argentina) System

2005 Pemex Terrace-Wall™ 2 28,000 APH

Minatitlan (Mexico) System

2005 Cenex Terrace-Wall™ 1 15,000

Laurel/MT (USA)

2005 Enercon Terrace-Wall™ 2 10,000 APH

Aconcagua (Chile) System

2003 Emerol Terrace-Wall™ 2 10,000

Turkmenbashi (Turkmenistan)

2002 Valero Terrace-Wall™ 2 23,600 APH, SCR

Texas City/TX (USA) Systems

2001 Petrolera Ameriven Terrace-Wall™ 2 33,000

Jose (Venezuela)

2001 Pemex Terrace-Wall™ 2 23,800

Madero (Mexico)

2001 Sincor Terrace-Wall™ 3 25,000

Jose (Venezuela)

2001 MOL Terrace-Wall™ 2 10,250

Slazombatta (Hungary)

1998 Petropower, S.A. Terrace-Wall™ 1 13,200 APH

Talcahuano (Chile) System

1998 Premcor (Valero) Terrace-Wall™ 3 28,000 APH

Port Arthur/TX (USA) System

F:\dip154\REFERENCE LIST\ fwfhd\Delayed Cokers Heaters1006.doc Page 5 of 9

 Delayed Coker Fired Heaters Experience by Foster Wheeler

Date Company & Location Type No. Size BPD Note

2000 Shell Terrace-Wall™ 1 28970 APH

Deer Park/TX (USA) System

1998 BP Terrace-Wall™ 1 28970

Toledo/OH (USA)

1998 Repsol Petroleo HTB w/BW 1 Revamp APH

La Coruña (Spain) to 21,000 System

1998 Repsol Petroleo HTB w/BW 1 Revamp APH

Puertollano (Spain) to 20,000 System

1998 Reliance HTB w/BW 4 32,200 APH

Jamnagar (India) System

1998 Pemex Terrace-Wall™ 2 23,850 APH

Cadereyeta (Mexico) System

1997 Lyondell-Citgo Refining Terrace-Wall™ 2 23,635 APH

Houston/TX (USA) System

1996 Shell Terrace-Wall™ 1 23,500 SCR

Martinez/CA (USA) System

1996 BP Oil HTB w/BW 1 25,000

Lima/OH (USA)

1995 Permnefteorgsyntez Terrace-Wall™ 2 22,680 APH

Perm (Russia) System

1995 Maraven HTB w/BW 3 21,000

Cardon (Venezuela)

1995 Shell Oil Terrace-Wall™ 2 26,250 APH

Deer Park/TX (USA) System

1991 Husky Oil Terrace-Wall™ 1 9,350

Saskatchewan (Canada)

1988 Kukdong Oil Co. HTB w/BW 1 23,290

Daesan (South Korea)

1988 Repsol Petroleo HTB w/BW 1 16,400 APH

Puertollano (Spain) System

1986 Esso A.G. HTB w/BW 1 18,000

Karlsruhe (Germany)

F:\dip154\REFERENCE LIST\ fwfhd\Delayed Cokers Heaters1006.doc Page 6 of 9

 Delayed Coker Fired Heaters Experience by Foster Wheeler

Date Company & Location Type No. Size BPD Note

1985 Union Oil (Conoco Phillips) HTB w/BW 1 31,000 APH, SCR
Rodeo/CA (USA) Systems

1984 Union Oil (Citgo) HTB w/BW 1 11,000

Lemont/IL (USA)

1983 Union Oil (Citgo) HTB w/BW 1 12,000

Lemont/IL (USA)

1983 Coastal (Valero) HTB w/BW 1 16,500

Corpus Christi/TX (USA)

1983 Champlin Oil (Citgo) HTB w/BW 1 29,000

Corpus Christi/TX (USA)

1983 Cities Service (Citgo) HTB w/BW 2 20,000

Lake Charles/LA (USA)

1983 Chevron HTB w/BW 3 24,000

Pascagoula /MS (USA)

1983 Repsol/YPF HTB w/BW 2 15000 APH

La Plata (Argentina) System

1982 Repsol/YPF HTB w/BW 2 15,000 APH

Lujan Cuyo (Argentina) System

1981 Repsol Petroleo HTB w/BW 1 16,200 APH

La Coruña (Spain) System

1977 Exxon HTB w/BW 2 19,000

Baton Rouge /LA (USA)

1975 Shell HTB w/BW 2 8,000

Moerdijk (The Netherlands)

1971 Chevron HTB w/BW 1 15,000

Salt Lake City /UT (USA)

1969 Esso Campana HTB w/BW 1 15,000

(Argentina)

1969 Arco (BP Oil) HTB w/BW 1 22,000

Cherry Point /WA (USA)

1969 Clark Oil (Conoco Phillips) HTB w/BW 1 15,000

Wood River /IL (USA)

F:\dip154\REFERENCE LIST\ fwfhd\Delayed Cokers Heaters1006.doc Page 7 of 9

 Delayed Coker Fired Heaters Experience by Foster Wheeler

Date Company & Location Type No. Size BPD Note

1969 Gelsemberg A.G. HTB w/BW 1 33,000

Gelsenkirchen (Germany)

1968 Sohio (BP Oil) HTB w/BW 1 14,200

Lima /OH (USA)

1968 Crown Central (Pasadena Ref.) HTB w/BW 1 12,350

Pasadena /TX (USA)

1968 Sinclair Oil (Citgo) HTB w/BW 1 35,000

Houston /TX (USA)

1967 Chevron HTB w/BW 3 20,600

El Segundo /CA (USA)

1967 Exxon HTB w/BW 1 20,000

Baton Rouge /LA (USA)

1967 Arco (BP Oil) HTB w/BW 1 17,000

Watson /CA (USA)

1967 Mobil Oil (Exxon Mobil) HTB w/BW 1 11,350

Torrance /CA (USA)

1966 Mobil Oil (Exxon Mobil) HTB w/BW 1 18,000

Oleum /CA (USA)

1965 Marathon HTB w/BW 1 19,100

Burghausen (Germany)

1965 Union Oil (Conoco Phillips) HTB w/BW 1 11,400

Torrance /CA (USA)

1965 Arco (BP Oil) HTB w/BW 1 34,000

Watson /CA (USA)

1964 Union Oil (Conoco Phillips) HTB w/BW 1 6,100

Rodeo /CA (USA)

1964 Shell (Motiva) HTB w/o BW 1 18,200

Norco /LA (USA)

1963 Marathon HTB w/BW 1 13,800

Robinson /IL (USA)

1962 Exxon HTB w/BW 1 30,000

Baton Rouge /LA (USA)

F:\dip154\REFERENCE LIST\ fwfhd\Delayed Cokers Heaters1006.doc Page 8 of 9

 Delayed Coker Fired Heaters Experience by Foster Wheeler

Date Company & Location Type No. Size BPD Note

1961 Texaco HTB w/BW 1 16,000

Lockport /IL (USA)

1960 Koch (Flint Hills) HTB w/BW 1 9,100

Corpus Christi /TX (USA)

Legenda:

HTB w/BW: Horizontal Tubes Box with Bridge Wall

HTB w/o BW: Horizontal Tubes Box without Bridge Wall

F:\dip154\REFERENCE LIST\ fwfhd\Delayed Cokers Heaters1006.doc Page 9 of 9