Processing: time & tech are of the essence

GE's Oil & Gas business is known for managing risk and optimizing performance with a continuous evolutionary approach to product development – gradually combining new designs with longstanding, well-proven technologies. In the past two years, we have focused significant resources to provide advanced solutions for our ethylene, refinery and oil sands customers – with a focus on timely development and on-time delivery.

After more than 70 years in a wide range of petrochemical and refinery applications, our technologies for downstream equipment and services include:

• Steam and gas turbines for mechanical drive and power generation
• Centrifugal, axial and reciprocating compressors
• Positive displacement rotary compressors
• Turboexpanders
• Heavy wall reactors
• Centrifugal pumps and valves
• Air-cooled heat exchangers

Refinery

While time to market is critical to a refinery's success, increasing environmental and safety regulations can delay production because deteriorating supplies clash with new standards for gravity and sulfur content.

The advantage GE offers is its unique ability to provide advanced technologies for all critical equipment. Our integrated approach typically speeds up a new build project by as much as 4-6 months. There are also long-term benefits for the operation stage, since owners can leverage synergies in scheduled maintenance and capital parts.

All GE's equipment is designed to work together from the start – making installation smooth and straightforward, optimizing performance for all aspects of the process. It is a far more efficient solution than a multiple-supplier approach.

Of particular significance to refineries are GE’s latest improvements in heavy wall reactors where the driving forces are size, strength and delivery time. Advanced welding and materials technologies have made us the most referenced company in the world for Cr-Mo-Vanadium welding. Our massive new pulsing manufacturing and assembly line with twin tandem welding stations and multi-belt overlay stations can produce reactors as large as 15,000 tons. In the past year alone, our production capacity has doubled with a 100% on-time delivery record.

We cover all the critical processing requirements of FCC units – the core of every refinery – including axial compressors for air blower service and centrifugal compressors for handling wet gas.

In response to the demand for larger hyrdotreating plants, GE offers a 10-cylinder, single-frame reciprocating compressor that delivers a hydrogen flow rate well above 90,000 Nmc per hour.

Similarly impressive innovations for our air-cooled heat exchangers have resulted in a one-third reduction in unit size and weight – with no capacity loss. We will also double our production capacity in 2007 to meet customer demand.

Our strong commitment to the environment is exemplified by the recent ecomagination certification of our hot gas expanders. By maximizing energy recovery from waste gas, CO2 emissions and energy costs are reduced.

Ethylene

The ethylene industry is undergoing a significant structural shift. Just a few years ago, a large fraction of the world’s plants were based in North America and Europe where the demand was concentrated. Each plant was therefore designed for regional distribution with relatively small capacities. Today, the key region for new plant development is the Middle East, thanks to its feedstock cost advantage. Since production will be primarily for large export markets, equipment has to be much larger and more efficient than ever before.

At the core of capacity and performance are the plant's turbines and compressors – machines for which GE has posted remarkable achievements in recent years. Our engineering teams work closely with customers and process licensors to constantly push the conventional limits of unit size and performance. Recent technologies have extended ethylene plant capacity beyond 1.2 MTPY, with impeller dimensions of 1.8 m and mechanical drive steam turbines well above the 60 MW mark.

Our latest turbine for processing applications incorporate technologies from GE Aviation and GE Energy. They are designed for a wider variety of fuels and lower emissions. Compressor efficiency has increased 2-6% over the past five years through improvements in flow path design and manufacturing processes – including 3D impeller design and single-piece forged steel impellers.

Our single-piece forged impeller manufacturing is one of the industry's most significant and unique capabilities. Rotors can be milled from either stainless steel or carbon steel to meet the needs of the application, and can have from 1 to 8 impellers. There are no power limits on an individual compression stage, since the weakest point (between the hub and shroud) is automatically eliminated – resulting in increased stability and high/variable-speed performance. Moreover, the manufacturing process itself is more efficient and reliable than traditional welded methods.

Oil sands

As with refining, GE provides a much-needed comprehensive solution for oil sands customers – including water treatment for SAGD, dispersants and dust control for mining, separation technologies, process additives for demulsifying, pumps, corrosion inhibitors and pipeline integrity services.

Our heavy-wall reactors are ideal for high-pressure (up to 200 bar) and high-temperature (up to 450°C) applications. Our reciprocating compressors are designed for heavy-duty service and the H series, in particular, is ideal for hydrogen make-up service in heavy-oil processing.

GE also offers a full range of process pumps designed for continuous handling of high-temperature liquids while maintaining the highest levels of performance, reliability and availability. Both heavy-duty and aeroderivative gas turbines are provided with power outputs of 13-120 MW.

We have more than 50 years of experience in gasification – with proven technologies that convert asphaltenes and petroleum coke, and that economically generate hydrogen, power and steam. Other solutions include treatment equipment, chemicals and tools for monitoring and analysis.

Conclusion

By the end of 2007, GE’s Oil & Gas business will have invested more than $100 million in technological advancements. We work closely with our customers and industry associations to stay abreast of their needs, and we regularly inject designs from GE's other high-tech businesses so that we bring the best possible solutions forward for our oil and gas processing customers.

By optimizing the balance of time and technology, we help customers optimize their balance of risk and reward.

For more information please contact:

Giorgio Greco
Giorgio.Greco@ge.com