Need

YPF S.A., the Seeker for this Innocentive Challenge, is looking for design and detailed technical documentation describing a fully or partially automated system to operate coke drums.

Coke drums are used in oil refining processes, such as thermal cracking. As a by-product of thermal cracking, solid carbon compound (coke) accumulates, which needs to be periodically removed from drums. Given the size of coke drums and complex, often hazardous, conditions under which they operate, there is an urgent need to automate the process of coke drum handling, which includes bolting, unbolting, and torquing of coke drum heads.

Designing and documenting such an automated (or partially automated) system is the objective of this Challenge.

Solvers are expected to outline their approach to the project’s design and execution based on the principles of Front-End Engineering Design (FEED). In addition, they should demonstrate their capacity to implement the proposed design, supported by proof of successful implementation of this type of technology in the past.

Collab Opp

This is a Scouting Challenge seeking a partner or supplier to provide systems and expertise to solve YPF’s business challenge; the Solver is invited to submit a written proposal to be evaluated by YPF with the goal of establishing a collaborative partnership, including running a pilot.

For any Challenge winner selected, a USD $20,000 pilot in Buenos Aires will be requested, aligned with the technical guidelines and specifications defined by YPF. This pilot will enable the formalization of an agreement with the winning Solver and support progress toward the full-scale implementation of the project across, potentially, three coke units comprising fourteen drums located in two refineries.

Submissions to this Challenge must be received by 11:59 PM (US Eastern Time) on June 30, 2026.

Please review the later Participation Guidance section before submitting a proposal.

Log in or register your interest to start collaborating and scouting!

Seeker/Eligibility

YPF is an Argentine energy company dedicated to the exploration, production, refining, distribution, and commercialization of gas, oil, and hydrocarbon derivatives. It is also involved in the sale of fuels, lubricants, fertilizers, plastics, and other products related to the industry.

It is one of the largest companies in Argentina and one of the most important oil companies in the region. YPF operates three refineries located in La Plata (Buenos Aires), Luján de Cuyo (Mendoza), and Plaza Huincul (Neuquén), as well as more than 1,600 service stations across the country (both company-owned and franchised).

Employees of YPF are ineligible to be awarded this Challenge.

Challenge

Background

Coke drums are massive, cylindrical metal vessels (Figure 1) used in oil refining processes, such as thermal cracking. Standing roughly 28 meters tall and 6 meters wide (see Attachment 1 for precise dimensions), they act as pressurized containers where solid carbon byproduct (coke) accumulates.

Figure 1. A typical coke drum.

To handle high pressure and temperature, a coke drum is designed with heavy, bolted lids at the top and bottom that allow it to be opened and resealed for each new operation. More specifically, each coke drum is equipped with:

• Top flanged head (see Attachment 2 for description)
• Bottom flanged head (see Attachment 3 for the description)
• Flanges associated with the feed inlet, the entry point where the oil stock is pumped into the drum to begin the cracking process (see Attachment 4 for the description)

The accumulated coke must be removed every 48 hours per drum, and since a typical refinery unit has four coke drums, the coke removal operation must be performed every 12 hours in one of the four drums.

Currently, this process is performed manually and includes two major steps:

1. Drum Opening (Unbolting)

• Loosening and removal of bolting:
  • 32 bolts on the top head
  • 12 bolts on the feed flange
  • 48 bolts on the bottom head
• Mandatory application of specific loosening sequences (see Attachment 5 for the detailed description of the protocol)
• Removal of used gaskets
• Handling and movement of heavy heads

2. Drum Closing (Bolting and Torquing)

• Manual cleaning of the contact surfaces between flanges
• Installation of new gaskets
• Positioning of heads and flanges
• Installation and retightening of bolts
• Application of defined tightening sequences and specific torque values
• Verification of proper torquing through standardized procedures and steam leak testing (see Attachment 5)

It is important to note that the procedure described above is performed under the following conditions:

• High residual temperatures in the drum in the presence of localized hot spots
• Possible presence of residual water and hydrocarbon gases inside the equipment
• Handling large-scale vessels, with significant weight and stored energy, exacerbating risks associated with handling
• Workspaces with restricted access and limited visibility, which make operational and inspection tasks more difficult
• Presence of coke particulate in the work area

The Challenge

The complexity of the coke removal process itself and the aggravating circumstances under which the process is conducted – especially given its manual character – represents the most critical stage of the process from both safety and operational reliability standpoints.

More specifically, the following factors point to the need for improvements:

• High exposure of personnel to mechanical, thermal, ergonomic, and environmental risks
• Repetitive, physically demanding, and highly standardized tasks
• Dependence on the human factor for the correct tightening sequence, applied torque, and sealing quality
• Variability in execution times, tightening quality, and process repeatability

It is, therefore, highly desirable to automate the process of coke removal in the following directions:

• Fully or partially automate the operations of unbolting, bolting, controlled and sequenced torquing, and the handling/movement of heads and flanges
• Ensure correct torque application and compliance with tightening sequences
• Guarantee process repeatability and traceability of applied torque values
• Ensure proper flange positioning and successful leak testing

YPF envisions that all the above can be accomplished by designing an application of the following tools, processes, and operations:

• Automated or robotic systems for loosening, tightening, and torquing bolting
• Manipulators or devices for positioning tools and flanges
• Intelligent tools with torque and angle control, including integrated data recording capabilities.

Solution Requirements

To be considered a winner of this Challenge, the Solvers should outline and justify their approach to the project’s design and execution based on the principles of FEED. In addition, they should demonstrate their capacity to implement the proposed design, supported by proof of successful implementation of this type of technology in the past.

YPF expects the proposed solutions to have a Technology Readiness Level (TRL) between 6 and 9; it must be proven in industrial settings and adaptable to the operation of thermal cracking.

Every proposal must include the following mandatory sections:

1. Assessment and analysis of the current situation

• Existing design conditions
• Operations carried out in the current process
• Relevant operational constraints

2. Description of the proposed solution

• Selected technical concept
• Scope of the solution (what is automated and what is not)
• Operating philosophy and principles (opening, closing, and interlock mechanisms)
• Assumptions and design criteria
• Analysis of the proposed process vs. current process
  • Comparative description of both processes
  • Impact on safety, operating times, and human intervention

3. Diagrams and schematics of the solution

• Design diagrams (functional diagrams, drawings, 3D models, etc.)
• Interfaces with existing equipment

4. Technical feasibility, safety, and costs

• Technical feasibility assessment
• Risk identification and preliminary analysis (a HAZID study) compared to the current situation
• Estimated implementation cost covering all project phases, specifying cost variability ranges for each stage
• List of critical materials and spare parts

Special consideration will be given to proposals that, besides the mandatory sections, include the following:

5. Automation and control at a conceptual level

• Control philosophy (how the automated system will be integrated with the plant logic controller)
• Proposed level of automation
• Operator–system interaction (local/remote)

YPF will welcome proposals that borrow from the experience of other industries, as long as they are suitable for the coke drum application.

Submitted proposals will be considered successful if a solid and feasible technical solution is developed, materialized through the FEED, clearly demonstrating how manual intervention in the coke drum opening and closing process can be reduced or eliminated.

We also expect the Solvers to demonstrate their ability to implement the proposed design through clear evidence of past successful implementations. We’re specifically looking for case studies with context, solution deployed, and measurable results, as well as client references or testimonials confirming the effectiveness of the Solver’s work.

Important! Modifications to the chemical process, changes to the overall configuration of the thermal cracking unit, and the complete redesign of the drums are out of scope for this Challenge.

Important! Given the presence of residual hydrocarbon gases inside coke drums, the proposed solutions must use only explosion-proof materials. The use of polymers of any kind is not allowed.

Success will be measured based on:

• The quality and level of detail of the proposed solution, aligned with technical, operational, and safety requirements
• Demonstration of technical feasibility under real industrial operating conditions
• The extent to which the solution reduces personnel exposure to operational risks
• The presentation of realistic cost and timeline estimates
• The ability to implement the solution within the next 6 (six) months

Solutions with Technology Readiness Levels (TRLs) 6-9 are invited.

This Scouting Challenge has the following features:

1. YPF will evaluate your submission to determine their interest for further business and collaboration discussions, including launching a USD $20,000 pilot.
2. The terms of the contract (including scope of work, tasks and duration) for any winner will be determined directly with YPF. The monetary value of any additional contract will vary depending on the amount of work to be delivered and the agreed upon time frame.
3. YPF may subsequently directly request that certain IP arrangements are agreed should a partnership be pursued.

Your Submission

Please log in and register your interest to complete the submission form.

The submitted proposals must be written in English or Spanish and can include:

1. Participation type – you will first be asked to inform us how you are participating in this challenge, as a Solver (Individual) or Solver (Organization).

2. Solution Level - the Technology Readiness Level (TRL) of your proposal or not applicable.

3. Problem & Opportunity - highlight the innovation in your approach to the Problem, its point of difference, and the specific advantages/benefits this brings (up to 500 words).

4. Solution Overview - detail the features of your proposal and how they address the SOLUTION REQUIREMENTS (500 words, there is space to add more in the summary field, and attach supporting data, diagrams, etc).

5. Experience - Your proof of successful implementation of this type of technology in the past. Any further expertise, use cases and skills you or your organization have in relation to your proposal (up to 500 words).

6. Solution Risks - any risks you see with your solution and how you would plan for this. This information will need to be further developed later through a HAZID study during the FEED phase.

7. Schedule & Cost. A high-level Gantt schedule implementation chart is required, including:

• Project phases and estimated duration
• Cost per phase and total project cost
• Integrated view of timeline and costs

8. Online References - provide links to any publications, articles or press releases of relevance (up to 500 words).

9. Attachments: Core attachment requirements include:

• Front-End Engineering Design(FEED) as stated in the Solution Requirements section.

Participation Guidance

1. Submission Close Date: Submissions to this Challenge must be received by 11:59 PM (US Eastern Time) on June 30, 2026.

2. Late submissions: Late submissions will not be considered.

3. Multiple submissions, One Maximum: In case of multiple submissions by the same Solver, only one submission – the final one submitted – will be considered. Any other submissions will be deleted prior to evaluation.

4. Submission form and attachments: Your submission will be evaluated by the evaluation team first reviewing the information and content you have submitted at the submission form, with attachments used as additional context to your form submission. Submissions relying solely on attachments will receive less attention from the evaluation team.

5. Evaluation notification steps: After the Challenge submission close date, YPF will review and select the winning ideas/solutions according to the timeline in the Challenge header. Everyone who submits a proposal will be notified about the status of their submissions.

6. Use of AI: Please note that any submissions produced solely with generative AI are not of interest.

7. Learn more: Find out more about participation in Innocentive Challenges.