An Overview of DCU

7/22/2019 An Overview of DCU

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A Sunrise Project for A Sunshine FutureParadip Refinery

OVERVIEW

ON

DELAYED COKER UNIT

Prepared by

Production-CG Team

Faculty

Mujeeb Ahmad

SPNE-CG
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To process heavy petroleum residue (bottoms from atmospheric and

vacuum distillation) and upgrade into valuable distillates leaving

behind a solid concentrated carbon material (petroleum coke).

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PURPOSE
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1860 - Petroleum coke was first made by the pioneer oil refineries in

Northwestern Pennsylvania.

1891- Shuknov cracking process

1913 - Burton process developed by Standard Oil at Whiting, Indiana

converted gas oil to gasoline with the production of petroleum coke

1919 - Dubbs and other thermal cracking processes also produced

petroleum coke.

1929 - The first delayed coker was built by Standard Oil of Indiana at

Whiting, Indiana in 1929 .The development of hydraulic decoking came

in the late 1930's.

1955 - Delayed coker construction boom

2003 - second delayed coker construction boom

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DELAYED COKER CHRONOLOGY


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THERMAL UPGRADING PROCESS

ENDOTHERMIC : Application of thermal heat during the cracking

process, large molecules decompose and form smaller (lighter)

molecules.

During thermal cracking generally two types of reactions take place.

Primary reactions by decompositions of large molecules to smallmolecules.

Secondary reactions by which active products from primary cracking

reactions further crack or react to form other molecule cracking

molecules or polymerize to generate heavy products (coke).

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DELAYED COKER PROCESS


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Batch-continuous process :

Flow through the tube furnace is continuous. The feed stream is

switched between two drums. One drum is on-line filling with coke

while the other drum is being steam-stripped, cooled, decoked,

pressure checked, and warmed up.

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DELAYED COKER PROCESS


7/42A Sunrise Project for A Sunshine FutureParadip Refinery

UNIT OVERVIEW

UNIT CAPACITY : 4.1 MMTPA

UNIT LICENSOR : F&W USA

EPCM : TOYO INDIA

FEED : VACUUM RESIDUE

RECYCLE RATIO : 8 %

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PROPERTIES UNIT Values

Feed temperature oC 190

Specific gravity @ 15 oc 1.046

wt% 26.8

Metal ( Ni/Va) wppm 44.3/150.4

Total sulfur wt% 5.73

Sodium(max) wppm 10

Asphaltene wt% 9.8

FEED PROPERTIES


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HYDROCARBON SIDEFLOW

Heatexchanger

Fractionatorcolumn

Heater Coke drum FractionatorGas consection /

side stripper

Coke

cuttingtank

cokedrum

Coke pit Maze

Coke

cuttingtank

WATER SIDE FLOW

BOX FLOW CONCEPT FOR UNIT



Fractionator Section

Coke drum section

Heater

Coke drum

Blow down

Gas con section

Compressor/ stripper absorber

Sponge absorber/amine scrubber

Debutanizer/Naphtha splitter

LPG amine contactor

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PROCESS FLOW DIAGRAM



Separate drum vapour ( cracked product and water ) in to different

boiling product

HCGO

LCGO

Naphtha

Off gasSecondary purpose : Feed surge drum

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FRACTIONATOR SECTION


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A Sunrise Project for A Sunshine FutureParadip Refinery 13



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Heater section

Provide the heat to feed for thermal cracking

Coke drum

Complete reaction is taking place inside the drum

Blowdown section

Control the emission and recover the hydrocarbon vapour

from cooling and heating cycle .

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COKE DRUM SECTION


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Compressor and Stripper / Absorber

Recover the lighter hydrocarbon from the fractionator over head

section

Stripper

- strip off the lighter from heavy cut (C3, C4, C5+ cut )

Absorber

trap the escape LPG component in absorbent

naphtha is used as absorbent

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GAS CON SECTION


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Sponge absorber and Amine scrubber

Recover the carried away C3,C4 and naphtha part in off gasfrom absorber

Sponge oil ( part of LCGO ) used as lean oil

H2S is removed from off gas in Amine scrubber

Fuel gas as product routing to Fuel gas header

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GAS CON SECTION



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GAS CON SECTION


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Debutanizer and Naphtha Splitter

Separate the LPG from the heavy part in theDebutanizer section.

Light and Heavy naphtha are separated in Naphtha

Splitter Section .

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GAS CON SECTION


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GAS CON SECTION


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LPG amine contactor

Sweetening the LPG in amine contactor

Amine used as absorbent

Remove the H2S from LPG

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GAS CON SECTION



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OPERATING VARIABLE


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CONTRIBUTE TO QUALITY AND PRODUCT YIELD

COIL OUTLET TEMPERATURE

- Increase in COT will result in coke yield decrease & liquid

yield increase ,

- Decrease in COT will lead to soft pitch coke formation.

- Too high COT will result in too hard coke to cut , coking in tube

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OPERATING VARIABLE

OPERATING VARIABLE


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CONTRIBUTE TO QUALITY AND PRODUCT YIELD

DRUM PRESSURE

- Increase - coke yield increase , gas yield

increase

- Decrease increase the liquid yield

RECYCLE RATIO

- Increase - coke yield increase , gas yield

increase

- Decrease increase the liquid yield

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OPERATING VARIABLE

SALIENT FEATURES: COKE DRUM


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NUMBEROFCOKEDRUMS: 4

COKINGCYCLE, HOURS: 24

RECYCLE: 8 LIQ. VOL.%

COKEDRUMOVERHEADTEMPERATURE :441 C

DESIGNTEMPERATURE:474 DEGC

Coke Drum ID :9.8M

Coke Drum Height : 45 M (F/F)

SALIENT FEATURES: COKE DRUM

COKE DRUM BLOCK DIAGRAM


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COKE DRUMBLOCK DIAGRAM

COKE DRUM CYCLE


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Waterquench

Waterdrain

Decokingoperation

Pre heatand

pressuretest

VaporHeating

Coking

Steamout

COKE DRUM CYCLE

Waterquench

Water drain

Decokingoperation

Pre heat andpressure test

VaporHeating

Coking

Steam out


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MAIN FRACTIONATOR DETAILS


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MAIN FRACTIONATOR DETAILS

SALIENT FEATURES: HEATER


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PMC : Jacob Engineering India Ltd.

LSTK-2: Heurtey Petrochem

Heat Duty : 50.22 MM Kcal/Hr

Number Of Heater : 02

Numbers of cells per heater 03No of passes per cell 02

Total no of Passes per heater 06

No of Burners per row 18

Total No of Burners per heater 108

velocity condensate flow per pass 549 kg/hr

SALIENT FEATURES: HEATER

HEATER DECOKING OPERATION


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STEAM AIR DECOKING.

Design for offline

MECHANICAL PIGGING

ONLINE SPALLING

Performed when heater is in service.

One pass is taken off service and rest of the passes are inline.

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HEATER DECOKING OPERATION

SALIENT FEATURES: COKER GAS COMPRESSOR


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Design feature :

Centrifugal compressor

Manufacture : BHEL

2 stage compressor

Motor driven

Dry gas sealing

Operating condition

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1st stage 2nd stage

Inlet volume (kg/hr) 88917 65525

Inlet pressure kg/cm2 0.39 4.07

Inlet temperature ,Deg C 54.4 43.9

Discharge Pressure

kg/cm2 g

4.07 14.7

Discharge temp ,deg C 135 121

SALIENT FEATURES: COKER GAS COMPRESSOR


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UNHEADING & HEADING DEVICE


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Fully Automated Part of a totally enclosed system

Low maintenance

Steam purged

Single button operation( remote )

Quick, safe unheading

Vendor Name : Delta Valve , Z&J

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UNHEADING & HEADING DEVICE

SALIENT FEATURES: COKE CUTTING SYSTEM


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COKE CUTTING PUMP

PUMP MANUFACTURE : RUHRPUMPEN , GERMANY

PUMP TYPE : CENTRIFUGAL MULTISTAGE

PUMP DISCHARGE PRESSURE : 351.50 KG/CM2 G

PUMP CAPACITY : 318.0 M3/HR

PUMP MOTOR RATING : 4.5 MW

COKE CUTTING TOOL

AUTO SHIFT CUTTING TOOL

BORING ,CUTTING

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MOVIE

Manual Cutting Tool

Manual Boring Tool

SALIENT FEATURES: COKE CUTTING SYSTEM

COKE HANDLING SYSTEM
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Purpose : Take the coke from Coke pit to coke yard

Chute

Bridge crane

Hopper

Conveyor Belt

Stock yard

Coke Handling system

1 Coke Production Capacity 4456 TPD.

2 operation modality 12 hr/d

3 CHS design 900 TPH

4 Storage Pile Size

Height- 7 metresWidth -25Mtr

Length 335 Mtrs

5 No 2

6 coke stack yard capacity 10 days




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Bridge crane

Chute

Hopper


COKER HANDLING SYSTEM


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COKER HANDLING SYSTEM

WHAT MAY GO WRONG?


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Any mal-operation in coke drum may lead to fire due to expose of hot vapor

to atmosphere

Any steam valve isolation may lead to chocking problem in the cokersection .

Improper operation of heater may lead the chocking in tube

Higher rate of cooling and heating may reduce the drum life .

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WHAT MAY GO WRONG?

UNIT SUMMARY


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COKE DRUM: large residence time to allow reaction to complete

HEATER

primary source for heat input to drive coking reaction

FRACTIONATORproduct recovery and separation

GAS CON SECTION

lighter product recovery

BLOWDOWN -air pollution control and recover hydrocarbon and water during cokecutting

DECOKING EQUIPMENT : for coke cutting

COKE HANDLING EQUIPMENT: transfer the coke from unit to coke pile area

UNIT SUMMARY


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Documents

An Overview of DCU