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CONFIDENTIAL PROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY January, 2017
1
Performance Improvements in Delayed Coker of KNPC MAB Refinery
Faten Taqi Process Engineer KNPC-MAB Refinery 23rd -24th January, 2017.
MERTC (Middle East Refining Technology Conference)
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Outline
KNPC Refinery Role of Delayed Coker in MAB Refinery Delayed Coking Technology Delayed Coker in MAB Refinery Configuration MAB- Delayed Coker Unit History / Details MAB Coker Unit Performance Improvement o Yield Improvement oMechanical Improvement Advanced design features of new Coker unit in CFP. Future MAB Coker Revamp Modifications.
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KPC Subsidiaries
KPC 1934
1963
1957
1963 1981
1983
2002
1960
1980
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KNPC
KNPC, Refining wing of KPC with three refineries, five gas trains and local marketing network.
Products from KNPC Refineries are predominantly for export markets. The three refineries are being upgraded as total conversion refineries as part of Clean Fuels Project and will be consolidated as two operating refineries.
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KNPC Refinery
SHU Refinery
200 KBPSD
Planning & Local Marketing
MAB Refinery 270 KBPSD
MAA Refinery
466 KBPSD
Current Refining capacity : 936,000 BPD
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Role Of Delayed Coker In MAB Refinery Bottom of Barrel (700 °F+ fraction) in Kuwait Export Crude is nearly 45%-50%. Fuel oil demand is decreasing.
Bottoms upgrade is the best option to enhance Refinery profitability.
Residue desulfurizer/HCR/DCU is the process configuration selected for existing refinery and CFP project.
DCU in KNPC, produce Coke with low sulfur and low metals meeting the anode grade coke quality requirements. A very flexible process, able to operate with varied operating conditions and feeds.
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Coking kinetics are a function of: Feed quality (i.e. asphaltenes, con. carbon, sulfur, metals, etc…) Feed contaminates (i.e. sodium, iron oxides/sulfides, general inorganic solids) Operating Conditions : o High temperature and low pressure favor cracking. o High residence time favors the polymerization (cracking) reactions.
1500 Boiling Point, °F
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Delayed Coking Technology
Thermal Cracking Is Both Cracking And Polymerization
0 500 1000 2000 2500 3000
Coke Liquids
Vacuum Resid or other coker
feeds
polymerization cracking
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NAPH KERO Diesel
LPG Naphtha to Storage
KERO
Diesel
AR
MAA ARDR
AGO
Diesel Diesel to Storage
Diesel to DHTU
Diesel
Diesel
Kerosene to Storage
KERO to KHTU
Naphtha NAPH to NHTU /Merox
Naphtha
LSAR
LSAR
Slop Oil
VGO
TGO
VR
CGO to FCC / HCR
Coke Treated Naphtha to MoGas
Naphtha ATK
UCO
LPG
AR
ATK Merox NHTU
KHTU
Vacuum
ARDS
Crude Unit
Delayed Coker
Crude Unit
RCD Unibon
DHTU
Naph Merox
PCN
Delayed Coker in MAB Configuration
Crude Oil
HCR
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KNPC MAB Coker History / Details
Planned as part of MAB Refinery Modernization Project Commissioned in 1989 Two identical Delayed Coker Trains
Feed –Hydrotreated Vacuum Residue Original design : 30,000 BPD/train
Revamped in 1998 for higher capacity operation @ 40,000 BPD / Train Unit shutdown every year for Heater Decoking & Every Alternate year for M&I.
Coker margin : 12-20 $/BBL feed (during 2016).
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MAB – Coker Unit Capacity
Each train consists
• Two fired heaters • Fractionation • Four Coke Drums • Coke drum size is 26 ft ID and 80 ft flange to flange
Unit Design Capacity Current Capacity
COKER 2 x 30.0 KBPD @ 10-30% RR
2 x 40 KBPD @ 17-20% RR
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Poll question
How do you rate Coker unit in terms of its contribution to your company’s profitability, compared to Hydrocracker, FCCU, etc.,?
a) High b) Moderate c) Not significant
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Coker Unit Performance Improvement / Optimization
Yield Improvement
Mechanical Improvement
As part of Profit Improvement program, MAB has undertaken the following unit performance
improvement initiatives as follows:
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Coker Unit Performance Improvement / Optimization
Yield Improvement
Mechanical Improvement
As part of Profit Improvement program, MAB has undertaken the following unit performance
improvement initiatives as follows:
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Coker Unit Performance Improvement / Optimization
Yield Improvement
Reduction of RR
Shorter cycle time
Heater operation
Produce Coker Gas Oil
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Coker Unit Performance Improvement / Optimization
Yield Improvement
Reduction of RR
Shorter cycle time
Heater Operation
Produce Coker gas oil
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MAB – Coker unit performance improvement / optimization
Reduction of RR (from 30% to 17% ) for Optimizing liquid yields.
With this RR, Anode Coke quality could be maintained within required specification.
Increased feed capacity by 33% resulting in higher capacity utilization in upstream units and increased quantity of coke production.
Reduction of RR
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Coker Unit Performance Improvement / Optimization
Yield Improvement
Reduction of RR
Shorter cycle time
Heater Operation
Produce Coker gas oil
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MAB – Coker Unit Performance Improvement / Optimization
Shorter cycle time for increased feed.
Reduced from original design of 24 hours to 20 hrs.
As compared to that of typical 17 – 18 hours for anode coke producing units.
Coke drum Ullage : 22 ft Coke drum pressure : 30 -35 psig
Shorter cycle Time
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Coker Unit Performance Improvement / Optimization
Yield Improvement
Reduction of RR
Shorter cycle time
Heater Operation
Produce Coker gas oil
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Produce Coker gas oil suitable for conversion feedstock. Increased Coker Gas Oil production by 2% with acceptable quality to be processed further in FCC and Hydrocracker to improve value addition. FCC throughput maximized from 38 to 43 KBPD with additional CGO
Coker Gas Oil processing in Hydrocracker Up to 10% of feed slate.
Produce Coker gas oil
MAB – Coker Unit Performance Improvement / Optimization
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Coker Unit Performance Improvement / Optimization
Yield Improvement
Reduction of RR
Shorter cycle time
Heater Operation
Produce Coker gas oil
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Heater Operation vis-à-vis Green coke production
Unit Operating Design Inlet Temp oF 650 640 Coil Inlet P psig 284 390 Outlet Temp oF 930 940 Coil Outlet P psig 54.9 60 Flow BPD 5950 5700 Velocity Steam wt% 0.6 0.7- 1.0 Average Radiant Flux Btu/hr-ft2 9950 11570
Heater operation is limited by maximum tube metal temperature (1200 oF) for a run length of 1 year between consecutive decoking meeting Green coke quality
MAB – Coker Unit Performance Improvement / Optimization
Green Coke quality
HGI : 100 (max.)
VCM : 12 wt.% (max.)
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Feed distribution for flexibility
0.9-1 wt% S
1.3 wt% S
1.7 wt% S max 1.3 wt% S max
MAB RCD UNIBON
Bottoms
MAB ARDS Bottoms
Coker TR-1 (40 KBPD)
High S Coke (4 wt.%)
MAA ARDS Bottom
VRU TR-1 (78.4 KBPD)
VRU TR-2 (78.4 KBPD)
Coker TR-2 (40 KBPD)
Low S Coke (3 wt.%)
Feed Segregation for production of Low Sulfur Green Coke
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Coker Unit Performance Improvement / Optimization
Yield Improvement
Mechanical Improvement
As part of Profit Improvement program, MAB has undertaken the following unit performance
improvement initiatives as follows:
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Coker Unit Performance Improvement / Optimization
Mechanical Improvement
Heater run length
Coke drum life
Fractionator top trays modification
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Coker Unit Performance Improvement / Optimization
Mechanical Improvement
Heater run length
Coke drum life
Fractionator top trays modification
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MAB – Coker Unit Performance Improvement / Optimization Heater run length
The degree of cracking and polymerization depends on
feed quality (CCR, Asphaltenes mainly)
heater design.
Heater operation.
12 months run length between two consecutive heater decoking comparable to New Coker Heater design of 1 year with acceptable sponge Coke quality.
Decoking operation Steam / air decoking ~ 5 days. Mechanical pigging ~ 3 days.
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MAB – Coker Unit Heater Typical effect of Asphaltene and con.carbon content on Coker heater fouling. MAB Coker heater run length ~ 1 year for feed API of 13 and CCR of 13 and Heptane insolubles of 4
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Coker Unit Performance Improvement / Optimization
Mechanical Improvement
Heater run length
Coke drum life
Fractionator top trays modification
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MAB – Coker Unit Performance Improvement / Optimization Coke drum life
Original Coke drums are still in service.
Minor repairs on Coke drum cracks.
No bulges have been reported in MAB Coke drums.
No significant wall cracks
Typical drum life is less than 8000 cycles with a severe or difficult coke morphology
MAB Coke Drums have so far operated for ~ 9500 cycles.
Coke drum cooling and heating cycles by following best operating practices resulting in no major repair of coke drums or any replacement.
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Coker Unit Performance Improvement / Optimization
Mechanical Improvement
Heater run length
Coke drum life
Fractionator top trays modification
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Tray Modification
High pressure drop on the top section trays.
Coke fines carry over from Coke drum.
Chocking of fractionator Bottom strainer.
Tower top trays replacement.
Moving valve Fixed valve tray.
Improved pressure drop significantly.
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ABB Lummus licensed Delayed Coker unit with 37 KBPD capacity being installed as part of Clean Fuels Project.
RR will be 5 – 30%.
Co-processes FCC Light and Heavy Cycle Oils. Feed preheat system.
Online water wash for Fractionator top section trays.
Hydrocyclone for removal of coke fines from Water Reuse system.
Advanced design features of new Coker unit in CFP
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Automated Coke Drum Switch valves.
Automated heading/un heading for coke drum top & bottom covers.
Online Spalling/ Mechanical pigging for Coker heater decoking.
Automated valves interlocked with coke cutting water system.
KNPC will produce only one grade low Sulfur Coke (2.7 wt%) post CFP.
Advanced design features of new Coker unit in CFP (cont.)
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Objectives:
Sustained Unit Throughput at 40,000 BPSD.
Heater RR@ 15 to 20%.
Improved diesel quality production post CFP ( i.e. 90% recovery @ 654°F)
Address concerns related to Mechanical Integrity, Operability, Reliability, HSE and Technology up-gradation. Revamp Scope includes:
Modifications in Coker Fractionator, Gas oil stripper and Debutanizer. Addition of new water wash vessel, pumps, Hydro-cyclone in Water Reuse system and other Miscellaneous Equipment.
Future MAB Coker Revamp Modifications
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Summary
MAB Coker debottlenecking was done in-house successfully meeting qualities for all products including the coke.
There is large potential for improving existing Coker units operation and safety by implementing minor process modifications and adopting best practices, as was done in MAB Coker unit .
Automated Coke drum switching, drum head removal and cutting operations in new MAA Coker unit improve Coker units operations, reliability, mechanical availability and safety.
Current trend is to go for low recycle, low pressure Delayed Cokers for maximizing liquid yield.
Delayed Coking is still an attractive option for upgradation of bottom of the barrel.
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Thank You
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Ice breaker questions
Reduction of Recycle Ratio from 30% to 17% in debottlenecking. What was the impact on product yield?
Any issues with heater coil coking with increased feed rate and
heater duty?
