DCU overview.pdf
- 1. A Sunrise Project for A Sunshine Future Paradip Refinery OVERVIEW ON DELAYED COKER UNIT Prepared by Production-CG Team Faculty Mujeeb Ahmad SPNE-CG
- 2. A Sunrise Project for A Sunshine Future Paradip Refinery 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). 2 PURPOSE
- 3. A Sunrise Project for A Sunshine Future Paradip Refinery 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 3 DELAYED COKER CHRONOLOGY
- 4. A Sunrise Project for A Sunshine Future Paradip Refinery Cracking reaction are carried out in coke drum over a delayed period of time rather than occurring completely in hot environment of furnace tube 4 WHY DELAYED ?
- 5. A Sunrise Project for A Sunshine Future Paradip Refinery 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 small molecules. • 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). 5 DELAYED COKER PROCESS
- 6. A Sunrise Project for A Sunshine Future Paradip Refinery 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. 6 DELAYED COKER PROCESS
- 7. A Sunrise Project for A Sunshine Future Paradip Refinery UNIT OVERVIEW UNIT CAPACITY : 4.1 MMTPA UNIT LICENSOR : F&W USA EPCM : TOYO INDIA FEED : VACUUM RESIDUE RECYCLE RATIO : 8 % 7
- 8. A Sunrise Project for A Sunshine Future Paradip Refinery 8 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
- 9. A Sunrise Project for A Sunshine Future Paradip Refinery 9 PRODUCT YIELD (Avg.) Wt% Distillation ( IBP/FBP ) o C Coker fuel gas 5.1 Coker LPG 3.9 Coker light naphtha 5.4 21/ 90 Coker heavy naphtha 4.6 90/140 Light coker gas oil (LCGO) 29.1 140/370 Heavy coker gas oil (HCGO) 18.7 370+ Coke 33.1 PRODUCTS PROPERTIES
- 10. A Sunrise Project for A Sunshine Future Paradip Refinery 10 HYDROCARBON SIDE FLOW Heat exchanger Fractionator column Heater Coke drum Fractionator Gas con section / side stripper Coke cutting tank coke drum Coke pit Maze Coke cutting tank WATER SIDE FLOW BOX FLOW CONCEPT FOR UNIT
- 11. A Sunrise Project for A Sunshine Future Paradip Refinery 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 11 PROCESS FLOW DIAGRAM
- 12. A Sunrise Project for A Sunshine Future Paradip Refinery Separate drum vapour ( cracked product and water ) in to different boiling product – HCGO – LCGO – Naphtha – Off gas Secondary purpose : Feed surge drum 12 FRACTIONATOR SECTION
- 13. A Sunrise Project for A Sunshine Future Paradip Refinery 13 PROCESS FLOW DIAGRAM
- 14. A Sunrise Project for A Sunshine Future Paradip Refinery – 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 . 14 COKE DRUM SECTION
- 15. A Sunrise Project for A Sunshine Future Paradip Refinery 15 PROCESS FLOW DIAGRAM
- 16. A Sunrise Project for A Sunshine Future Paradip Refinery 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 16 GAS CON SECTION
- 17. A Sunrise Project for A Sunshine Future Paradip Refinery 17 PROCESS FLOW DIAGRAM
- 18. A Sunrise Project for A Sunshine Future Paradip Refinery Sponge absorber and Amine scrubber – Recover the carried away C3,C4 and naphtha part in off gas from 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 18 GAS CON SECTION
- 19. A Sunrise Project for A Sunshine Future Paradip Refinery 19 PROCESS FLOW DIAGRAM
- 20. A Sunrise Project for A Sunshine Future Paradip Refinery Debutanizer and Naphtha Splitter – Separate the LPG from the heavy part in the Debutanizer section. – Light and Heavy naphtha are separated in Naphtha Splitter Section . 20 GAS CON SECTION
- 21. A Sunrise Project for A Sunshine Future Paradip Refinery 21 PROCESS FLOW DIAGRAM
- 22. A Sunrise Project for A Sunshine Future Paradip Refinery LPG amine contactor – Sweetening the LPG in amine contactor – Amine used as absorbent – Remove the H2S from LPG 22 GAS CON SECTION
- 23. A Sunrise Project for A Sunshine Future Paradip Refinery 23 PROCESS FLOW DIAGRAM
- 24. A Sunrise Project for A Sunshine Future Paradip Refinery 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 24 OPERATING VARIABLE
- 25. A Sunrise Project for A Sunshine Future Paradip Refinery 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 25 OPERATING VARIABLE
- 26. A Sunrise Project for A Sunshine Future Paradip Refinery 26 • NUMBER OF COKE DRUMS : 4 COKING CYCLE, HOURS: 24 RECYCLE : 8 LIQ. VOL.% COKE DRUM OVERHEAD TEMPERATURE :441 C DESIGN TEMPERATURE :474 DEG C Coke Drum ID :9.8M Coke Drum Height : 45 M (F/F) SALIENT FEATURES: COKE DRUM
- 27. A Sunrise Project for A Sunshine Future Paradip Refinery 27 COKE DRUM – BLOCK DIAGRAM
- 28. A Sunrise Project for A Sunshine Future Paradip Refinery 28 Water quench Water drain Decoking operation Pre heat and pressure test Vapor Heating Coking Steam out COKE DRUM CYCLE Water quench Water drain Decoking operation Pre heat and pressure test Vapor Heating Coking Steam out
- 29. A Sunrise Project for A Sunshine Future Paradip Refinery 29 Operation Hrs Coking 24.0 Steam Out To Fractionator 1.0 Steam Out To Blow Down 1.0 Water Quenching And Filling 7.0 Water Drain 3.0 Decoking Operation 4.0 Re Head And Pressure Test 1.0 Vapour Heating 7.0 Idle Time 0.0 Total 48.0 cycle COKE DRUM CYCLE
- 30. A Sunrise Project for A Sunshine Future Paradip Refinery 30 MAIN FRACTIONATOR DETAILS
- 31. A Sunrise Project for A Sunshine Future Paradip Refinery 31 • 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 03 No 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
- 32. A Sunrise Project for A Sunshine Future Paradip Refinery • 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. 32 HEATER DECOKING OPERATION
- 33. A Sunrise Project for A Sunshine Future Paradip Refinery Design feature : – Centrifugal compressor – Manufacture : BHEL – 2 stage compressor – Motor driven – Dry gas sealing Operating condition 33 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
- 34. A Sunrise Project for A Sunshine Future Paradip Refinery 34 MANUAL OPERATION HEADING/UNHEADING MANUAL OPEATION UNSAFE UNHEADING & HEADING DEVICE
- 35. A Sunrise Project for A Sunshine Future Paradip Refinery – 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 35 UNHEADING & HEADING DEVICE
- 36. A Sunrise Project for A Sunshine Future Paradip Refinery 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 36 MOVIE Manual Cutting Tool Manual Boring Tool SALIENT FEATURES: COKE CUTTING SYSTEM
- 37. A Sunrise Project for A Sunshine Future Paradip Refinery 37 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 metres Width -25Mtr Length – 335 Mtrs 5 No 2 6 coke stack yard capacity 10 days COKE HANDLING SYSTEM
- 38. A Sunrise Project for A Sunshine Future Paradip Refinery 38 Bridge crane Chute Hopper COKE HANDLING SYSTEM
- 39. A Sunrise Project for A Sunshine Future Paradip Refinery 39 COKER HANDLING SYSTEM
- 40. A Sunrise Project for A Sunshine Future Paradip Refinery • 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 coker section . • Improper operation of heater may lead the chocking in tube • Higher rate of cooling and heating may reduce the drum life . 40 WHAT MAY GO WRONG?
- 41. A Sunrise Project for A Sunshine Future Paradip Refinery 41 COKE DRUM: large residence time to allow reaction to complete HEATER – primary source for heat input to drive coking reaction FRACTIONATOR – product recovery and separation GAS CON SECTION – lighter product recovery BLOWDOWN -air pollution control and recover hydrocarbon and water during coke cutting DECOKING EQUIPMENT : for coke cutting COKE HANDLING EQUIPMENT: transfer the coke from unit to coke pile area UNIT SUMMARY
- 42. A Sunrise Project for A Sunshine Future Paradip Refinery Thank you 42