an overview of dcu
TRANSCRIPT
-
7/22/2019 An Overview of DCU
1/42
A Sunrise Project for A Sunshine FutureParadip Refinery
OVERVIEW
ON
DELAYED COKER UNIT
Prepared by
Production-CG Team
Faculty
Mujeeb Ahmad
SPNE-CG
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
2/42
A Sunrise Project for A Sunshine FutureParadip 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
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
3/42
A Sunrise Project for A Sunshine FutureParadip 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
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
4/42
-
7/22/2019 An Overview of DCU
5/42
A Sunrise Project for A Sunshine FutureParadip 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 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).
5
DELAYED COKER PROCESS
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
6/42
A Sunrise Project for A Sunshine FutureParadip 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
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
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 %
7
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
8/42A Sunrise Project for A Sunshine FutureParadip 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
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
9/42
-
7/22/2019 An Overview of DCU
10/42A Sunrise Project for A Sunshine FutureParadip Refinery 10
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
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
11/42A Sunrise Project for A Sunshine FutureParadip 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
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
12/42A Sunrise Project for A Sunshine FutureParadip Refinery
Separate drum vapour ( cracked product and water ) in to different
boiling product
HCGO
LCGO
Naphtha
Off gasSecondary purpose : Feed surge drum
12
FRACTIONATOR SECTION
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
13/42
A Sunrise Project for A Sunshine FutureParadip Refinery 13
PROCESS FLOW DIAGRAM
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
14/42
A Sunrise Project for A Sunshine FutureParadip 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
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
15/42
A Sunrise Project for A Sunshine FutureParadip Refinery 15
PROCESS FLOW DIAGRAM
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
16/42
A Sunrise Project for A Sunshine FutureParadip 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
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
17/42
A Sunrise Project for A Sunshine FutureParadip Refinery 17
PROCESS FLOW DIAGRAM
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
18/42
A Sunrise Project for A Sunshine FutureParadip Refinery
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
18
GAS CON SECTION
PROCESS FLOW DIAGRAM
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
19/42
A Sunrise Project for A Sunshine FutureParadip Refinery 19
PROCESS FLOW DIAGRAM
GAS CON SECTION
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
20/42
A Sunrise Project for A Sunshine FutureParadip Refinery
Debutanizer and Naphtha Splitter
Separate the LPG from the heavy part in theDebutanizer section.
Light and Heavy naphtha are separated in Naphtha
Splitter Section .
20
GAS CON SECTION
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
21/42
GAS CON SECTION
-
7/22/2019 An Overview of DCU
22/42
A Sunrise Project for A Sunshine FutureParadip Refinery
LPG amine contactor
Sweetening the LPG in amine contactor
Amine used as absorbent
Remove the H2S from LPG
22
GAS CON SECTION
PROCESS FLOW DIAGRAM
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
23/42
A Sunrise Project for A Sunshine FutureParadip Refinery 23
PROCESS FLOW DIAGRAM
OPERATING VARIABLE
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
24/42
A Sunrise Project for A Sunshine FutureParadip 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
OPERATING VARIABLE
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
25/42
A Sunrise Project for A Sunshine FutureParadip 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
SALIENT FEATURES: COKE DRUM
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
26/42
A Sunrise Project for A Sunshine FutureParadip Refinery 26
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
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
27/42
A Sunrise Project for A Sunshine FutureParadip Refinery 27
COKE DRUMBLOCK DIAGRAM
COKE DRUM CYCLE
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
28/42
A Sunrise Project for A Sunshine FutureParadip Refinery 28
Waterquench
Waterdrain
Decokingoperation
Pre heatand
pressuretest
VaporHeating
Coking
Steamout
COKE DRUM CYCLE
Waterquench
Water drain
Decokingoperation
Pre heat andpressure test
VaporHeating
Coking
Steam out
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
29/42
MAIN FRACTIONATOR DETAILS
-
7/22/2019 An Overview of DCU
30/42
A Sunrise Project for A Sunshine FutureParadip Refinery 30
MAIN FRACTIONATOR DETAILS
SALIENT FEATURES: HEATER
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
31/42
A Sunrise Project for A Sunshine FutureParadip 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 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
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
32/42
A Sunrise Project for A Sunshine FutureParadip 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
SALIENT FEATURES: COKER GAS COMPRESSOR
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
33/42
A Sunrise Project for A Sunshine FutureParadip 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
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
34/42
UNHEADING & HEADING DEVICE
-
7/22/2019 An Overview of DCU
35/42
A Sunrise Project for A Sunshine FutureParadip 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
SALIENT FEATURES: COKE CUTTING SYSTEM
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
36/42
A Sunrise Project for A Sunshine FutureParadip 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
COKE HANDLING SYSTEM
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://localhost/var/www/apps/conversion/tmp/scratch_7/coke%20cutting%20movie.VOBhttp://localhost/var/www/apps/conversion/tmp/scratch_7/coke%20cutting%20movie.VOBhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
37/42
A Sunrise Project for A Sunshine FutureParadip 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 metresWidth -25Mtr
Length 335 Mtrs
5 No 2
6 coke stack yard capacity 10 days
COKE HANDLING SYSTEM
COKE HANDLING SYSTEM
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
38/42
A Sunrise Project for A Sunshine FutureParadip Refinery 38
Bridge crane
Chute
Hopper
COKE HANDLING SYSTEM
COKER HANDLING SYSTEM
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
39/42
A Sunrise Project for A Sunshine FutureParadip Refinery 39
COKER HANDLING SYSTEM
WHAT MAY GO WRONG?
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
40/42
A Sunrise Project for A Sunshine FutureParadip 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 cokersection .
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?
UNIT SUMMARY
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
41/42
A Sunrise Project for A Sunshine FutureParadip Refinery 41
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
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.comhttp://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com -
7/22/2019 An Overview of DCU
42/42
hank you
http://intranet/ctrlCounterUpdate.asp?uCtrlCode=1001&uCtrlURL=http://www.iocl.com