Detail description about Delayed Coker Unit of the refinery.

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

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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).
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PURPOSE

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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
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DELAYED COKER CHRONOLOGY

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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
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WHY DELAYED ?

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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).
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DELAYED COKER PROCESS

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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.
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DELAYED COKER PROCESS

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Paradip 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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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

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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

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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
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PROCESS FLOW DIAGRAM

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Paradip Refinery
Separate drum vapour ( cracked product and water ) in to different
boiling product
– HCGO
– LCGO
– Naphtha
– Off gas
Secondary purpose : Feed surge drum
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FRACTIONATOR SECTION

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Paradip Refinery 13
PROCESS FLOW DIAGRAM

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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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Paradip Refinery 15
PROCESS FLOW DIAGRAM

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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
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GAS CON SECTION

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PROCESS FLOW DIAGRAM

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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
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GAS CON SECTION

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PROCESS FLOW DIAGRAM

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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 .
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GAS CON SECTION

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Paradip Refinery 21
PROCESS FLOW DIAGRAM

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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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Paradip Refinery 23
PROCESS FLOW DIAGRAM

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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
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OPERATING VARIABLE

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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
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OPERATING VARIABLE

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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

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Paradip Refinery 27
COKE DRUM – BLOCK DIAGRAM

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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

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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

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Paradip Refinery 30
MAIN FRACTIONATOR DETAILS

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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 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

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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

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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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MANUAL OPERATION
HEADING/UNHEADING MANUAL
OPEATION
UNSAFE
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

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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
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MOVIE
Manual Cutting Tool
Manual Boring Tool
SALIENT FEATURES: COKE CUTTING 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 metres
Width -25Mtr
Length – 335 Mtrs
5 No 2
6 coke stack yard capacity 10 days
COKE HANDLING SYSTEM

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Bridge crane
Chute
Hopper
COKE HANDLING SYSTEM

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Paradip Refinery 39
COKER HANDLING SYSTEM

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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 .
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WHAT MAY GO WRONG?

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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

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Paradip Refinery
Thank you
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