The document provides an overview of a delayed coker unit that will be installed at a refinery. It describes the purpose of delayed coking as upgrading heavy petroleum residue into valuable distillates and petroleum coke. Key aspects of the delayed coker process, equipment and operating parameters are outlined, including the fractionator, coke drums, gas conditioning systems, heaters and product yields.
Process furnaces are widely used in petroleum refineries and petrochemical plants to generate heat through the combustion of fuels. This heat is transferred to process fluids inside coil tubes and can range from a few thousand to a few million MW. Common applications include crude distillation units and reaction heaters containing catalysts. Furnaces come in various designs like vertical cylindrical, box type, or cabin furnaces and must maximize heat transfer while minimizing emissions and fuel consumption. Burners, refractory, insulation and controls are important components that require consideration for optimal furnace performance.
This document discusses three case studies related to circulating fluidized bed combustion (CFBC) boilers:
1) A case study of a CFBC boiler co-firing rice husk and coal that developed cracks in the cyclone outlet cone.
2) The importance of loop seal air nozzle arrangement in transferring ash particles between the cyclone and furnace and preventing gas bypass.
3) A case study of frequent failures of panel superheater tubes in a CFBC boiler due to insufficient anchoring of refractory bricks and erosion of tubes from the bottom. Modifications to the anchoring arrangement and use of a phosphate-bonded refractory were recommended.
Fired Heaters-Key to Efficient Operation of Refineries and PetrochemicalsAshutosh Garg
Fired Heaters are a critical to successful operation of refineries and petrochemical plants. They are a major energy consumer as well as a major source of air pollution. There are also concerns about the run length of the heaters as well safety issues.
Circulating fluidized bed boiler (cfb boiler) how does it work and its principlePichai Chaibamrung
This document provides an overview of circulating fluidized bed boilers. It begins with biographical information about the author Pichai Chaibamrung, followed by an outline of the content to be covered. The content sections include introductions to circulating fluidized bed design, hydrodynamics, combustion, heat transfer, and cyclone separators. Key points are made about fluidization regimes, characteristics of fast fluidized beds, stages of combustion, and factors impacting combustion efficiency.
The document discusses different types of reformers used in ammonia plants, including pre-reformers, primary reformers, and secondary reformers. It provides details on the process, internals, catalysts, and operating conditions of each reformer type. Primary reformers are described as duplex reforming furnaces containing nickel catalyst-loaded tubes that are fired by natural gas burners to drive the endothermic reforming reactions. Key variables that impact the reforming reactions such as temperature, pressure, steam-to-carbon ratio, and catalyst activity are also summarized.
.Coker heaters are one of the most critical heaters in the refineries. The feed is heated to a very high temperature. Run length is one of the important factors for coker heaters. We have worked recently worked on a conventional Coker heater and implemented several improvements while retubing the radiant section.
Process furnaces are widely used in petroleum refineries and petrochemical plants to generate heat through the combustion of fuels. This heat is transferred to process fluids inside coil tubes and can range from a few thousand to a few million MW. Common applications include crude distillation units and reaction heaters containing catalysts. Furnaces come in various designs like vertical cylindrical, box type, or cabin furnaces and must maximize heat transfer while minimizing emissions and fuel consumption. Burners, refractory, insulation and controls are important components that require consideration for optimal furnace performance.
This document discusses three case studies related to circulating fluidized bed combustion (CFBC) boilers:
1) A case study of a CFBC boiler co-firing rice husk and coal that developed cracks in the cyclone outlet cone.
2) The importance of loop seal air nozzle arrangement in transferring ash particles between the cyclone and furnace and preventing gas bypass.
3) A case study of frequent failures of panel superheater tubes in a CFBC boiler due to insufficient anchoring of refractory bricks and erosion of tubes from the bottom. Modifications to the anchoring arrangement and use of a phosphate-bonded refractory were recommended.
Fired Heaters-Key to Efficient Operation of Refineries and PetrochemicalsAshutosh Garg
Fired Heaters are a critical to successful operation of refineries and petrochemical plants. They are a major energy consumer as well as a major source of air pollution. There are also concerns about the run length of the heaters as well safety issues.
Circulating fluidized bed boiler (cfb boiler) how does it work and its principlePichai Chaibamrung
This document provides an overview of circulating fluidized bed boilers. It begins with biographical information about the author Pichai Chaibamrung, followed by an outline of the content to be covered. The content sections include introductions to circulating fluidized bed design, hydrodynamics, combustion, heat transfer, and cyclone separators. Key points are made about fluidization regimes, characteristics of fast fluidized beds, stages of combustion, and factors impacting combustion efficiency.
The document discusses different types of reformers used in ammonia plants, including pre-reformers, primary reformers, and secondary reformers. It provides details on the process, internals, catalysts, and operating conditions of each reformer type. Primary reformers are described as duplex reforming furnaces containing nickel catalyst-loaded tubes that are fired by natural gas burners to drive the endothermic reforming reactions. Key variables that impact the reforming reactions such as temperature, pressure, steam-to-carbon ratio, and catalyst activity are also summarized.
.Coker heaters are one of the most critical heaters in the refineries. The feed is heated to a very high temperature. Run length is one of the important factors for coker heaters. We have worked recently worked on a conventional Coker heater and implemented several improvements while retubing the radiant section.
1) GBHE has extensive experience designing and evaluating methane steam reformer tubes and can perform detailed simulations and modeling to optimize reformer performance during retube evaluations.
2) The methodology involves understanding current operations, simulating the existing reformer, selecting improved tube materials and catalysts, and modeling stress levels and temperatures to determine maximum operating conditions.
3) Case studies demonstrate how optimizing tubes and catalyst can increase production by 3-15% while reducing pressure drop, temperatures, and methane slip.
The document discusses different types of boilers, including fire tube and water tube boilers. It also describes the basic model of ignition and flame propagation in boilers. Key points covered include the conditions needed to form a stable flame during coal combustion, and the processes of nucleate/convective boiling and film boiling that occur as heat is transferred to water in boiler walls. Departure from nucleate boiling is explained, along with how it can be avoided by increasing pressure, fluid flow rate, or using a lower temperature bulk fluid.
A full package presentation about Hydrogen Production Unit including an overview about steam reformers, combustion reaction, moods of heat transfer, draft systems, reactors, chemicals used in HPU, and types of compressors. Moreover, it describes the process description, process variables, and opens the way for some possible improvements which can be implemented to develop the unit performance.
The document provides information on the operation of a crude and vacuum distillation unit. It separates crude oil into different products based on boiling point differences and prepares the feed for secondary processing units. Key features include two kerosene draw-off flexibilities to meet changing specifications and a heavy gas oil draw off to minimize load on the vacuum heater and vacuum column. The crude distillation unit processes various crude oil cases to produce products like fuel gas, LPG, naphtha, kerosene, light gas oil, heavy gas oil, and reduced crude oil.
Burner Design, Operation and Maintenance on Ammonia PlantsGerard B. Hawkins
The document discusses burner design, operation, and maintenance on ammonia plants. It covers reformer burner types and designs, including premix and staged burners. It also addresses combustion characteristics like excess air and fuel viscosity effects. Maintenance best practices like checking burner pressures and atomizing steam temperatures are emphasized. Low NOx equipment uses techniques like staged air, fuel, and flue gas recirculation to reduce emissions. Good combustion requires attention to design, operation, maintenance, and partnership among related roles.
Study and Analysis of Tube Failure in Water Tube boilerArunMalanthara
This report explain about Study and Analysis of Tube failure in water tube boiler. It tells about safe conditions to prevent accident. Different Mathematical modelling, Design, Thermal analysis, Structural analysis and Pressure analysis have been carried out to get optimum safe conditions.
Amine Gas Treating Unit - Best Practices - Troubleshooting Guide Gerard B. Hawkins
Amine Gas Treating Unit Best Practices - Troubleshooting Guide for H2S/CO2 Amine Systems
Contents
Process Capabilities for gas treating process
Typical Amine Treating
Typical Amine System Improvements
Primary Equipment Overview
Inlet Gas Knockout
Absorber
Three Phase Flash Tank
Lean/Rich Heat Exchanger
Regenerator
Filtration
Amine Reclaimer
Operating Difficulties Overview
Foaming
Failure to Meet Gas Specification
Solvent Losses
Corrosion
Typical Amine System Improvements
Degradation of Amines and Alkanolamines during Sour Gas Treating
APPENDIX
Best Practices - Troubleshooting Guide
This document discusses the control and instrumentation system for the Jaypee Bina Thermal Power Plant's 2x250 MW furnace safeguard and supervisory system (FSSS). The FSSS is designed to safely start up and shut down the boiler and prevent operator errors. It monitors the burner block assembly and controls the furnace purge sequence, oil gun operation in pair or elevation mode, and high energy arc igniter system to safely initiate combustion. The FSSS ensures maximum safety and efficiency during plant operation.
Thermal Power Plant Simulator Hands-on MalfunctionsManohar Tatwawadi
The presentation describes some of the malfunctions in a Power Plant. Many more can be simulated and operators told to handle the situations in the simulator. The trippings of Generator, turbine, boilers and all auxiliaries can be simulated to get hands on practice on the simulator before operating the actual turbogenerator and boiler associated equipment.
This document provides information about boilers, including their definition, principle of operation, types, parts, and auxiliaries. It defines a boiler as a closed vessel that converts water into steam using heat energy from fuel. The key points are:
- Boilers work by transferring heat from hot flue gases to water via convection, converting the water to high-pressure steam.
- Boilers are classified based on whether tubes contain water or fire (fire tube or water tube), number of tubes, furnace position, shell axis orientation, and circulation method.
- Boiler parts include mountings like the water level indicator, pressure gauge, and safety valve, as well as accessories like the feed pump
The slides describe the factors that affect the performance of AFBC boilers and how to improve the performance of AFBC boilers. These type of boilers are mainly used in the below 100 MW power boilers.
This document discusses the electrical systems and procedures for a power plant during a failure of the 220V DC system. It outlines how various components like breakers, protections, and trips will be affected and need to be operated manually. It describes the actions to take like tripping the turbine, pulverizers, and fans manually and transferring the unit to another bus. It also discusses the healthiness checks for the DC system.
The document provides an overview of petroleum refining, covering topics like the growth and development of the refining industry in India, characteristics of crude oil and its significance, specifications of petroleum products and related tests, integrated refinery and petrochemical plants, future refining scenarios, and advances in petroleum refining. It describes India's refining capacity increasing from 6 MMTPA in 1962 to over 100 MMTPA currently through establishing numerous public and private sector refineries. The module aims to provide insights into various facets of petroleum refining and processes used in refineries to produce finished products meeting stringent specifications.
Fired heaters are used to provide heat through the combustion of fuel. They involve combustion fundamentals like the reaction of methane and oxygen. Fired heaters have a furnace design and use draft systems and air preheaters. They employ different types of burners like those used in hot oil heaters and regeneration gas heaters. The start-up process involves inspection, purging, lighting pilots and burners, and adjusting temperatures and flows. Operation requires monitoring air adjustment, temperatures, and addressing potential issues like deposits, failures, or flame-outs. Control strategies manage variables like temperatures, fuels, and flows.
Heaters are used in refineries to raise the temperature of process fluids. There are different types of heaters classified by design and firing method. Key components include tubes, burners, and sections for convection and radiation. Proper draft, excess air, and complete combustion are important for safe and efficient operation. Regular checks help ensure heaters are functioning properly and identify any issues.
The document discusses the key benefits and evolution of circulating fluidized bed combustion (CFBC) boiler technology. It provides details on the design and operation of CFBC boilers, including their furnace design, U-beam particle separator system, convection pass, and improved performance from two-stage particle separation. CFBC boilers offer benefits like high combustion efficiency, fuel flexibility, compact design, low emissions, and reduced maintenance costs compared to earlier boiler technologies.
The document discusses excess air and heat distribution in boilers. It explains that excess air above the theoretical minimum is needed for complete combustion due to imperfect mixing of fuel and air. Typical excess air values range from 5-60% depending on the fuel and furnace type. Heat distribution systems discussed include steam radiators, which use steam piped through the home, and hot water radiators, which can be zoned to improve efficiency. Regular maintenance of radiators includes bleeding air and cleaning/replacing steam traps and air vents.
This document provides an overview of the oil refinery process. It discusses the three main stages of crude oil refining: separation, treating, and conversion. It describes the distillation unit and catalytic reforming unit processes. The conclusion summarizes that the document discussed crude oil and refineries, largest importers/exporters of crude oil, distillation, treatment units, and catalytic reforming.
This document provides information on fired heaters, including methods of heat transfer, combustion, types of fired heaters, furnace parts, problems that can occur, and introduces several heaters at a refinery. It discusses the three main methods of heat transfer as conduction, convection, and radiation. Fired heaters use combustion of fuel to generate heat that is transferred to process fluids through tubes. Box and cylindrical designs are described. Key furnace parts and issues like overfiring, vibration, and inefficiency are outlined. Example heaters at the refinery include crude, vacuum, visbreaker, and hydrotreating unit heaters.
Final internship refinery Presentation (1).pptxAdisanu
This document provides an overview of Indian Oil Corporation and its Panipat Refinery in India. Some key points:
- Indian Oil is India's largest oil and gas company, operating 11 refineries with a total capacity of 80.7 MMTPA.
- The Panipat Refinery is one of Indian Oil's refineries. It has a capacity of 15 MMTPA and processes various grades of crude oil.
- The refinery houses several secondary processing units like catalytic reforming units, hydrocracking units, and sulfur recovery units to upgrade the quality of products.
The document provides an overview of AEP's Mountaineer Commercial Scale Carbon Capture & Storage (CCS II) Project Phase I and lessons learned. Key points include: (1) The project aimed to demonstrate Alstom's Chilled Ammonia Process CO2 capture technology and deep saline CO2 storage at commercial scale. (2) Technical challenges included integrating the capture system with the existing power plant and variable coal supply, and managing water from the capture process. (3) Lessons involved selection of anhydrous ammonia as the reagent, exhaust stack options, water management approaches, steam sourcing for the capture system, and using variable speed pumping for CO2 compression and injection.
1) GBHE has extensive experience designing and evaluating methane steam reformer tubes and can perform detailed simulations and modeling to optimize reformer performance during retube evaluations.
2) The methodology involves understanding current operations, simulating the existing reformer, selecting improved tube materials and catalysts, and modeling stress levels and temperatures to determine maximum operating conditions.
3) Case studies demonstrate how optimizing tubes and catalyst can increase production by 3-15% while reducing pressure drop, temperatures, and methane slip.
The document discusses different types of boilers, including fire tube and water tube boilers. It also describes the basic model of ignition and flame propagation in boilers. Key points covered include the conditions needed to form a stable flame during coal combustion, and the processes of nucleate/convective boiling and film boiling that occur as heat is transferred to water in boiler walls. Departure from nucleate boiling is explained, along with how it can be avoided by increasing pressure, fluid flow rate, or using a lower temperature bulk fluid.
A full package presentation about Hydrogen Production Unit including an overview about steam reformers, combustion reaction, moods of heat transfer, draft systems, reactors, chemicals used in HPU, and types of compressors. Moreover, it describes the process description, process variables, and opens the way for some possible improvements which can be implemented to develop the unit performance.
The document provides information on the operation of a crude and vacuum distillation unit. It separates crude oil into different products based on boiling point differences and prepares the feed for secondary processing units. Key features include two kerosene draw-off flexibilities to meet changing specifications and a heavy gas oil draw off to minimize load on the vacuum heater and vacuum column. The crude distillation unit processes various crude oil cases to produce products like fuel gas, LPG, naphtha, kerosene, light gas oil, heavy gas oil, and reduced crude oil.
Burner Design, Operation and Maintenance on Ammonia PlantsGerard B. Hawkins
The document discusses burner design, operation, and maintenance on ammonia plants. It covers reformer burner types and designs, including premix and staged burners. It also addresses combustion characteristics like excess air and fuel viscosity effects. Maintenance best practices like checking burner pressures and atomizing steam temperatures are emphasized. Low NOx equipment uses techniques like staged air, fuel, and flue gas recirculation to reduce emissions. Good combustion requires attention to design, operation, maintenance, and partnership among related roles.
Study and Analysis of Tube Failure in Water Tube boilerArunMalanthara
This report explain about Study and Analysis of Tube failure in water tube boiler. It tells about safe conditions to prevent accident. Different Mathematical modelling, Design, Thermal analysis, Structural analysis and Pressure analysis have been carried out to get optimum safe conditions.
Amine Gas Treating Unit - Best Practices - Troubleshooting Guide Gerard B. Hawkins
Amine Gas Treating Unit Best Practices - Troubleshooting Guide for H2S/CO2 Amine Systems
Contents
Process Capabilities for gas treating process
Typical Amine Treating
Typical Amine System Improvements
Primary Equipment Overview
Inlet Gas Knockout
Absorber
Three Phase Flash Tank
Lean/Rich Heat Exchanger
Regenerator
Filtration
Amine Reclaimer
Operating Difficulties Overview
Foaming
Failure to Meet Gas Specification
Solvent Losses
Corrosion
Typical Amine System Improvements
Degradation of Amines and Alkanolamines during Sour Gas Treating
APPENDIX
Best Practices - Troubleshooting Guide
This document discusses the control and instrumentation system for the Jaypee Bina Thermal Power Plant's 2x250 MW furnace safeguard and supervisory system (FSSS). The FSSS is designed to safely start up and shut down the boiler and prevent operator errors. It monitors the burner block assembly and controls the furnace purge sequence, oil gun operation in pair or elevation mode, and high energy arc igniter system to safely initiate combustion. The FSSS ensures maximum safety and efficiency during plant operation.
Thermal Power Plant Simulator Hands-on MalfunctionsManohar Tatwawadi
The presentation describes some of the malfunctions in a Power Plant. Many more can be simulated and operators told to handle the situations in the simulator. The trippings of Generator, turbine, boilers and all auxiliaries can be simulated to get hands on practice on the simulator before operating the actual turbogenerator and boiler associated equipment.
This document provides information about boilers, including their definition, principle of operation, types, parts, and auxiliaries. It defines a boiler as a closed vessel that converts water into steam using heat energy from fuel. The key points are:
- Boilers work by transferring heat from hot flue gases to water via convection, converting the water to high-pressure steam.
- Boilers are classified based on whether tubes contain water or fire (fire tube or water tube), number of tubes, furnace position, shell axis orientation, and circulation method.
- Boiler parts include mountings like the water level indicator, pressure gauge, and safety valve, as well as accessories like the feed pump
The slides describe the factors that affect the performance of AFBC boilers and how to improve the performance of AFBC boilers. These type of boilers are mainly used in the below 100 MW power boilers.
This document discusses the electrical systems and procedures for a power plant during a failure of the 220V DC system. It outlines how various components like breakers, protections, and trips will be affected and need to be operated manually. It describes the actions to take like tripping the turbine, pulverizers, and fans manually and transferring the unit to another bus. It also discusses the healthiness checks for the DC system.
The document provides an overview of petroleum refining, covering topics like the growth and development of the refining industry in India, characteristics of crude oil and its significance, specifications of petroleum products and related tests, integrated refinery and petrochemical plants, future refining scenarios, and advances in petroleum refining. It describes India's refining capacity increasing from 6 MMTPA in 1962 to over 100 MMTPA currently through establishing numerous public and private sector refineries. The module aims to provide insights into various facets of petroleum refining and processes used in refineries to produce finished products meeting stringent specifications.
Fired heaters are used to provide heat through the combustion of fuel. They involve combustion fundamentals like the reaction of methane and oxygen. Fired heaters have a furnace design and use draft systems and air preheaters. They employ different types of burners like those used in hot oil heaters and regeneration gas heaters. The start-up process involves inspection, purging, lighting pilots and burners, and adjusting temperatures and flows. Operation requires monitoring air adjustment, temperatures, and addressing potential issues like deposits, failures, or flame-outs. Control strategies manage variables like temperatures, fuels, and flows.
Heaters are used in refineries to raise the temperature of process fluids. There are different types of heaters classified by design and firing method. Key components include tubes, burners, and sections for convection and radiation. Proper draft, excess air, and complete combustion are important for safe and efficient operation. Regular checks help ensure heaters are functioning properly and identify any issues.
The document discusses the key benefits and evolution of circulating fluidized bed combustion (CFBC) boiler technology. It provides details on the design and operation of CFBC boilers, including their furnace design, U-beam particle separator system, convection pass, and improved performance from two-stage particle separation. CFBC boilers offer benefits like high combustion efficiency, fuel flexibility, compact design, low emissions, and reduced maintenance costs compared to earlier boiler technologies.
The document discusses excess air and heat distribution in boilers. It explains that excess air above the theoretical minimum is needed for complete combustion due to imperfect mixing of fuel and air. Typical excess air values range from 5-60% depending on the fuel and furnace type. Heat distribution systems discussed include steam radiators, which use steam piped through the home, and hot water radiators, which can be zoned to improve efficiency. Regular maintenance of radiators includes bleeding air and cleaning/replacing steam traps and air vents.
This document provides an overview of the oil refinery process. It discusses the three main stages of crude oil refining: separation, treating, and conversion. It describes the distillation unit and catalytic reforming unit processes. The conclusion summarizes that the document discussed crude oil and refineries, largest importers/exporters of crude oil, distillation, treatment units, and catalytic reforming.
This document provides information on fired heaters, including methods of heat transfer, combustion, types of fired heaters, furnace parts, problems that can occur, and introduces several heaters at a refinery. It discusses the three main methods of heat transfer as conduction, convection, and radiation. Fired heaters use combustion of fuel to generate heat that is transferred to process fluids through tubes. Box and cylindrical designs are described. Key furnace parts and issues like overfiring, vibration, and inefficiency are outlined. Example heaters at the refinery include crude, vacuum, visbreaker, and hydrotreating unit heaters.
Final internship refinery Presentation (1).pptxAdisanu
This document provides an overview of Indian Oil Corporation and its Panipat Refinery in India. Some key points:
- Indian Oil is India's largest oil and gas company, operating 11 refineries with a total capacity of 80.7 MMTPA.
- The Panipat Refinery is one of Indian Oil's refineries. It has a capacity of 15 MMTPA and processes various grades of crude oil.
- The refinery houses several secondary processing units like catalytic reforming units, hydrocracking units, and sulfur recovery units to upgrade the quality of products.
The document provides an overview of AEP's Mountaineer Commercial Scale Carbon Capture & Storage (CCS II) Project Phase I and lessons learned. Key points include: (1) The project aimed to demonstrate Alstom's Chilled Ammonia Process CO2 capture technology and deep saline CO2 storage at commercial scale. (2) Technical challenges included integrating the capture system with the existing power plant and variable coal supply, and managing water from the capture process. (3) Lessons involved selection of anhydrous ammonia as the reagent, exhaust stack options, water management approaches, steam sourcing for the capture system, and using variable speed pumping for CO2 compression and injection.
This document provides an overview of oil refinery processes. It begins with some historical events in oil exploration and refining. It then discusses what petroleum is composed of and provides a generic schematic of the major refinery unit operations. The document proceeds to describe the key crude distillation, vacuum distillation, coking, fluid catalytic cracking, and alkylation unit processes in more detail, including process objectives, techniques, steps, schematics and typical product yields.
This document provides an overview of oil refinery processes, beginning with a brief history and description of petroleum. It then summarizes key unit operations including crude distillation, vacuum distillation, fluid/delayed coking, fluid catalytic cracking, hydrofluoroalkylation, hydrotreating, hydrocracking, and catalytic reforming. Process diagrams and typical yields are included for each unit operation.
This document provides a brief overview of oil refinery processes, including historical events and descriptions of key unit operations like crude distillation, vacuum distillation, fluid/delayed coking, fluid catalytic cracking, alkylation, and hydrotreating. Process schematics and typical yields are shown for each unit operation.
The document presents details of a proposed 32 MW captive power plant project in an existing ferro alloy unit. The key points are:
1) The existing ferro alloy plant stopped operations 10 years ago due to unreliable power supply and the proposed CPP will generate 32 MW of power for the plant's operations.
2) The CPP will use Indonesian coal as fuel in a 140 TPH fluidized bed boiler to generate power. It will require 418 m3/day of water and generate 245 m3/day of effluents.
3) An electrostatic precipitator and stack of adequate height will be installed to control air pollutants from the boiler and ensure they meet standards after dispersion.
The document provides information about the Saba Power Plant located in Shaikhupura, Pakistan. It details that the plant has a total generation capacity of 134 MW from its steam turbine generator and 4x0.9 MW from natural gas engines. It also lists the major components of the plant including the 413 ton main boiler, 134 MW steam turbine, 170 MVA generator, cooling tower, and demineralization plant. The document includes specifications, diagrams, and details about the various systems and processes within the power plant.
UlSD Hydrotreater Challenges Overcome to Improve on Stream Factor - MEPEC 2013Alpesh Gurjar
The presentation outlines the experience in overcoming the challenges that faced and the lessons learned, to achieve safe, reliable and profitable Diesel Hydrotreater (2HDU) operation, while meeting all throughput and yield targets and product specifications. The 2HDU success over the 6½ years clearly demonstrated the importance and value of in-house process engineering expertise and experience, while working as a part of cross-functional team.
Nilikesh masyadas completed a month-long internship at Hindustan Zinc Limited in Debari, Udaipur from May 21 to June 19, 2018 under the guidance of PC Garg. As part of the internship, Nilikesh mapped mercury levels in the roasting process and improved mercury collection in the mercury removal tower section from 50% to 90%. Nilikesh analyzed mercury levels in raw materials and calcine, finding the highest mercury contents in the Rampura Agucha and Rajpura Dariba mines. The internship provided valuable experience in understanding the roasting process and smelting of zinc from zinc ore.
Presentation on Accretion removal in BF2 at JSW Salem.pptAshoksinghDhurua
The document describes the accretion buildup in Blast Furnace 2 of JSW Salem Works and the efforts taken to remove it. Key points:
- Visual inspections in December 2009 and January 2010 revealed a large accretion formation of 30-35 cubic meters high in zinc and alkalis that was blocking 25-30% of the furnace area.
- Various options were considered to remove the accretion, and the Cardox method using liquid carbon dioxide activation was selected.
- In February 2010, the accretion was successfully dislodged from the furnace in 3 stages of Cardox activation over 17 hours.
- Furnace performance parameters like blast volume, fuel rate and productivity improved after the removal of the accretion
The document provides information about Indian Oil Corporation and its Panipat Refinery in India. It discusses the history and facilities of Indian Oil, including its 11 refineries with a total refining capacity of 80.7 MMTPA. It then focuses on details about the Panipat Refinery, including its current capacity of 15 MMTPA and plans to increase capacity to 25 MMTPA. It describes several key units at the Panipat Refinery, such as the atmospheric and vacuum distillation unit, hydrocracking unit, diesel hydrotreating unit, and hydrogen generation unit. It also discusses Indian Oil's pipelines, crude oil imports, storage tanks, and product application development center.
Webinar: 'Applying carbon capture and storage to a Chinese steel plant.' Feas...Global CCS Institute
The document summarizes a feasibility study conducted by Toshiba Corporation on applying carbon capture and storage (CCS) technology to a steel plant in China. It discusses two potential cases for installing a CCS facility at Shougang Jingtang Steel Works that would capture 300 tons of CO2 per day. Case 1 involves capturing CO2 from the plant's lime kiln flue gas, while Case 2 focuses on capturing CO2 from hot blast stove flue gas. Both cases evaluate using hot blast stove flue gas as a heat source for CO2 recovery. The presentation provides details on plant layout, economics evaluation, and outstanding issues for further investigation.
'Applying carbon capture and storage to a Chinese steel plant.' Feasibility s...Global CCS Institute
The Global CCS Institute has recently published a feasibility study report on applying carbon capture and storage (CCS) to a steel plant in China. Toshiba was commissioned to conduct the study in collaboration with Chinese corporations.
The feasibility suggests that carbon capture in Chinese steel plants is a cost effective means of reducing carbon emissions compared with similar plants around the world. In this webinar, Toshiba presented on the major findings of this feasibility study.
The document discusses Stamicarbon's Urea 2000plus technology. It introduces the pool condenser concept, which reduced investment costs by combining equipment and simplifying the design. The pool reactor was a subsequent development that combined two process steps into one vessel, further lowering costs. Operational experience with pool condenser and reactor plants has been positive, with reliable performance and reduced maintenance needs. The technology offers significant advantages in capital cost, energy efficiency, and plant flexibility.
What i learnt as an intern by Ihsan Wassan Ihsan Wassan
The document summarizes the key learnings from an internship at Pakistan Steel. It provides an overview of the company and its various production units, including the coke oven by-product plant, sintering plant, iron making department, and steel making plant. It describes the processes within the coke oven batteries, coke quenching plant, and by-product section. It also discusses the roles and responsibilities of the Directorate of Industrial Liaison in facilitating internship opportunities between universities and industries.
This document presents a case study and methods to re-establish a condemned boiler. It includes an introduction, contents listing, acknowledgements, abstract on the Hindustan Storage & Distribution Company where the boiler is located, specifications and diagrams of the boiler, scope of dismantling and repair work, results of dismantling, scope of work after renovation including flue gas analysis and boiler tuning.
Veera Babu Gollapalli is applying for a position as a Process Operator or Panel Operator with over 8 years of experience working in ammonia plants and utilities in India and Saudi Arabia. He has a Bachelor's degree in Chemistry and is proficient in plant operations, pre-commissioning, commissioning, and maintenance activities. His responsibilities have included operating equipment across various plant sections including reforming, synthesis, refrigeration, and more. He is skilled in operating systems like compressors, turbines, heat exchangers, and other process equipment.
Batteries -Introduction – Types of Batteries – discharging and charging of battery - characteristics of battery –battery rating- various tests on battery- – Primary battery: silver button cell- Secondary battery :Ni-Cd battery-modern battery: lithium ion battery-maintenance of batteries-choices of batteries for electric vehicle applications.
Fuel Cells: Introduction- importance and classification of fuel cells - description, principle, components, applications of fuel cells: H2-O2 fuel cell, alkaline fuel cell, molten carbonate fuel cell and direct methanol fuel cells.
Embedded machine learning-based road conditions and driving behavior monitoringIJECEIAES
Car accident rates have increased in recent years, resulting in losses in human lives, properties, and other financial costs. An embedded machine learning-based system is developed to address this critical issue. The system can monitor road conditions, detect driving patterns, and identify aggressive driving behaviors. The system is based on neural networks trained on a comprehensive dataset of driving events, driving styles, and road conditions. The system effectively detects potential risks and helps mitigate the frequency and impact of accidents. The primary goal is to ensure the safety of drivers and vehicles. Collecting data involved gathering information on three key road events: normal street and normal drive, speed bumps, circular yellow speed bumps, and three aggressive driving actions: sudden start, sudden stop, and sudden entry. The gathered data is processed and analyzed using a machine learning system designed for limited power and memory devices. The developed system resulted in 91.9% accuracy, 93.6% precision, and 92% recall. The achieved inference time on an Arduino Nano 33 BLE Sense with a 32-bit CPU running at 64 MHz is 34 ms and requires 2.6 kB peak RAM and 139.9 kB program flash memory, making it suitable for resource-constrained embedded systems.
Literature Review Basics and Understanding Reference Management.pptxDr Ramhari Poudyal
Three-day training on academic research focuses on analytical tools at United Technical College, supported by the University Grant Commission, Nepal. 24-26 May 2024
Comparative analysis between traditional aquaponics and reconstructed aquapon...bijceesjournal
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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