P10 Introduction To Coking Process

Introduction to Coking Process
Gary Gianzon
Heavy Oil Technologist
Crude Oil Cuts
2
Heavy Oil Characteristics
 Characteristics of Atmospheric and Vacuum Resid
Crude Atmospheric Vacuum
Bottoms Bottoms
Boiling Range, F Whole 680 1000+
API Gravity 34.0 15.7 6.4
Sulfur, wt% 1.8 3.2 4.2
Yield, Vol % 100 40.6 16.3
Pour Point, F 50 101
Carbon Residue, wt% 8.9 20.1
Nickel, PPM 10 25
Vanadium, PPM 37 89
3
Process Options for Resid
 Sold as Products
 Visbreaking
 ROSE
 Catalytic Cracking – FCC
 Hydrotreating / Hydrocracking
 Delayed Coker
4
Sold As Products
 Road and Roofing Asphalt
 Fuel Oil
5
Visbreaking
 Milder form of thermal cracking.
 Used to reduce viscosity and pour
point of vacuum resid to meet
specification for heavy fuel oil.
 Reduces Distillate Cutter
requirement
6
ROSE Unit
Residual Oil Supercritical Extraction for production of metal free gasoil,
asphaltenes, and resin.
7
Resid FCCU
Similar to Gas Oil FCC but processes heavier feed. Feed concarbon limited to
10 wt%. Catalyst circulation and regeneration section much larger than
conventional FCCU.
8
H-Oil & LC Fining
Resid Hydrotreater/Hydrocracker. Uses catalyst and hydrogen to convert
resid to valuable products. Significantly better yield than coker but much
higher investment cost.
9
Delayed Coking
Thermal cracking process
10
History of Delayed Coker
 1860
 Petroleum coke was first made by Pioneer Oil Refinery in northwest Pennsylvania.
This primitive refinery boiled oil in iron stills to recover kerosene using wood and coal
fires. Coke accumulated at the bottom of the still where workers dug out the coke
and tar before the next run.
11
 1880
 Several Stills were operated in series with the first still producing the coke.
 Used chains in the sump to break up coke, formed during run, for removal.
12
 1929
 Standard Oil of Indiana built the first
delayed coker.
 Coke was removed using steel
cables on a holding devise in the
drum.
13
Lesson 4: History of Delayed Coker
 1930
 Shell Oil patented hydraulic
decoking.
14
Delayed Coker
Delayed coking is a thermal cracking process which upgrades / converts
petroleum resid into lighter liquid & gas products while accumulating
petroleum coke material in the drum.
15
Delayed Coker Process
Heat
Delayed
Coker Liquid and Gas
Heavy Oil
Products
Unit
(DCU)
Petroleum Coke
Product
16
Delayed Coking Process
A fired heater is used for the process
to reach the thermal cracking
temperature of 910 F to 940 F.
The short residence time in the
heater tubes (around 50 seconds),
delays the coking of the resid until it
reaches the coke drum.
17
Delayed Coking Process
Coking Reaction Kinetics
750 F – 16 to 24 hours
800 F – 5 to 6 hours
840 F – 1 ½ to 2 ½ Hours
Reaction rates varies with feed
composition
18
Process Flow
A delayed coker has four main sections:
 Feed, Furnace, and Coke Drum Section
 Main Fractionation Section
 Gas Recovery Section
 Closed Blowdown Section
Closed Blowdown Gas Recovery
Heavy Oil Feed, Furnace,
Main Fractionation Products
and Coke Drums
19
Process Flow
Coker Feed – Fractionator Bottoms
 Feed is Preheated with HCGO product and pumparound
 Bottoms of the main fractionator provides feed surge.
 Recycle is added to the feed
20
Process Flow
Furnace
 Charge pump boost pressure to 300 to 400 psig
 Velocity steam is added to the furnace charge (500 to 1000 lbs/hr)
 Heater outlet temperature to 915 to 930 F
21
Process Flow
Coke Drum
 Coke drum inlet above 900 F
 Endothermic Reaction
 Drum Outlet around 825 to 840 F
 Antifoam Injection at the end of
the drum cycle
 Coke level Detection, Nuclear or
Continuous
22
Process Flow
FZGO Section
 Feed preheated by the HGO product and pumparound before entering
the bottom of the main fractionator.
 Coke drum vapors enters the flash zone section. HGO sprays contact
the coke drum vapor. This controls the C7 insoluble in the HGO
product.
 Flash Zone Liquid is filtered and mix in with the feed.
23
Process Flow
Heavy Coker Gas Oil Section
 Wash sprays to control C7 insoluble.
 Heavy gasoil pumparound remove heat from the column.
 Heavy gasoil product is routed to the hydrocracker or gasoil
hydrotreater for further processing.
24
Process Flow
Distillate Section
 Distillate pump‐back controls endpoint of distillate.
 Distillate pumparound for heat removal.
 Distillate product process further in the distillate hydrotreater.
25
Process Flow
Main Fractionator Overhead
 Reflux to control endpoint.
 Fractionator Overhead is cooled using fin fans and water cooler.
 Continuous water wash to remove salts.
 Overhead liquid and vapor is further process in the coker gas plant.
26
Coker Process Variables
 Furnace Outlet Temperature/Coke Drum Inlet Temperature
 Higher Temperature increases gas and naphtha yields while decreasing the
gasoil and coke yields.
 Higher Temperature reduces the volatile material that gets trapped in the
coke (VCM), resulting in harder coke.
 Increasing the temperature towards the end of the coking cycle reduces
upsets caused by drum switches.
T emperature Affect on Coker Yield
70
60
50
t%)
40
ld(w
900 F
930 F
ie
30
Y
20
10
0
% Coke % Liquid % Gas
27
 Coke Drum Pressure
 At a higher pressure, more of the material in the drum remains in the liquid
phase and can therefore be involved in the reactions that lead to coke
formation.
 Low pressure can affect drum velocity and increase the tendency of coke
carryover.
Coker Yield @ 930 F
80
70
60
50
t%)
6 psig
Yield(w
40 15 psig
40 psig
30
20
10
0
% Coke % Liquid % Gas
28
 Natural Recycle
 Higher increases the quality of HCGO.
 Higher increases coke yield/decrease LV yield.
 Higher can increase furnace runlength.
 Higher natural recycle improves the quality of coke.
29
Coke Drum
Coke drum operation
 Beginning of drum cycle
 Drum is cold
 Volatiles condense on the walls
 Condensate trapped in coke
 Pools forming at the bottom
 Low boiling VCM
30
Coke Drum
Coke drum operation
 Middle of the cycle
 Drum temperature steady
 No volatile condensation
 Lowest VCM coke
 Pool level at steady state
31
Coke Drum
Coke Drum Operation
 End of cycle
 Some volatile left
 Pool liquid soaks into
coke
 Suspended coke particle
remain on top
 High boiling VCM
32
Coke Drum and Structure
Coke Drum Level Detector
 Design consideration
 Level indication
–Neutron backscatter
– Point source level
detection.
• Detector penetrates around
1 ft from the source.
33
Coke Drum and Structure
Coke Drum Level Detector
Gamma Detection
 Continuous Level Detection
 Source and Detector on Opposite
sides of the drum.
 Optimizes Antifoam Usage
 Charge Rate Advance Controls
 Coke Drum Outage Management
34
Petroleum Coke
 Three physical structure of
petroleum coke:
 Shot
 Sponge
 Needle coke
35
Petroleum Coke
 Shot Coke
 Feeds with high level of asphaltene, nitrogen,
sulfur, and oxygen predominately make shot coke.
 Small, tight, non attached clusters that look like
pellets, marbles or BB’s
 Usually very hard (i.e., low HGI)
 Less desirable to end users
– Difficult to handle and grind
– During Calcining process Shot Coke tends
to “pop” in the kiln reducing the thermal
stability.
 Shot coke is predominately used as fuel
36
Petroleum Coke
Shot Coke Operational Issues
 Unquenched hot spot in the coke bed resulting in blowouts
and eruptions
 Coke Dumps
 Poor Drainage
37
Petroleum Coke
 Sponge Coke
 Resembles a sponge
– bubbly looking
 Sponge Coke Usage
– Electrodes for Electric Furnace
– Anodes for Electrolytic Cells
– Chemical Carbon Source
– Graphite Manufacturing
– Fuel
38
Petroleum Coke
 Needle Coke
 Special quality coke produced from aromatic
feed stocks.
 Has crystalline structure with more
unidirectional pores.
 Used for high quality graphite anodes
– Steel industry electric arc furnaces.
– Electrode Manufacture
39
Petroleum Coke
 Typical Properties of Coke
40
Coker Drum Cycle
41
Coke Drum Cycle
Operation Time Ranges Comment
Switch 5 to 20 min. Use slow switch
Steam to Fractionator 0.25 to 1 hr.
Depressure 10 to 30 min. Avoid foamover
Steam to Blowdown 0 to 1 hr.
Quench & Fill 4 to 7 hrs. Slow = low stress
Vent & Drain 0.5 to 2 hrs.
Unhead 10 to 30 min.
Coke Bore & Cut 1.5 to 6 hrs. Shot coke = short
Rehead; Steam; Test 0.75 to 1.5 hr.
Warm‐up 1.5 to 3.5 hrs.
42
Switch
 Open backwarm butterfly valve
 Close backwarm valve to main fractionator
 Open inlet isolation valve
 Open Spool Steam
 Swing 4 way switch valve to halfway
 Swing 4 way switch valve to warm‐up drum
43
Small Steam to the Main Fractionator
 Open steam valve
 Slowly raise steam rate (10 to 15 mlbs/hr)
 Close feed isolation valve
44
Steam to the Blowdown
 Open line to blowdown
 Close overhead vapor valve
 Raise steam rate
45
Water Quench and Fill
 Open water isolation valve
 Slowly open water control valve
 Close steam valve once water flow has been stablish
 Set water ramp program
46
Drum Vent
 Depressure the drum to blowdown
 Stop water addition and isolate water valve
 Isolate the drum to blowdown
 Open vent valve
47
Drum Drain
 Open the drain valve
48
Unhead and Cutting
 Open the top head
 Open the bottom head
 Turn on the eductor
 Turn on top water quench
49
Air Free and Pressure Test
 Close vents
 Close eductor
 Close drain
 Close delta valve
 Pressure the drum with steam
50
BackWarm to Quench Tower
 Balance pressure of the blowdown tower and the main fractionator
 Open overhead vapor valves
 Open backwarming valve to blowdown
 Pinch in backwarm butterfly valve
51
Backwarm to Main Fractionator
 Temperature above 350 F before backwarm to fractionator
 Close backwarm valve to blowdown
 Open backwarm valve to main fractionator
52
Coke Cutting System
53
Hydraulic Decoking System
54
Hydraulic Decoking System
55
Coke Cutting System
 Hydraulically Remove Coke Out of the Drum
 Coke Cutting Mode
 Pilot Mode, Bore 6 ft pilot hole
 Cutting Mode
 Cut coke from top down on 10 ft increments
 Coke Cutting Time Varies from 2 to 6 Hours
56
Coke Cutting System
 Coke Cutting System Design Consideration
 Coke Type and VCM content
 Coke Drum Diameter
 Cutting time Target
 Coke Handling System Design
57
Coke Cutting Safety System
 Limit switches to prevent live drill bit from exiting the drum.
 Low pressure shutdown – shutdown the jet pump on low
discharge pressure to prevent exposing personnel to high
pressure water during cutting hose failure.
 High pressure shutdown – prevents deadheading the pump
 Isolation valve position permissive
 Low suction pressure shutdown
 Cutting water tank level permissive/shutdown
58
Delta Valve Top Cutting Containment
59
Delayed Coker Safety Incident
 At least 40 incident reported since 1993 in North America.
 At least 16 fatalities in North American cokers.
 The list is not all inclusive
 Restricted only to US and Canada
60
Delayed Coker Safety Incident
 Primary Cause Category
 Training and Procedure
–Inadequate procedure, no procedure, failure to follow
procedure, inadequate training or lack of understanding of
the process
 Engineering Error
–Improper design
–Improper metallurgy
61
Common Failure Mechanisms
 Piping Failure  Over-Pressure
 Erosion
– Water + Hot Oil
 Corrosion
 Material Selection
 Operator Error
 Vapor Release
 Opening valve on live drum
 Improper quenching of Drum  Lightening
 Drill Bit Exited the drum during
cutting
 Improper draining resulting in
 Flare System Failure
operator exposure to hot
water
 Relief System Design
 Equipment Failure
 Unheading Gasket Leak
 Flange Leak  Procedures
 Pump Seals
 Valve Leaks
62
Coker Unit Safety Incidents
 South Texas Refinery– 1993
 Operator open live drum to drain
resulting in fire/explosion
 1 fatality resulted in this incident
 Unit was shutdown for 6 months
for repairs
63
 Louisiana Refinery
 Carbon steel joint installed in alloy
pipe at the discharge of the coker
charge pump
 Fire resulted from line failure, east
coker destroyed
 3 fatalities resulted in this incident
for repairs
64
 Houston Area Refinery
 Opened bottom head on a live
drum resulting in fire
for repairs
65
 South Texas Refinery
 Drum Blowout + Fallout
of hot coke, water,
steam, after deheading
prior to raising the chute.
 2 operators injured
during this incident
 Unit shutdown for 2 days
66
 California Refinery
 Hahn and Clay devise was found
to be inadequately close after the
drum was put online resulting in
fire.
 2 operators were injured during
this incident
 This also happened in Marathon’s
Garyville, luckily the oscillating
monitor saves the unit!
67
 Washington State Refinery
 Opened interrupted drum, not
properly quench (tar ball)
resulting in explosion, fire
 6 fatalities resulted form this
incident. 2 fatalities at the bottom
head and 4 at grade under the
deck.
for repairs
68
 Hot work on top of empty drum
was not property isolated from
the live drum
 1 leaking valve use for isolation
 Weld slag ignite flamable mixture
in the drum causing explosion/fire
 Two fatalities resulted from this
incident
69
 Indiana Refinery
 Drill Bit existed drum in cutting
mode, protective limit switch was
bypass/not operable
 High pressure water causes severe
lacerations
 One fatality resulted from this
incident
70
 Los Angeles California Refinery
 Line failure on coke drum
vapor line quench piping
due to wrong metallurgy
resulting in fire
 Unit was shutdown for 5
months for repairs
71
 Los Angeles California Refinery
 2nd degree burn to operator on unheading cart due to hot water release from the
bottom of the drum (multiple occurrence)
 1 injury resulted from this incident
 Charge pump seal failure resulting in fire
 2 injuries resulted from this incident
 Unit was shutdown from 3 weeks for repairs
72
 Kansas Refinery
 Drill Bit existed drum in cutting mode
 1 fatality resulted from this incident
 Canadian Refinery (Fort McMurray, AB Canada)
 Incorrect metallurgy installed in fractionator bottoms pump
piping resulting in a large fire
 The unit was shutdown for 9 months for repairs
73
SAFETY DESIGN FEATURES
 100% PMI on all alloy piping
 Water deluge on unheading and cutting deck
 Water deluge on coke drum egress routes
 Automated unheading system
 Remote stair case on top deck
 Coke drum safety intelocks
 Procedure on dealing with tarball.
 Standard operating procedures.
 Well trained operators.
74
Questions?
75

P10 Introduction To Coking Process

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Introduction to Coking Process

Crude Atmospheric Vacuum

T emperature Affect on Coker Yield

Coker Yield @ 930 F

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