DELAYED COKING INNOVATIONS AND NEW DESIGN TREND

By John D. Elliott Foster Wheeler USA Corporation Introduction This paper will address a few specific points of interest that are of high current profile among engineers and refiners dealing with delayed cokers. These are: Yield Strategy Shot Coke Production Short Cycles Design and Operation of Coke Drums, Coker Heaters, and Coker Fractionators Recent Enhancements for Safety and Operability

Yield Strategies Over the last five years, the great majority of the new and revamp coker projects in-volved conversion of high sulfur and metals containing residues to maximum liquid yields and fuel grade coke. Considerable thought must go into the strategies for setting the coker design basis to determine the best operating conditions that will provide: Maximum Liquid Yield Liquid Products, especially heavy coker gas oil, with properties acceptable to down-stream processes

Occasionally other requirements will affect yield strategies: for instance, limitation on the quality of the coke. Fuel grade coke is generally expected to have VCM (Volatile Combustible Material) levels in excess of 8 to 10 wt percent and HGI (Hardgrove Grind-ability Index) values in excess of 35 to 40. However, there can be overriding specifica-tions on these values to meet the needs of a captive market. Many new cokers are being designed to convert very low value residue from Western Hemisphere heavy and high sulfur crudes. Typical yields for several of these vacuum residues are given below and provided with a comparison to a mixed Arabian vacuum residue.
Table 1: Typical SYDECsm Yields Gas, LV% FOE C3/C4, LV% Naphtha, LV% LCGO, LV% HCGO, LV% Orinoco Heavy 5.36 7.04 14.07 28.38 28.48 Merey Blend Maya Mixed Arabian 5.20 6.64 12.64 27.09 31.24

5.52 7.66 16.71 31.69 20.79

5.58 7.08 13.50 28.77 20.81

Coke, wt% HCGO Gravity, API Ni + V, ppmw CCR, wt% Coke Sulfur, wt%

32.44

35.77

39.80

30.91

16.56 0.5 0.31

16.55 0.7 0.53

14.27 0.6 0.55

13.86 0.4 0.41

4.65

3.96

6.02

6.39

The above yields are based on Low Pressure (15 psig) and Ultra-low recycle ratio (1.05) operation with the purpose of producing maximum liquid yields. Impact of Zero Recycle Operations: In the interest of further reducing coke yields and maximizing liquids production from the delayed coker, Foster Wheeler has designed several cokers with true zero-recycle operation. A true zero-recycle operation is one in which even the liquid resulting from the coke drum overhead line quench is collected with the heavy coker gas oil. A number of refiners successfully operate modified zero recycle operations in which an ultra low recycle coker is operated without pump back wash oil and only a minimum amount of coke drum overhead line quench. This opera-tion type is equivalent to operating with throughput ratio of 1.01 to 1.02. The trick to this type of operation is keeping a minimum amount of liquid in the overhead line; otherwise the line will experience coking at the point of dry-out. When considering a zero recycle operation, it is important to consider the incremental value of the additional HCGO produced and the incremental loss of lighter liquids. Usu-ally these lighter liquids are less desirable as raw delay coker products, but not always. A typical comparison with both operations at low pressure (15 psig) is noted below. Inspection shows that the increased volumetric yield of HCGO is partially offset by the decrease in other liquid products. The true-zero recycle operation produces only 0.64 LV% more total liquids; on the other hand it produces 1.32 wt% more total liquids, all as HCGO. Inspection of the incremental properties of the HCGO below shows that the incremental gas oil is quite heavy with some properties starting to approach that of the feedstock it-self. The distillation curves for the two HCGO's show that the liquid volume percentage boiling above 1050 F is about 7% for the ultra-low recycle HCGO whereas it is nearly double that for the HCGO produced in the True-Zero Recycle Operation.
Table 2: Yield Comparison for Ultra-Low Recycle and True-Zero Recycle Operations Ultra Low Recycle Dry Gas, LV% FOE C3/C4, LV% 5.80 7.27 True Zero Recycle 5.78 7.07 Incremental

+0.02 +0.20

Naphtha, LV% LCGO, LV% HCGO, LV% Coke, wt%

13.34 32.52 24.02 32.73

12.41 30.48 27.83 31.43

+0.93 +2.04 -3.81 +1.30

Table 3: Comparison of Heavy Coker Gas Oil Properties for Ultra-Low Recycle and True-Zero Recycle Operations Properties Ultra Low Recycle 12.78 2.58 5303 0.53 432 1.0 True Zero Recycle 11.55 2.55 5087 2.43 2000 3.8 Incremental

Gravity, API Sulfur, wt% Nitrogen, wppm CCR, wt% C7 Insol, wppm Ni + V, wppm Distillation 10% LV 50% LV EP Watson K

4.35 2.37 3806 13.70 11,300 20.4

729 864 1072 11.13

734 893 1141 11.12 11.07 1074 VABP

Further comparison of the HCGO's from the two-operations shows that the zero-recycle HCGO is of poorer quality in terms of gravity, carbon residue, asphaltenes, metals and distillation endpoint although significantly higher in yields. Note however, that the sulfur and nitrogen content is lower because of the reduced conversion. There is no simple rule of thumb to decide which type of operation to adopt; each case study needs to be determined based on the refinery specifics. True-zero recycle opera-tions can have significant benefits when delayed coking is used for synthetic crude pro-duction or, in some cases, if the HCGO is fractionated to produce an XHCGO (extra heavy coker gas oil) product which is a heavy fuel oil blend stock. Lastly, since Foster Wheeler's Ultra-low Recycle Cokers have been shown to operate at throughput ratios less than 1.05, it may be worthwhile to investigate 2 or 3 percent recycle ratio operations (modified zero recycle). One exception might be if the coker is to be integrated into a hydrocracker based refin-ery. Depending on the licensor, design specifics, catalyst, etc., most hydrocrackers will limit one or more of the following: metals, distillation end point, carbon residue, and/or heptane insolubles. These specifications are generally more stringent than those re-quired for FCC Feed Hydrotreaters. In one study the limiting value of the HCGO product

was 500 ppmw heptane insolubles. Foster Wheeler investigated commercially and pilot tested coker gas oils and determined that heptane insoluble content remains relatively low below 1,000 F on a component basis. Above this point, the heptane insoluble con-tent rises quickly. Foster Wheeler's analysis has resulted in a prediction model of that value. The comparison of the general purpose yield structure for a coker having a low pressure, ultra-low recycle operation suitable for integration with modern hydrocracking technology with a coker operation tailored for producing HCGO to be fed to a hy-drocracker with older technology is shown below
Table 4 Yield Comparison of Cokers Operated for Modern and Older Hydrocracking Operations Integration with Modern Hydrocrack-ing Technology (Low Pressure, Ultra-low Recycle Operation) Gas, LV% FOE C3/C4, LV% Naphtha, LV% LCGO, LV% HCGO, LV% Coke, wt% HCGO Gravity Ni + V, ppmw CCR, wt% C7 Ins, wt% D-1160 EP, F 13.86 0.44 0.41 362 1072 16.41 0.10 0.17 111 950 5.20 6.64 12.64 27.09 31.24 30.91 Integration with Older Hydrocracking Technology(Properties of HCGO limiting) 5.53 7.33 14.86 31.85 21.63 34.08

While SYDEC sm delayed cokers are excellent means of carbon and metals rejection, the results above are unit operation specific. Coke Quality - Shot Coke The heavier coker feedstocks noted in the first section of this paper universally produce shot coke when the delayed coker is operated at conditions for maximum liquid products and minimum coke. Shot coke is characterized by small round spheres of coke loosely bound together. Interestingly, even sponge coke may have some percentage of embedded shot coke. The test for such a measurement is not precise but low shot coke percentages are sometimes specified for anode grades of petroleum coke. However, in the case of fuel coke production, there is a general belief that shot coke production means that the coker is being run at the most economic conditions. Shot coke can disrupt coke drum quench and drum operations and

because it is loosely held, it can cause coke bed dumps that can overwhelm the coke handling equipment and require costly cleanups. The proliferation of advanced unheading systems such as the one offered by Foster Wheeler is driven by the general increase of shot coke production. Shot coke formation itself is mainly dependent on feed properties. In addition to what is presented below, it is believed that heteroatoms such as nitrogen, oxygen, sulfur and organometallic compounds containing high levels of nickel and vanadium can also influence shot coke formation. While the exact mechanism of shot coke formation is not well known, there is evidence that shot coke formation is influenced by the concentration of polar aromatics and polar cyclic compounds above a certain molecular weight. While changes in operating conditions can increase or decrease shot coke formation, the characteristics of a feedstock are the dominant factors. However, variation of operating conditions throughout the cycle have been used to minimize the production of shot coke in feeds having a general tendency to form shot coke. Operating conditions can impact the quality of the shot coke. For example, higher temperatures will increase the hardness (decrease the HGI) of the shot coke and lower the VCM content. Localized spouting velocities in the drum and transfer line inlet velocities may contribute to or even initiate shot coke formation. Grindability of the coke is a function of time and temperature for a given feedstock. This translates to a correlation on VCM content and coking cycle length. For a given feedstock, the average drum HGI can be lower for longer coking cycles if a constant average VCM is produced. Obviously this would also require lowering the heater coil temperature. Thus coke drum volume selection and cycle length can affect HGI of the coke. The mechanism responsible for the formation of shot coke has been defined as a combination of reaction kinetics, solubility, and mass transfer phenomena. Specifically, the potential to form shot coke in a commercial delayed coker is higher when using feedstocks having an asphaltene content which starts to approach the Conradson carbon content. At Foster Wheeler, we rely on parameters such as CCR, HI, and metals as well as a knowledge of the crude origin to predict the tendency of a residue to form shot coke. Following is a description of the interaction between the coking potential, the asphaltenes, and the velocity of a feedstock on shot coke formation. As the feed is heated, vaporization occurs and cracking reactions begin. The reactions taking place in the liquid phase may lead to the precipitation of the asphaltenic components which will continue to react to form precoke and eventually, coke. The precoke material is a high viscosity material having high plasticity. The two-phase flow and the velocity of this two-phase flow in the fired heater transfer line and in the coke drum, combined with the surface tension of the precoke material, act to shape this material into smooth spheres of various sizes, typically found in shot coke. Shot coke formation can be suppressed by increasing the delayed coke pressure and/or the recycle. Higher pressure will inhibit hydrocarbon

vaporization, resulting in a dilution of the reacting species in the liquid phase and a reduction in the concentration of these species and the overall reaction rate. Higher recycle will achieve a similar effect. Also, the reduction in vaporization associated with the higher pressure will result in an overall reduction in the velocity of the reacting mass in the fired heater. The addition of FCC slurry into the coker feed will help to inhibit shot coke formation because of the solubilizing effect of the slurry oil on the asphaltenes. This effect is limited, however, and will depend on the properties and quantity of the slurry oil used. Higher temperature will tend to promote shot coke formation because of the corresponding increase in reaction kinetics. Lower temperatures may therefore be considered desirable. However, the temperature must not be so low that the reaction does not proceed to coke. Dynamic manipulation of the fired heater outlet temperature throughout the coking cycle can help minimize operating issues associated with shot coke formation. Short Cycles - Considerations Nearly all the new delayed cokers being built are specified with moderately short operating cycles, in the range of 36 to 40 hours overall. Per drum pair this is normally spoken of as 18 to 20 hours for the coking cycle. One operating schedule example for a 16 hour coking cycle is attached as Figure 3. While the schedule is fairly typical the decoking half of the schedule needs to be fitted for each coker operation. The decoking operations noted as quench and fill; coke cutting; and heating are the most critical in developing a cycle. The factors involved in those operations are listed below: Many of these new cokers have been designed with the ability to operate at shorter cycles and higher feed capacity through the preinvestment in larger safety relief systems. Accordingly it is not uncommon for these units to be pushed beyond their design capacity within a few years following initial startup. Generally this can be accomplished by minor debottlenecking and raising the operating pressure of the coker itself. While the increased pressure results in a lower percent yield of liquid products this is typically more than justified by the increased barrels of production and the need to convert larger amounts of residue. Today it is not uncommon for older cokers to be operated on 14 hour coking cycles. A few refineries are also pushing the limits of 12 hour coking cycles. Typical schedule cycles are given for the decoking operations in the following table.
Table 5 Important Decoking Cycle Operations Operation Quench and Fill Factors Involved in Setting Duration Drum size; coke amount and type; blowdown operation; coke bed hot spot issues; drum life Drum size; coke amount and type; possible mechanical time factors on vendor equipment Consistent, high temperature warm-up; coke condensate recovery

Coke Cutting

Warm up

Table 6 Schedule of Decoking Operations for Very Short Cycle Cokers 14 Hours Steam to Fractionator Steam to Blowdown Quench and Fill Drain Unhead Bore and Cut Rehead/Pressure Test Warm-up 1 5 1 2 3 12 Hours 5 1 2

In considering these shorter cycle operations, the impact of the unit configuration is important. Cokers with 2 or 3 drum pairs are generally built with common systems to handle the various operations in the decoking schedule. These systems are coke handling; water supply and recovery for quenching and cutting; blowdown systems and coke condensate systems. The reason drum cycles are staggered when there are multiple drum pairs is so these systems need only service one drum at a time and thereby their design is economized. For a 14 hour operation, a 2 drum coker only uses these systems once every 14 hours; a 4 drum coker every 7 hours; but a 6 drum coker requires their availability every 14/3 hours (4 hours - 40 minutes). On the basis of the above 14 hour cycle, this means that the water supply/recovery and blowdown systems would need to be redesigned and debottlenecked to permit resource sharing. 3 Drum Operations: A few refiners looking for expansion capacity have elected to add a third coke drum to an existing pair rather than debottleneck for very short cycle operation. Frequently this option is useful when there is also to be a change to a heavier feedstock producing a disproportionately greater amount of coke. A typical schedule for a 3 drum operation is attached as Figure 4. Note that the 12 hour coking cycle results in a relatively easy to operate 24 hour decoking cycle. Further debottlenecking of the decoking cycle to 18 hours would result in an aggressive 9 hour coking cycle. Coke Drums Drum Life: In the last five (5) years, there has been a significant amount of study by Foster Wheeler and others concerning the mechanical issues surrounding coke drum life. Significant academic controversy surrounds the postulated causes of coke drum failures and design/maintenance options for drum life extensions. As cokers are pushed to shorter cycles to maximize throughput, the drums suffer additional stress shortening their usable life. The major

contending theories for drum failure due to bulging initiated mechanism are: Increased incidence of hot spots/cold spots caused by faster drum quenching necessary to meet short cycles. Frequently, the quench schedule is developed without consideration to minimizing the drum stresses. Metal distortion or drum "swelling" leading to drum diameter increase because of the differential expansion between coke and steel.

Poor preheating on a consistent basis can also induce accumulative stresses in the area of the skirt drum attachment that leads to cracking. Foster Wheeler is actively participating in the industry-sponsored study team that is further investigating causes, mechanisms and remedies for coke drum failure. Our studies have shown that good operations coupled with preemptive maintenance are necessary to achieve reasonable, useful drum life. A few specific operational recommendations include: Use a quench schedule that is checked to meet requirements for minimum stress. Foster

Wheeler prefers either a stepped or ramped quench schedule that starts at low rates early in the quench operation and finishes at high quench flow rate. An example is:
Table 7: Typical Coke Drum Quench Schedule Duration (minutes) 30 30 30 30 75 165 Flow, GPM 275 625 775 925 975 1000

Alternate quench schedules using large water rates early in the quench allowing pressures to run up to the relief valve set pressure are detrimental to drum life regardless of the shell thickness. Avoid "proofing". Proofing is an older operating procedure that blasts a large water flow into the drum to ensure that coke bed passageways are open (or to open them further). Proofing has been shown to induce high stresses in coke drums.

Proofing can also create a safety issue. The large water rate meeting the very hot coke bed will instantaneously vaporize, sometimes lifting the relief valves. The operator must anticipate the reaction and take action prior to overpressure. We have found this procedure to be a serious concern. Consequently, we now specify an interlocked double control valve station designed to limit the initial quench water rate to match the capacity of the coke drum relief valves based on a single valve being wide open (see Figure 5). Always preheat to minimum of 450 F on coke condensate as measured at the drum process inlet. The preferred preheat temperature is 600 F or greater. Achieving this level of preheat in a low pressure coker operating on very short cycles (e.g. 14 hours) can be difficult. Because of the low pressure differential between the coke drums and the fractionator, a coke condensate system may be needed on low pressure cokers. This adds additional pressure drop to the coke condensate hydraulic path. As a consequence, it may be necessary to line up the coke condensate system to the relatively lower pressure blowdown system. If this is not sufficient, then alternative hydraulic boosters such as ejectors or blowers may be required. Maximum Coke Drum Size: The ability to design and operate larger drums can have significant capital cost advantages if the larger drum size eventually reduces the number of drum pairs for a specific residue processing requirement. Five years ago, the maximum coke drum size was 27 ft. dia by 113 ft. OAL. Since then, Foster Wheeler has built a coker with 4 drums each 28 ft. dia by 120 ft. OAL. By the end of the year 2002, there will be 5 Foster Wheeler cokers in operation with eighteen 28 ft. diameter coke drums. This trend to larger drums continues; currently a Foster Wheeler coker is being built with 29 ft. dia by 120 ft. OAL drums. We expect that in the near future, we will engineer coke drums with diameters of 32 ft. and overall length of up to 140 ft. A decade or more ago, it was believed that the coke drum size was limited to 27 feet diameter or less by coke cutting technology. While this is still true for specialty needle and high quality anode coke, our analysis of fuel grade shot cokers showed it was not the case, allowing Foster Wheeler to push the design envelope. For these coker operations, the concerns have been Size of auxiliary systems, e.g. blowdown; water handling Size and operation of the coke handling system

With respect to the auxiliary systems, equipment sizes become only incrementally larger to handle the larger batch quantities for these larger coke drums. With respect to coke handling, design strategies had to be employed to keep the process economic. To this end, Foster Wheeler employs its own computerized simulations for coke volume and pit utilization studies. The graphical output for the Foster Wheeler computer program is attached for one such design study (see Figure 6). In the case shown it

was used to confirm that double handling of the coke in the pit was more economic than oversizing the pit to handle multiple drums of coke. The first graphic shows how the coke fills the pit from one drum, and the second shows how the coke builds up with the second drum decoking, leaving little space for a third drum of coke without risking chute blockage. The third graphic shows how the third drum of coke can be accommodated with the coke moved to the end of the pit. The result of this particular study concluded that it was more economic to use a smaller pit size and include a second bridge crane and an adjacent emergency storage pad. Coker Heaters The operating history of Foster Wheeler's modern delayed coker furnaces has been quite good, especially with the use of on-line spalling with run lengths in excess of one year, even on coker heaters fired beyond their original design duty. The two types of furnaces offered by Foster Wheeler are: Single fired design which has the majority of the radiant heat input on one side of the tube. With this arrangement the typical design average peak heat flux is 9000 Btu/hr-ft with a peak heat flux of 16200 Btu/ hr-ft. Double fired design in which radiant heat is provided equally to both sides of the coil. This allows an altered design which is especially suitable for achieving long heater run lengths when processing unstable or high fouling feedstocks. This arrangement produces a design which allows a higher average radiant heat flux resulting in lower peak film and tube temperature, shorter residence time and lower pressure drops, or higher velocities. Foster Wheeler's design uses sloped heater walls, which balances the radiant heat along the coil.

SELECTION OF FURNACE TYPE: With the use of the Foster Wheeler-supplied On-line Spalling Procedure, both furnace types have been shown to be capable of achieving run lengths in excess of one year when the furnace type is properly applied. The decision to use a double fired heater instead of a single fired heater depends on the coking tendencies of the design feedstock. Foster Wheeler has developed a fouling test and correlation to actually measure the relative coking and fouling tendency of a feedstock using an in-house proprietary fouling device. A schematic representation of the fouling device is attached as Figure 9. The fouling test equipment includes a tube-shell heat exchanger, where the sample fluid is brought to high temperature and coke deposition can occur. Supporting equipment consists of one feed and one return reservoir, a metering pump downstream of the heat exchanger, and temperature controllers for heating, reservoirs, pump and transfer lines. The tube is resistance heated. The test fluid flows along the outer surface of the tube where it can thermally degrade, forming a coke deposit, whose

characteristics are dependent upon the Fouling Index evaluation parameters. The fluid outlet temperature is monitored for the duration of the test. The fluid outlet temperature will fall over time as the tube fouls and heat transfer is inhibited. The amount of deposition and fluid outlet temperature change over time determines the Fouling Index of a feedstock. The results obtained with this device are used to calculate a relative Fouling Index. This Fouling Index is then ranked against known Foster Wheeler standards for determination of final heater configuration. Presently, three standards are in use as described here:
Foster Wheeler Standard 1 Description

Readily fouls and is considered a difficult feedstock for a conventional delayed coker heater. It has been run commercially with good results in a Foster Wheeler heater utilizing an advanced design for difficult feeds. Calibration feed is a vacuum residue from a high conversion bed hydrocracker. Borderline feedstock that tends toward unacceptable fouling. An advanced design heater is recommended but a conservative conventional heater design may be utilized with on-line spalling to achieve acceptable run lengths. Feedstock exhibiting acceptable fouling with conventional heater design.

The Fouling Index Figure attached (Figure 10) shows the relative fouling index by weight deposit and the relative fouling index by temperature difference for the three Foster Wheeler standards. Heater Run Length can be improved by Improved metallurgy: The T-91 material used in some of Foster Wheeler's recent cokers has been shown to be durable while allowing higher tube design temperatures. Maintaining Lower Sodium Contents: Sodium is an accelerant of furnace tube coking. The general relationship of sodium levels in the feed and heater run length is shown in the attached Figure 11. Use of On-line Spalling: This is a Foster Wheeler procedure that allows individual furnace coils to be spalled with steam or condensate to remove coke from the tube wall while the adjacent coils remain in coker service. The procedure has been shown to be highly effective, with some refiners are using it to eliminate scheduled shutdowns for furnace decoking using only "opportunity" steam-air or pigging decokings during unscheduled shutdowns.

Other Coker Heater Issues which are of current interest are: Double Fired Heater Operation: Because of the inherent lower coil residence fire, these furnaces may need to be fired at 5 to 10&#deg;F

higher outlet temperature than a comparable single fired furnace when making a constant coke VCM content. The higher velocities in the double fired design prevent film temperatures from being an issue. High Coke Fines Content in Feed: Tighter operating parameters on modern cokers together with high feed rates and high drum velocities can result in higher than expected carry over of coke fines into the Fractionator bottoms. In an Ultra-low recycle operation, the small particle sizes allow some coke to carry through to the heater charge. This phenomenon has necessitated changes to feed instrumentation and inlet piping requirements. Instrumentation is specified with flow measurement devices that can deal with the coke fines - the current device most specified is the wedge meter. The control valve selections and piping layout also need to be specified for light slurry service. In particular the piping layout should not permit preferential solids flow or packing of the solids into dead ends. Coker Fractionator Foster Wheeler uses an open wash zone spray chamber concept in the coker fractionator in Ultra Low Recycle cokers because the liquid rates are too low to prevent coking of trays or packing. A schematic of this system is shown in Figure 12. Below the spray chamber contact zone Foster Wheeler employs several rows of shed trays. The vapor inlet from the coke drum overhead impinges on the shed trays knocking out heavy tar and coke fines which the vapor entrains. Consequently the shed decks do coke up sacrificially over a period of time. Some refineries have found it economic to eliminate these sheds and accept slightly higher contaminant levels in the HCGO and eliminate shed tray hydroblasting at turnaround. Foster Wheeler has performed revamps on older trayed coker fractionators to convert them to Ultra-low recycle operation using a spray chamber concept. The resulting analysis of one such conversion, based on operating data taken over a one (1) week period, is shown in the following table. Inspection of the bulk properties of the HCGO from the revamp operation implies a feed-stock change from the original operation and design basis. That, coupled with measurement tolerances, will explain the lower than the predicted MCR content of the HCGO. While these types of results are typical, the actual variation in fractionator performance and HCGO properties also depends on fractionator vapor velocity, design compromises for fractionators internals and feedstock and yield issues. Interlocks for Enhanced Operation and Safety There is a continuing industry trend to provide instrumentation and interlock enhancements for increased safety and operability for all process units. It is noted however that while these enhancements are beneficial, they should not be considered replacements for thorough operator training and attentiveness. The delayed coking process has been significantly affected by this trend. The objective of most of these enhancements has been the semi-batch nature of the coke drum

operation. While the instrumentation and safety interlocks in some new cokers have been complex enough to nearly automate the drum cycle, the following is now considered the minimum for prudent design. Please refer to the attached Figure 13 for reference. Permissive interlock of Switch Valve, Inlet Isolation Valves (SP6's) and Utility Header Valves (SP-7's): This is a permissive system that performs the following functions: - Prevents a switch valve from being switched into a close inlet isolation valve thereby deadending the heater.

- Prevents the Utility Isolation Valves (SP-7) from being opened if the respective Inlet Isolation Valve is open. This prevents hot oil from the transfer line from being inadvertently directed to the drain line.

- Requires that the Utility Isolation Valve (SP-7) be closed before the switch valve can be switched to its respective drum.

- And optionally, prevents the Inlet Isolation Valve from being closed if the switch valve is positioned to feed into it.

Permissive Interlock of Coke Drum Overhead Relief and Vent: A motorized block valve is located on the discharge of the coke drum relief PSV's. This is especially important when there are multiple drum pairs to prevent backflow of blowdown vapors to an open coke drum. This valve is interlocked to prevent its inadvertent closure unless the respective coke drum vent and/or top head is open.

Table 8: Spray Chamber Conversion and Operation Original Operation Recycle, LV% Wash Oil + O/H Quench, BPSD HCGO Properties 10,800 10,600 to 12,600 10 Revamp Predictions 5 Actual Operation 3.6 to 5.4

D-1160 EP, F Gravity, API Sulfur, Wt% Nitrogen, Wt% MCR, Wt% Solids, ppmw

976 17.0 2.55 2200 0.38 9

1016 16.3 2.93 2400 0.9 15

992 AVG 20.3 AVG 1.93 AVG 2240 AVG 0.69 AVG/0.94 MAX 15 AVG

Summary Delayed coking is an old process that remains a major method for residue upgrading. Its current importance to refineries is due to the fact that the process, always inherently flexible, has been updated and improved to meet the requirements of modern refinery operations. This paper was presented at the NPRA 1999 Annual Meeting in San Antonio, Texas, USA.
Figure 1

Ultra-Low Recycle Operation Figure 2 True Zero

Recycle Operation Figure 3

Coke Drum Cycle, 16 Hour Figure 4

Three Drum Cycle Figure 5

Coke Drum Quench Valve Arrangement Figure 6

Sequential Coke Pit Management Figure 7

Delayed Coker Charge Heater 4 Pass - Single Fired Figure 8

Delayed Coker Charge Heater 2 Pass - Double Fired Figure 9

Bench Scale Coker Charge Fouling Test Figure 10

Fouling Index Figure 11

Effect of Feedstock Na+ on Coker Heater Run Length Figure 12 Coker Fractionator

Ultra-Low Recycle Design Figure 13

Coke Drum Interlocked Valves