Professional Documents
Culture Documents
Gary Gianzon
Heavy Oil Technologist
Crude Oil Cuts
2
Heavy Oil Characteristics
Characteristics of Atmospheric and Vacuum Resid
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
History of Delayed Coker
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
History of Delayed Coker
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.
70
60
50
t%)
40
ld(w
900 F
930 F
ie
30
Y
20
10
0
% Coke % Liquid % Gas
27
Coker Process Variables
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.
80
70
60
50
t%)
6 psig
Yield(w
40 15 psig
40 psig
30
20
10
0
% Coke % Liquid % Gas
28
Coker Process Variables
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
Coker Unit Safety Incidents
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
Unit was shutdown for 6 months
for repairs
64
Coker Unit Safety Incidents
Houston Area Refinery
Opened bottom head on a live
drum resulting in fire
Unit was shutdown for 5 months
for repairs
65
Coker Unit Safety Incidents
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
Coker Unit Safety Incidents
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
Coker Unit Safety Incidents
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.
Unit was shutdown for 6 months
for repairs
68
Coker Unit Safety Incidents
Louisiana Refinery
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
Coker Unit Safety Incidents
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
Coker Unit Safety Incidents
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
Coker Unit Safety Incidents
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
Louisiana Refinery
Charge pump seal failure resulting in fire
2 injuries resulted from this incident
Unit was shutdown from 3 weeks for repairs
72
Coker Unit Safety Incidents
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