ON Delayed Coker Unit: Prepared by

A Sunrise Project for A Sunshine Future
Paradip Refinery

OVERVIEW
ON
DELAYED COKER UNIT

Prepared by
Production-CG Team
Faculty
Mujeeb Ahmad
SPNE-CG
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
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
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 ?
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
Paradip Refinery
Batch-continuous process :
Flow through the tube furnace is continuous. The feed stream is
switched between two drums. One drum is on-line filling with coke
while the other drum is being steam-stripped, cooled, decoked,
pressure checked, and warmed up.

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DELAYED COKER PROCESS
Paradip Refinery
UNIT OVERVIEW
UNIT CAPACITY : 4.1 MMTPA
UNIT LICENSOR : F&W USA
EPCM : TOYO INDIA
FEED : VACUUM RESIDUE
RECYCLE RATIO : 8 %

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Paradip Refinery

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PROPERTIES UNIT Values
Feed temperature
o
C 190
Specific gravity @ 15
o
c 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
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
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
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
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
Paradip Refinery
13
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
Paradip Refinery
15

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
Paradip Refinery
17

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
Paradip Refinery
19

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
Paradip Refinery
21

Paradip Refinery

LPG amine contactor
Sweetening the LPG in amine contactor
Amine used as absorbent
Remove the H2S from LPG

22
GAS CON SECTION
Paradip Refinery
23

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
Paradip Refinery
CONTRIBUTE TO QUALITY AND PRODUCT YIELD
DRUM PRESSURE
- Increase - coke yield increase , gas yield
increase
- Decrease increase the liquid yield
RECYCLE RATIO
- Increase - coke yield increase , gas yield
increase
- Decrease increase the liquid yield

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OPERATING VARIABLE
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
Paradip Refinery
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COKE DRUM BLOCK DIAGRAM
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
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
Paradip Refinery

30
MAIN FRACTIONATOR DETAILS
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
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
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
Paradip Refinery
34

MANUAL OPERATION

HEADING/UNHEADING MANUAL
OPEATION
UNSAFE
UNHEADING & HEADING DEVICE
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

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UNHEADING & HEADING DEVICE
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
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
Paradip Refinery
38
Bridge crane
Chute
Hopper
COKE HANDLING SYSTEM
Paradip Refinery
39
COKER HANDLING SYSTEM
Paradip Refinery
Any mal-operation in coke drum may lead to fire due to expose of hot vapor
to atmosphere
Any steam valve isolation may lead to chocking problem in the coker
section .
Improper operation of heater may lead the chocking in tube
Higher rate of cooling and heating may reduce the drum life .

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WHAT MAY GO WRONG?
Paradip Refinery
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COKE DRUM: large residence time to allow reaction to complete

HEATER primary source for heat input to drive coking reaction

FRACTIONATOR product recovery and separation

GAS CON SECTION lighter product recovery

BLOWDOWN -air pollution control and recover hydrocarbon and water during coke
cutting

DECOKING EQUIPMENT : for coke cutting

COKE HANDLING EQUIPMENT: transfer the coke from unit to coke pile area

UNIT SUMMARY
Paradip Refinery

42

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A Sunrise Project for A Sunshine Future

Manual Cutting Tool

Manual Boring Tool

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