Environment-Friendly Economical Safeccss.triplan.com/download/ccss-presentation.pdf · Dewatering Bin Proprietary Design

www.triplan.com

TRIPLAN AGAuf der Krautweide 3265812 Baden SodenGermany

Closed Coke Slurry System

• Environment-Friendly

An Advanced Coke Handling Process

• Safe

• Economical

Content

Page 2Closed Coke Slurry System (CCSS)

Topic

A Introduction

B Coke Handling Systems

C Process & Operating Features of CCS System

D Special Design of Selected Components

E Advantages of CCS System

F CCS System Implementation

G Conclusion

Introduction – Global Situation in Crude RefiningA

Page 3

Worldwide Shiftto Heavier Crudes

Global Heavy Crude Proc. [mio. b/d]

Source: Oil & Gas Journal 2010

More Stringent Regulationsfor Heavy Fuel Oils

Global Sulphur Limit [% w/w]

Source: MARPOL 73/78

Replacement of Heavy Fuels byLNG

LNG Demand Marine Sector [bil. m³/a]

Source: GAZPROM 2011

10

12

14

16

18

20

2010 2015 2020

050

100150200

2015 2020 2030

012345

2010 2012 2020

Focus on Bottom Upgrading

Processes

Closed Coke Slurry System (CCSS)

Distribution of Bottom Upgrading Processes Distribution by Coking Technologies

Source: Hydrocarbon Publishing 3Q, 2010

Introduction – Bottom Upgrading

51%

36%

5%3% 3% 2%

Coking RFCC

Fixed-bed hydroproc. Visbreaking

Ebullated-bed Hydrocracking Solvent Deasphalting

78%

8%8%6%

Delayed Coking Fluid CokingOther unspecified

A


Delayed Coking Processing (Schematic)

Introduction – Key Process Steps Delayed CokingA

Cutting Water

Coke

Residue

Frac

tiona

tor

Furnace

LPG

CokerNaphtha

LCGO

HCGO

Coke Handling System

Coke Drum

Coke Drum

Coke Drum

Heating in theFurnace

Cracking in theCoke Drum

Generating Petro Coke from Heavy Tars

Decoking byHydraulic Measures

Coke Handling andShipment

Preheating in theFractionator

RecoveringCracked Products

Directing Vapors tothe Fractionator

Residue

Valuable Distillates, e.g. Transportation Fuels


Content

Page 6

Topic

A Introduction






G Conclusion


Pit or Pad System (95% Existing Coker Units)

Railcar Loading System

TRIPLAN‘s Proprietary Closed Coke Slurry System – CCSS

Coke Handling Systems – Different SetupsB

SumpPit or Pad

Maze

Coke Drum

Reclaimed bycrane or Front-end Loader

To Clean Water Tank

Sump

Sluiceway

Railcar

Coke Fines

WaterClarification

System

To Clean Water Tank

Coke Drum

Crusher

Sump

Chute

• Open System• No In-Line Crusher• Crane or Front-End

Loader for Coke Transport• Sludge Settling in Maze

• Open System• Just-In-Time Unloading• Water Separation by

Overflowing & throughHoles in the Car

• Closed System• Continuous Process

between Cutting & Unloading

Page 7

Slurry Pump

for Reuse

Slurry Basin

Coke

Coke Fines

CrusherChute

Vent

Coke Drum

DewateringBin

WaterSettlingTank

Drain WaterBasin

Clean Water Pump

Clean Water Tank


Having a look at Conventional Open Pit/Pad System

Coke Handling Systems – Conventional Pit/Pad SystemB

Coke Pile

Slurry Pump

Maze

Coke Drum

Coke Drum

Sum

p

Clean WaterPump Recovery

Water

Coke-FilledBaskets

Water Flow

Top Region Water Removal via

Vaporization (Dry Tip)

Pit FloorMaze Maze

Ground Region Water Accumulation

(Wet Feet)

Middle Region Up-Flow Vapor & Down-Flow Liquid


Disadvantages of Conventional Open Pit/Pad System

Coke Handling Systems – Conventional Pit/Pad SystemB

Page 9

High Emission Coke Fines & 20% VOC to the Atomosphere with Exhaust Steam from Open Pit

Separate Coke Crushing Step Coke Fines to the Atomosphere

Poor Dewatering Unhomogeneous in Different Coke Pile Regions Post-Drainage within Load Area / Railcars / Trucks Required

High Quantity of Make-Up Water 1/3 to 1/2 of Total Water Inventory per Batch

Maze Clogging Repeatedly Manual Sludge Disposal Required

Low Efficiency of Water Clarification System Fines in the Cutting Water

Poor Reliability and High Maintenance Cost e.g. Bridge Crane & Pumps


Content

Page 10

Topic

A Introduction






G Conclusion


Process & Operating Features of CCSSC

Page 11

What can be expected from the Closed Coke Slurry System…?

Measures to Improve Coke Handling Operation

Low Emission Closed System to “cover” Processing

Continuous Operation In-line Crusher

Efficient Dewatering Special Dewatering Bin (Water Content ≤ 8%)

Low Make-Up Water Consumption Less Exhaust Steam Losses

Low Manpower Requirement High Level of Automation

Effective Sludge Management Internal Sludge Recycle

Higher System Reliability Unique Design & Construction


How the Closed Coke Slurry System works?

Process & Operating Features of CCS SystemC

Coke Drum

Crusher

DewateringBin

Chute

WaterSettling

Tank

Coke

Ven

t

Clean WaterTank

Slurry PumpClean Water

Pump

Dra

in W

ater

Slu

dg

e

Drain WaterPump

Slurry Pit Drain Water Basin

Make-Up Water

1

2

3

4

5

6

7

9

8



Processing Steps

In-Line Crushing during Cutting Operation

Water Feeding for Coke Transport and Further Cooling

Forwarding Coke Slurry into the Dewatering Bin

Water Diffusing through the Voids of the Coarse Material into the Drain WaterBasin

Trapping and Retaining of Coke Fines (≥99.5%) in Coke Bed

Forwarding Drain Water into the Water Settling Tank for Separation ofRemaining Coke Fines (<0.5%)

Discharging Collected Sludge into the Slurry Pit

Converting Clean Water into the Clean Water Tank for Reuse

Coke Product Unloading from Dewatering Bin

1

2

3

4

5

6

7

9

8




Process & Operating Features of CCS SystemC

Dedicated Crushing Principle...

Chute Raising and Docking to Drum Bottom Valve Remotely

Holding the Full Coke Drum Inventory Positively Back

Unlimited Crushing Capacity

Handling any Type of Coke from Premium Calcinate Grade to Shot Coke

Matching any Impact Loads & any Cutting Rates

In-line Grinding from 40"/1,000 mm to 2"/ 50 mm in One Single Step

Releasing Uniformly Crushed Coke




Page 15

Dedicated Dewatering Principle...

Short and Uniform Distances to Screen enable Minimum Water Diffusing Time

Hydrostatic Pressure enhances Water Stream Velocity

Water Runs Through the Voids of the Coarse Material at High Velocity

High Velocity leads to Trapping and Retaining of Coke Fines on the Lumps and results

in Maximum Fines Retention (Sludge Retention Rate in Dewatering Bin >99,5 %)


Content

Page 16

Topic

A Introduction






G Conclusion


Proprietary Design

Special Design of Selected ComponentsD

Double Roll Crusher

Slurry Pump& Slurry Pipe Dewatering

Bin



Double Roll Crusher with Integrated Chute

Proprietary Design

√ 80 Tons of Special Material

√ Unique Design & Construction Features

√ 50 mm / 2” Wall Casing Thickness

√ German Craftsmanship, under 100 % TRIPLAN Supervision



Double Roll Crusher with Integrated Chute

Proprietary Design

√ High Torque Direct Drive Each Roll

√ Crushing Ratio 20:1; e.g. 40” --> 2”

√

Safe & Remote Operation

Hydraulic Chute Raising & Retracting

Docking Automatic to Drum Flange or Bottom Valve


Dewatering Bin

Proprietary Design

√ Closed Drum with Vent

√ Drum Wall and Cone Section Fitted with Special Screens

√ Uniform and Fast Dewatering

√ Non-Clogging Type Screens

√ Controlled Release of Coke Product with Vibration Feeder



To Drain WaterBasin

ScreensCircumference

Cone SectionFully Slotted

Drain Lines Circumference

Dewatering Bin

Proprietary Design

√ Typical Dewatering Performance for Batch Size from 1,000 up to 1,500 Tons

√ Dedicated Batch Dewatering

√ Permanent Water Removal due to HydrostaticPressure

√ Dewatering Time 6h from Cutting to Unloading

√ Free Water Content of Coke Product ≤ 8%0

10

20

30

40

50

60

70

80

90

100

0 1 2 3 4 5 6

Free

Wat

er in

Cok

e [%

w/w

]

Dewatering Time [h]

Dewatering Effect over Time



Dewatering Bin – Typical Dewatering Schedule

Hours 1 2 3 4 5 6 7 - X

Drum Decoking/Cutting 3

Coke Crushing ( In-Line ) 3

Instant Coke Dewatering 6

Coke Unloading

Total Time from Cutting to Unloading Dry Coke : 6 hours



Slurry Pump - Proprietary Design

√ No Fines Generation at Low Speed 600 rpm

√ Design, Construction and Materials Selection for Long Life Cycle

√ Cavitation Protection by Impeller Design and Material Selection

Closed Slurry Pipe - Proprietary Design

√ Design and Construction for Optimum Slurry Transportation

√ Special Material Selection for Long Life Cycle



Content

Page 24

Topic

A Introduction






G Conclusion


Advantages of CCS SystemE

Environment-Friendly, Safe, Efficient & Economical

EFNo Emission of Coke Fines & VOC to the Atomosphere

Minimum Steam Exhaust

SSafe & Healthy Environment für Fellow Worker

Minimization of Occupational Accidents & Fire Hazard within the DCU

EE

Almost 100% Fines Retention Efficiency (≥99.5% in Dewatering Bin + Remaining in Water Settling Tank)

Movable and Interchangeable Crusher for Maintenance Access

High Overall System Reliability (≥99.5%)

Low Operation & Maintenance Cost

Fully Automation / Low Manpower

Low Make-Up Water Consumption


Content

Page 26

Topic

A Introduction






G Conclusion


CCS System ImplementationF

Retrofit e.g. Replacement for Open PIT/ PAD

√ Suitable for Multi-Drum Coker

√ Footprint fits into any Existing Coker Units, Maximum Layout Flexibility

√System Separably - Slurry Transport via Pipeline (e.g. 4 Kilometers) for Feeding

remote Power Stations / Gasification Plants / Calciner Plants directly

√No Extra Shutdown Required for Execution due to Modular Construction /

Prefabrication

√Basin Construction in Concrete (above-/underground) or Steel Work

(aboveground)


CCS System ImplementationF

Greenfield Installation

√ Ease Authorities Environmental Concerns during Project Approval Phase

√ Early Involvement for Optimum Project Embedding & Cost Savings

√ Shorter Cycle Time enables lower CAPEX.

√Basin Construction in Concrete (above-/underground) or Steel Work

(aboveground)

√ Maximum Layout Flexibility

√System Separably - Slurry Transport via Pipeline (e.g. 4 Kilometers) for Feeding

remote Power Stations / Gasification Plants / Calciner Plants directly


Content

Page 29

Topic

A Introduction






G Conclusion


ConclusionG

Page 30

CCSS at a Glance - Features of CCSS vs. Conventional Systems

Items CCSS Conventional Systems

Emission of Coke Fines & VOC

Dewatering Efficiency

Water Consumption

Level of Automation

Operational Safety

Reliability

Plot Requirement

Total Investment (CAPEX)

Operating Costs (OPEX)

very low very high

very high poor

Very low high

high very low

very high low

very high low

moderate high

equal

low

equal

high


ConclusionG

Operating Experience with CCSS

Page 31

Best Available Technology (BAT)

√ No Dedicated Field Operators Required; Only 4 Technicians per Shift for the Entire Delayed Coker Unit.

√ Maintenance Free; Reliability Factor ≥99,5%

√ Uninterrupted Operation, Equivalent to 4.000 Cycles

√ No Deterioration of the Slurry & Cutting Water Pump Performances

√ No Corrosion and Erosion in the Total CCS System

√ No Fire, No Accidents, No ‘Near Miss’ Incidents

√ Free Water Content of Commercially Dry Coke ≤ 8%

8 Years Operation

at a German Refinery


Thanks for Your Attention

TRIPLAN AGAuf der Krautweide 32

65812 Bad SodenGermany

www.triplan.com [email protected]

www.triplan.com

India Contact:Sunil Kulkarni

[email protected]

China Contact:Zheng-Zhu Streich

[email protected]

US Contact:Artur Krueger

[email protected]


Documents

Environment-Friendly Economical Safeccss.triplan.com/download/ccss-presentation.pdf · Dewatering Bin Proprietary Design