Coking.com: Delayed Coking Conference 2008
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Delayed Coking at MiRO Refinery
Cologne, Germany, September 2008
Dr.-Ing. Jochen Eßer, Frank Schaefer
Coking.com: Delayed Coking Conference 2008
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Agenda
• Introduction: MiRO Refinery and Delayed Coking at MiRO
• Safety• Safety Review
• Automation
• Process technology• COP Fractionator Revamp
• Heater improvements
• Environment• Closed System
• Future Improvements / Outlook
Coking.com: Delayed Coking Conference 2008
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Mineraloelraffinerie Oberrhein in Karlsruhe
Largest Refinery in Germany andone of the most efficient
refineries in Europe
Coking.com: Delayed Coking Conference 2008
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An aerial view of MiRO
Coking.com: Delayed Coking Conference 2008
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MiRO fulfills the fuel and heating oil needs of approx. 10 mil. customers
Main supply areas:
• Baden-Württemberg• Southern Palatinate• Southern Hesse• Saarland• Western Bavaria• Northern Switzerland• Western Austria
Berlin
Karlsruhe
DEUTSCHLAND
SCHWEIZ
ÖSTERREICH
Coking.com: Delayed Coking Conference 2008
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MiRO processes crudes from all over the world
30,8%
0,3%
30,8%
1,6%
36,1%
0,4%
Origin of crude oil 2004:Eastern Europe /
Central Asia
In the Middle East
North Africa
South America
Central Europe
North Sea
36,1 %
30,8 %
30,8 %
1,6 %
0,4 %
0,3 %
Coking.com: Delayed Coking Conference 2008
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MiRO Delayed Coker
Coking.com: Delayed Coking Conference 2008
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Simplified Flow Scheme of MiRO Refinery
3 Atm.Dest.
3 Vac.Dest.
FCCU
DC
HDS
HDS
HDS
HDS
HDS
Iso
3 Re-former
BHC
Calciner
Oxidizer
ETBE
Alkylation
PrimeG
Gasplant
Crude Oil
LPG
Naphtha
Gas Oil
Atm. Resid.
VGO
Vac.Resid.
Coke
HKGO
LKGO
Slurry Oil (HCGO)
ICN(Naphtha)
FCC-Gas
C3=
C4-Mix
HPF
Benzene
LPF
Reformate
IsomerisateLPG
Gasoline Pool
Gasoline Pool
Gasoline PoolBenzene
MD PoolPropeneGasoline Pool
Gasoline Pool
Gasoline Pool
n-ButaneAlkylate
Gasoline Pool
MD Pool
own consumption
Green Coke
Calcinate
Bitumen
Dist.Bitumen(Bunker Oil)
Coking.com: Delayed Coking Conference 2008
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• Foster Wheeler Design• Closed Coke Handling System• Start Up 1984• 2 drums• 24 h cycle time / act: 15 h• Fresh Feed 120 t/h / act: 230 t/h
18 mbpsd / act: 34.5 mbpsd• Recycle rate 1.3 / act. 1.0• High sulfur feed Green coke• Low sulfur feed Calcination
General MiRO Delayed Coker Data
1984 Start Up1989 18h – Project
Automatic Control for DC CycleCombitool Drilling / CuttingSwivel Type Bottom Head
1994 Preheat Furnace1997 COP Technology: HKGO-Draw2000 COP Technology: New
Fractionator / FZGO-Draw Hydraulic Operated Crushers
2003 Parallel Onstream decoking2006 Redundant Slurry Pumps
Dewatering Bin Modifications Heater Ceramic Coating
Coking.com: Delayed Coking Conference 2008
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Coking.com: Delayed Coking Conference 2008
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Agenda
Safety
• Successful Safety Review with COP
• Automation
- Automatic Control of DC Cycle
- Isolation valves remote controlled
- Top and Bottom Head remote controlled
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2nd – Get worker out of line of fire - address high priority remote actuation issues, deluges, provide for high priority protected egress items like cutting deck.
Control cabins on cutting deck and switch deck: improve as safe places of natural egress
Protected egress routes required from points of natural egress to ground Water deluge system required Covering grating with solid checker plate
Safety Review
1st – Keep hazardous energy contained, specific to the semi-batch coking process, such as interlocks, double blocks.
3 items: double blocks
3rd – Items specific to protecting property.
Fire proofing of steel structure required Fire monitors and fire fighting equipment issues
Coking.com: Delayed Coking Conference 2008
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Safety Review
Proposal: Cutting deck egress route
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Safety Review
Realization: Cutting deck egress route
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• Objectives– Assist Operator– Help avoid operating errors– Implement interlock system– Optimize drum decoking
• Operational steps– Drum switch - Hydrocarbon purge – Cooling - Coke
Cutting - Pressure Test - Preheating
Safety: Automatic Control of DC Cycle (1)
Safety / Automation
Coking.com: Delayed Coking Conference 2008
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• Communication: Operator – Automatic Control– Basis: Sequencing screen for operator action steps
• Actions by automatic control / Actions by operator– Screen Messages
• When valves in erroneous position• Missing operator action
– Operator-Software-switch confirms readiness to proceed with next step
• Full acceptance by operators
Safety: Automatic Control of DC Cycle (2)
Safety / Automation
Coking.com: Delayed Coking Conference 2008
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• Communication: Operator – Automatic Control– Basis: Sequencing screen for operator action steps
• Actions by automatic control / Actions by operator– Screen Messages
• When valves in erroneous position• Missing operator action
– Operator-Software-switch confirms readiness to proceed with next step
• Full acceptance by operators
Safety: Automatic Control of DC Cycle (2)
Safety / Automation
Coking.com: Delayed Coking Conference 2008
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All isolation valves remote controlled
• Main Switch Valve– Wilson Snyder– Hydraulically operated
• Feed Isolation Valves– Wedge plug type– Hydraulically operated
• Overhead Valves– Forged wedge plug type– Hydraulically operated
Hydraulic actuator for plug lifting and rotation
forged body
Safety / Automation
Coking.com: Delayed Coking Conference 2008
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Safety / Automation
Z+J Double Disc Valve in blowdown line
- Installed in spring 2006
- Safe and reliableoperation
- No additionalmaintenanceneeded
- One Z&J isolation valve performs as two con-ventional block valves (capex savings)
Patents pending
Patents pending
Coking.com: Delayed Coking Conference 2008
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Safety / Automation
Z+J Double Disc Valve in blowdown line
- Installed in spring 2006
- Safe and reliableoperation
- No additionalmaintenanceneeded
- One Z&J isolation valve performs as two con-ventional block valves (capex savings)
Patents pending
Patents pending
Coking.com: Delayed Coking Conference 2008
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Safety / Automation
• Swivel-type bottom head
• Benefits:– SAFETY: Bottom
head is kept closed at full load by hydraulic system during unbolting of bottom flange
– Reduced cycle time
Automation: Semi-Automatic Bottom Head
Coking.com: Delayed Coking Conference 2008
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Safety / Automation
• Swivel type bottom head
• Benefits:– SAFETY: Bottom
Head is kept closed at full load by hydraulic system during unbolting of bottom flange
– Reduced cycle time
Automation: Semi Automatic Bottom Head
Coking.com: Delayed Coking Conference 2008
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Agenda
Process technology
• COP fractionator revamp
- Zero natural recycle
• Heater improvements
- Heater ceramic coating (Cetek / COP)
Coking.com: Delayed Coking Conference 2008
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ConocoPhillips Process Technology
Vacuum residue
Del
ayed
Cok
erFr
actio
nato
r
Heavy gas oil
Light gas oil
NaphthaG
asLPG
Del
ayve
dC
oker
Kok
skam
mer
Feedtank
Compressor
Del
ayed
Cok
er-
furn
ace
Del
ayed
cok
er c
oke
drum
Flash Zone gas oilVDU
HDS
HDS
Gas Plant
Feedtank
Delayed Coker: Hydrocarbons - Simplified Process Diagram
Cutter stock
Pre
Hea
tfu
rnac
e
Gas Plant
Coking.com: Delayed Coking Conference 2008
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ConocoPhillips Process Technology
• COP Technology– 1.0 Recycle
• HKGO draw to HDS / FCC• FZGO to VDU
– Minimum drum pressure– Maximize product yields– Minimize coke yield– Throughput increase by 30%– Increase of the Unit On-Stream
Factor• Replaced Fractionators Packing
with Trays• Installed Flash Zone Spray
System
Coking.com: Delayed Coking Conference 2008
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Heater Improvements
Coker Heater Schematic
Process Technology: Heater – Cetek Ceramic Coating
Coking.com: Delayed Coking Conference 2008
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Heater Improvements
Process Technology: Heater – Cetek Ceramic Coating
High & Low Emissivity Tube Coating
High Emissivity Tube Coating
High Emissivity Refractory Coating
Basis: Heater simulation• Cetek: fire box• COP: product
Coking.com: Delayed Coking Conference 2008
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Heater Improvements
600.0
800.0 °C
650
700
750
FLIR Systems
500.0
900.0 °C
550
600
650
700
750
800
850
FLIR Systems
Process Technology: Heater – Cetek Ceramic Coating
Before After
Coking.com: Delayed Coking Conference 2008
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Heater Improvements
Process Technology: Heater – Cetek Ceramic Coating
651.4
923.2 °C
700
750
800
850
900
FLIR Systems
After 2 years of operation647.7
901.2 °C
650
700
750
800
850
900
FLIR Systems
Coking.com: Delayed Coking Conference 2008
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Heater Improvements
F-001: TMTs after ceramic coating was applied (adjusted for furnace duty)
540
550
560
570
580
590
600
610
620
630
640
24/3/06 13/4/06 3/5/06 23/5/06 12/6/06 2/7/06 22/7/06 11/8/06 31/8/06
TMT Increase Rate: 0.35°C/day0.63 °F/day
Coking.com: Delayed Coking Conference 2008
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Agenda
Environment
• No hydrocarbons to atmosphere
• Closed coke handling system
Coking.com: Delayed Coking Conference 2008
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Environment - Hydrocarbons
• Hydrocarbon recovery system• Vent gas compressor to recover all hydrocarbons during drum steam
out and drum quench. HCs used as fuel gas.• Vent gas compressor used as flare gas recovery compressor if not
used in coker service no flare gas emissions during normal operation.
• Compressor type: 2 stage liquid ring pump.Steam Out Recovery .
Pressure: 2 bar(g) 5.5 bar(g) 25 mbar(g) 5.5 bar(g)29 psi(g) 80 psi(g) 0.36 psi(g) 80 psi(g)
Flow rate: 2000 Nm3/h up to 700 m3/h1.7 mmcsfd up to 0.6 mmscfd
• Open drum to atmosphere at low pressure / low temperature• Pressure: Below 0,05 bar(g) / 0,7 psi(g)• Temperature: Below 95°C / 203°F
Coking.com: Delayed Coking Conference 2008
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Environment – Coke
Del
ayed
Cok
erfu
rnac
e
Del
ayed
Cok
erFr
actio
nato
r
Heavy gas oil
Light gas oil
Coker - Naphtha
GasLPG
Del
ayve
dC
oker
Kok
skam
mer
Cok
e cu
tting
wat
er
Compressor
Wat
erta
nk
Del
ayed
cok
er c
oke
drumFlash Zone gas oil
Open Coke Pit
Typical coke handling system
Vacuum residue
Feedtank
Feedtank
Cutter stock
Pre
Hea
tfu
rnac
e
Coking.com: Delayed Coking Conference 2008
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Environment – Coke
Del
ayed
Cok
erfu
rnac
e
Del
ayed
Cok
erFr
actio
nato
r
Heavy gas oil
Light gas oil
Coker - Naphtha
GasLPG
Del
ayve
dC
oker
Kok
skam
mer
Slurrypit
Cok
e cu
tting
wat
er
Dew
ater
ing
Bin
Slurry pump
Loading
Compressor
Wat
erta
nk
Wat
er-
tank
Cok
e si
lo
Del
ayed
cok
er c
oke
drum
Flash Zone gas oil
Closed coke handling system
Vacuum residue
Feedtank
Feedtank
Pre
Hea
tfu
rnac
e
Cutter stock
Coking.com: Delayed Coking Conference 2008
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Environment – CokeBenefits • No coke dust emissions from open
pit or coke storage facilities• Coke fines in closed system• Water in closed system
Disadvantages• Coke dewatering is a challenge• Limited hold up in coke handling system• Coke drum cycle time influenced by coke
handling and coke dewatering.
2 x 2000 t
4 x 1500 t
2 x 2000 tCOKE
COKE SLURRY PIT
COKE / WATERPUMPS1300 m³/h5700 gpm
CUSTOMERS CALCINATION
(CEMENT INDUSTRY)
COKEBINS
CONVEYING SYSTEM
DEWATERING BIN
CRUSHER
CRUSHER
COKE CUTTING PUMP
COKEDRUM
SLUICE WAYPIPE
Coking.com: Delayed Coking Conference 2008
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Coking.com: Delayed Coking Conference 2008
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Environment – Coke
COKE
COKE SLURRY PIT
COKE / WATERPUMPS
CUSTOMERS CALCINATION
(CEMENT INDUSTRY)
COKEBINS
CONVEYING SYSTEM
DEWATERING BIN
CRUSHER
CRUSHER
COKE CUTTING PUMP
COKEDRUM
SLUICE WAYPIPE
Reliability Challenges of Closed Coke Handling System
Steady Coke Cutting
ReliableCokeCrusher
Dewatering Bins: Spare capacity
Redundant Slurry Pumps
Conveying System: Spare capacity
Coking.com: Delayed Coking Conference 2008
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Automation / Safety / Environment
Automation: Automatic Coke Cutting (1)
• Coke Cutting System:– Pump: Byron Jackson (internal thrust
balanced)– Pump Drive: Diesel 3.6 MW / 4800 hp– 280 bar / 4060 psi, 280 m3/h / 1230 gpm– Combi Tool for drilling and cutting
– 3 Vibration Sensors at each drum– Signal of sensors is transformed into the
information coke / no coke– Vertical movement of drilling stem is computer
controlled and continuously optimized
Coking.com: Delayed Coking Conference 2008
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Automation: Automatic Coke Cutting (2)
• Benefits:– Increased
reliability of coke cutting.
– Higher cutting velocity
– Best cutting parameters can be reproduced
– Less manpower– Cutting
parameters give information about coke quality
Automation / Safety / Environment
Automatic Coke Cutting (automatic tool)
0
5
10
15
20
25
30
35
40
0 50 100 150
time [min]Po
sitio
n of
dril
ling/
cutt
ing
tool
[m]
Coking.com: Delayed Coking Conference 2008
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Outlook
Future Improvements / Outlook
• Valve interlock system independent of DCS
Additional layers of protection on DC cycle valve operation -> SAFETY
• Completely closed and automated operation
Full automation of drum decoking:
• Remote controlled Top Head Valve SAFETY
• Remote controlled Bottom Head Valve SAFETY
Coking.com: Delayed Coking Conference 2008
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Outlook
Safe Operation and Clean Environment
It is possible in Delayed Coking:
COMPLETELY CLOSED AND AUTOMATED OPERATION
Automatic control of drum cycle Drum unheading Coke cutting Coke dewatering Coke transportation