DELAYED COKER UNIT.pptx for petroleum refinery

Petroleum refinery

1. DELAYED COKER UNIT PRESENTED BY: John WESLEY Gorremutchu University college of engineering Kakinada (a)-jntu Andhra pradesh

2. Contents Purpose Introduction Process Key benefits Conclusion

3. purpose To process heavy petroleum residue (bottom from atmospheric and vacuum distillation) and upgrade into valuable distillate leaving behind a solid concentrated carbon material (petroleum coke).

4. Introduction A delayed coker unit is a crucial component of a refinery's upgrading process, designed to handle the heavy residual oil left over after the initial distillation and other refining processes. Delayed coking is a thermal cracking process used to convert heavy residual oils into more valuable products, such as naphtha, LPG, and petroleum coke. The primary feedstock for the delayed coker is typically vacuum residuum, which is the heaviest product from the vacuum distillation column. The term "delayed " refers to the fact that the cracking reactions are delayed until the feed reaches the drum .

5. Process 1. Feed preparation Heater : The heavy residual oil, typically vacuum residuum, is first preheated and then fed into a furnace, also known as a coker heater. In the furnace, the feedstock is heated to a high temperature, usually between 480°c and 510°c (900°f and 950°f).

6. 2. Transfer to coking drums Hot feed transfer : The heated feed is then rapidly transferred to large coking drums. The quick transfer is crucial to avoid premature cracking in the furnace. 3. Thermal cracking in coking drums Coking drums : The heated feed enters the coking drums, where it undergoes thermal cracking. The process takes place at a lower pressure but sustained high temperature.

7. Inside the drum, the heavy molecules break down into lighter hydrocarbons and solid petroleum coke. Delayed coking process : The term "delayed" refers to the fact that the cracking reactions are delayed until the feed reaches the drum. As the heavy oil cracks, lighter hydrocarbons vaporize and are drawn off from the top of the drum, while the solid coke remains in the drum.

8. 4. Product separation Fractionator : The vaporized hydrocarbons from the coking drums are routed to a fractionator. In the fractionator, the vapors are cooled and separated into different product streams: Light gases : methane, ethane, propane, and butane. Naphtha : a light product that can be further processed into gasoline. Light and heavy gas oils : these can be further refined or blended into diesel and other middle distillates.

9. 5. Petroleum coke removal Decoking : As the coking drum fills up with solid petroleum coke, it is taken offline for decoking. The drum is cooled down, and the solid coke is removed using high-pressure water jets, which cut the coke into manageable pieces. While one drum is being decoked, another drum is brought online, allowing for continuous operation.

10. 6. Handling and storage Petroleum coke handling : The removed petroleum coke is processed, typically dried and crushed, and then stored or transported for use as a fuel or in industrial applications . 7. compressor and stripper/absorber: Compressor: Recover the lighter hydrocarbon from the fractionator overhead section.

11. Stripper: Strip off the lighter from the heavy cut Absorber: Trap the escape LPG component Naphtha is used as absorbent Sponge oil absorber: Recover the carried away C3, C4 and naphtha part in off gas from absorber. Sponge oil (part of LCGO) used as lean oil

12. Coke Drum Cycle: Operation hours Coking 15 steamout to fractionator 1 steamout to blowdown system 1.5 Slow water cooling 1.5 Fast water cooling 4.5 Drain Coke Drum 1.5 Remove Top and Bottom Head 1 Hydrualic coke Boring/cuttig 4 Reheading/Pressure Testing 2 Drum Heat-up 7 Idle 6 Total 45

13. Key benefits Maximizing resource utilization : Delayed coking allows the refineries to extract valuable products from what would other wise by low-value, heavy residue oils. Flexibility : the process can handle a wide range of feedstocks, including those with high sulfur and metal content Economic value : by producing lighter, more valuable products and petroleum coke, delayed coking enhances the overall Profitability of a refinery

14. Conclusion The delayed coker unit is an essential part of modern refinery operations, enabling the conversion of heavy residuals into valuable lighter products and solid petroleum coke. Its role in maximizing the economic value of crude oil makes it a key technology in the petroleum refining industry.