delayed coking at miro refinery - refining...

Coking.com: Delayed Coking Conference 2008

page 1

Delayed Coking at MiRO Refinery

Cologne, Germany, September 2008

Dr.-Ing. Jochen Eßer, Frank Schaefer


page 2

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


page 3

Mineraloelraffinerie Oberrhein in Karlsruhe

Largest Refinery in Germany andone of the most efficient

refineries in Europe


page 4

An aerial view of MiRO


page 5

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


page 6

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 %


page 7

MiRO Delayed Coker


page 8

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)


page 9

• 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


page 10


page 11


page 12

Agenda

Safety

• Successful Safety Review with COP

• Automation

- Automatic Control of DC Cycle

- Isolation valves remote controlled

- Top and Bottom Head remote controlled


page 13

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


page 14

Safety Review

Proposal: Cutting deck egress route


page 15

Safety Review

Realization: Cutting deck egress route


page 16

• 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


page 17

• 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 / Automation


page 18

• 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 / Automation


page 19

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


page 20

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


page 21

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


page 22

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


page 23

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


page 24

Agenda

Process technology

• COP fractionator revamp

- Zero natural recycle

• Heater improvements

- Heater ceramic coating (Cetek / COP)


page 25

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


page 26

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


page 27

Heater Improvements

Coker Heater Schematic

Process Technology: Heater – Cetek Ceramic Coating


page 28

Heater Improvements


High & Low Emissivity Tube Coating

High Emissivity Tube Coating

High Emissivity Refractory Coating

Basis: Heater simulation• Cetek: fire box• COP: product


page 29

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


Before After


page 30

Heater Improvements


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


page 31

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


page 32

Agenda

Environment

• No hydrocarbons to atmosphere

• Closed coke handling system


page 33

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


page 34

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


page 35


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


page 36

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


page 37


page 38


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


page 39

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


page 40

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]


page 41

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


page 42

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

delayed coking at miro refinery - refining...

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