environment-friendly economical safe - triplantec.com · duringgp gg q our presentation we will...

Closed Coke Slurry SystemClosed Coke Slurry SystemAn Advanced Coke Handling Process

• Environment-Friendlyy

• Economical

• Safe

TRIPLAN Technology GmbHEssostrasse 1676189 KarlsruheG

Ralf GastWerner J.A. Vermeire

2017 TRIPLAN Technology - Proprietary & Confidential2017 TRIPLAN Technology - Proprietary & Confidential

Germany

SUMMARY

TRIPLAN is offering a unique system for coke handling in a Delayed Coker Unit (DCU)Delayed Coker Unit (DCU).

Unique in a way that the system;• eliminates hazardous emissions• eliminates hazardous emissions• provides the utmost safety to operators• requires less water• requires less operatorsrequires less operators• reduces maintenance cost• requires less space• provides flexibility in plot planprovides flexibility in plot plan

compared with traditional DCU design.During our presentation we will highlight these unique features of g p g g qthe system, the benefits, and the many years of experience with extremely good results in an operating unit in Germany.


TRIPLAN AG – at a glance

CCSS RefComm® Galveston 2017CCSS – RefComm® Galveston 2017


TRIPLAN AG

• German Engineering company listed on Frankfurt Stock Exchange• German Engineering company listed on Frankfurt Stock Exchange• Specialized in Process Improvement & Optimization.• India subsidiary since 2014.• TRIPLAN Technology GmbH, Karlsruhe.

Patented Technology for state of the art coke handling forDelayed Coking Unit CLOSED COKE SLURRY SYSTEM


TRIPLAN Technology - Karlsruhe


DCU – How they are presented


Source: IOCL

Conventional Coke Handling


Conventional Pit/Pad System



Source: Google Earth



Disadvantages of Conventional Open Pit/Pad System

Hi h E i iHigh EmissionCoke Fines & 20% VOC to the Atmosphere with Exhaust Steam from Open Pit

Separate Coke Crushing Stepk h hCoke Fines to the Atomosphere

Poor DewateringUnhomogeneous in Different Coke Pile RegionsPost-Drainage within Load Area / Railcars / Trucks RequiredPost-Drainage within Load Area / Railcars / Trucks Required

High Water Loss due to the Exhaust Steam from Open PitHigh Quantity of Make-Up Water

Maze CloggingMaze CloggingRepeatedly Manual Sludge Disposal

Low Efficiency of Water Clarification System Fines in the Cutting WaterFines in the Cutting Water

Poor Reliability and High Maintenance Coste.g. Bridge Crane & Pumps


Closed Coke Slurry System

2017 TRIPLAN Technology - Proprietary & Confidential

Process & Operating Features of CCS System

In-Line Crushing during Cutting Operation

Water Feeding for Coke Transport and Further Cooling

Forwarding Coke Slurry into the D t i Bi

1

2

3

DewateringBin Water

SettlingTank

Clean WaterTank

9

Dewatering Bin

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

Forwarding Drain Water into the Water Settling Tank for Separation of Remaining C k Fi ( 0 5%)

4

5

Make-Up Water

3

Coke Drum

1

10

Coke Fines (<0.5%)

Flushing Water for Cleaning Equipment and Piping

Coke Product from Dewatering Bin

Q hi W t f D ki

6

7

8

Crusher

Transition Piece

4

5

7

8

FlushingWater Quenching Water for Decoking

Cutting water

Make-up water for Compensating Water Losses

Di h i C ll t d Sl d i t th

8

9

Slurry PumpTransport

Water PumpDrain Water

Pump

Slurry Basin Drain WaterBasin2

CuttingWater

Sluice Way

FlushingWater Pump

611

10

11 Discharging Collected Sludge into the Slurry Basin

Pump 11


Advantages of Closed Coke Slurry System

Environment-Friendly, Safe, Efficient & Economical

No Emission of Coke Fines & VOC to the Atomosphere

EF No Effluents

Minimum Steam Exhaust

SSafe & Healthy Environment for Fellow Worker

Minimization of Occupational Accidents & Fire Hazard within the DCU

Effective Water Clarification Effective Water Clarification

Extensively Automation / Low Manpower

High Overall System Reliability (≥99.5%)

EE Less Footprint

Omission of Open Pit/Pad with walls up to 17 Meter

Low Water Consumption

Low Operation & Maintenance Cost


Special Design of Selected Components

Transition Piece& Crusher

Slurry & Drain Water Pump

Dewatering Bins


Transition Piece

Critical EquipmentCritical Equipment

√Compensation of axial and radial expansions caused by temperature Bild differences in Coke Drum

√ Closed system

Transition Piece

√ Cladded surface which has contact with abrasive medium - Coke/Water mixing


Double Roll Crusher

Dedicated Crushing PrincipleDedicated Crushing Principle...

Holding the full coke drum inventory positively back – No avalanche outlet

H dli t f C k f P i C l i t G d t Sh t C k Handling any type of Coke from Premium Calcinate Grade to Shot Coke

In-line grinding from 40"/1,000 mm to 4"/100 mm in one single step


Double Roll Crusher

Critical Equipmentq p

√ 80 Tons of Special Material

√ Unique Design & Construction √ Features

√ 50 mm / 2” Wall Casing Thickness

√ German Craftsmanship, under 100 % √ German Craftsmanship, under 100 % TRIPLAN Supervision

√ High Torque Direct Drive Each Roll

√ Crushing Ratio till 10:1; 40” --> 4”

√ Safe & Remote Operation


Double Roll Crusher



Slurry Pump – Critical Equipment

√ No fines generation at low speed 600 RPM

√ Design construction and materials selection enable long cycle life√ Design, construction and materials selection enable long cycle life

√ Cavitation protection by impeller design


Dewatering Bin

Dedicated Dewatering PrincipleDedicated Dewatering Principle...

Hydrostatic Pressure enhances Drain Water Velocity

Course Material of Coke serves as Filter for Trapping and Retaining Coke FinesCourse Material of Coke serves as Filter for Trapping and Retaining Coke Fines

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


Dewatering Bin

Screens

Critical Equipment

√ Closed Drum with Vent

√ Drum Wall and Cone Section Fitted with Special Screens

√ Uniform and Fast Dewatering

Cone SectionFully Slotted

√ Uniform and Fast Dewatering

√ Non-Clogging Type Screens

Permanent Water Removal due to Static

To Drain Water Basin

Drain Lines √ Permanent Water Removal due to Static Draft


Dewatering Bin


Dewatering Bin

It can be placedanywhere where youy yneed dry coke.

…. thus kilometers away from your

Drain Water

away from yourDCU location.

COKE


Features of CCSS- Smaller footprint


Process & Operating Features of CCSS

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

Measures to Improve Coke Handling Operation

Low Emission Closed System to “cover” ProcessingLow Emission Closed System to cover Processing

Continuous Operation In-line Crusher

S i l D t i Bi Efficient Dewatering Special Dewatering Bin (Water Content ≤ 10%)

Low Make-Up Water Consumption Water Cooling -> Less Exhaust Steam Losses

Low Manpower Requirement High Level of Automation

Effective Water Clarification Water Filtering and Internal SludgelEffective Water Clarification Recycle

Higher System Reliability Unique Design & Construction


Conclusion

Closed Coke Slurry System vs. Conventional Systems

Items CCSS Conventional Systemsy

Emission of Coke Fines & VOC

Dewatering Efficiency

very low very high

very high poorDewatering Efficiency

Water Consumption

Level of Automation

very high poor

Very low high

high very lowLevel of Automation

Operational Safety

high very low

very high low

Reliability

Plot Requirement

very high low

moderate high

Total Investment (CAPEX)

Operating Costs (OPEX)

equal

low

equal

high


Closed Coke Slurry System for existing plants

Retrofit e.g. Replacement for Open PIT/PAD

√ Suitable for Multi-Drum Coker

√ Footprint fits into any existing Coker Unit, maximum layout flexibility

√ System Flexibility - Slurry Transport via pipeline (up to kilometers) for Petcokesupply to remote customer (power stations / gasification plants / calciner plants)

√ Basin construction in Concrete (above-/underground) or Steel (aboveground)


Retrofit existing DCU

Note:St t h i ht f NEW Structure height for NEW DCU can be lower


Source: KT

Closed Coke Slurry System

2017 TRIPLAN Technology - Proprietary & Confidential

Operating Experience with CCSS

R li bilitReliability

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

√ Maintenance Free; Reliability Factor ≥99,5%

√ Uninterrupted Operation, Equivalent to 5.000 Cycles

√ No Deterioration of the Slurry Pump Performances

√ No Corrosion and Erosion in the Total CCS SystemInitial installation in 80-s √ y

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

√ Free Water Content of Commercially Dry Coke ≤ 10%

Since 2005 YTD

Maintenance Free

Operation √ Free Water Content of Commercially Dry Coke ≤ 10%Operation

at a German Refinery


DCU – Have another look



Source: KT


Thank you for your attention

TRIPLAN Technology GmbHEssostrasse 16

76189 Karlsruhe76189 KarlsruheGermany

Phone: +49 721 8308524Fax: +49 721 8308510Fax: +49 721 8308510http://ccss.triplan.com

https://de.wikipedia.org/wiki/Closed-Coke-Slurry-Verfahren


environment-friendly economical safe - triplantec.com · duringgp gg q our presentation we will...

Documents