Delayed Coking at MiRO Refinery Cologne, Germany, September 2008 Dr.-Ing. Jochen Eßer, Frank Schaefer

Transcription

1 Delayed Coking at MiRO Refinery Cologne, Germany, September 2008 Dr.-Ing. Jochen Eßer, Frank Schaefer Coking.com: Delayed Coking Conference 2008 page 1

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 Coking.com: Delayed Coking Conference 2008 page 2

3 Mineraloelraffinerie Oberrhein in Karlsruhe Largest Refinery in Germany and one of the most efficient refineries in Europe Coking.com: Delayed Coking Conference 2008 page 3

4 An aerial view of MiRO Coking.com: Delayed Coking Conference 2008 page 4

5 MiRO fulfills the fuel and heating oil needs of approx. 10 mil. customers Berlin Main supply areas: DEUTSCHLAND Karlsruhe ÖSTERREICH Baden-Württemberg Southern Palatinate Southern Hesse Saarland Western Bavaria Northern Switzerland Western Austria SCHWEIZ Coking.com: Delayed Coking Conference 2008 page 5

6 MiRO processes crudes from all over the world 0,3% 0,4% 36,1% 30,8% 30,8% 1,6% Origin of crude oil 2004: Eastern Europe / 36,1 % Central Asia In the Middle East 30,8 % North Africa 30,8 % South America 1,6 % Central Europe 0,4 % North Sea 0,3 % Coking.com: Delayed Coking Conference 2008 page 6

7 MiRO Delayed Coker Coking.com: Delayed Coking Conference 2008 page 7

8 Simplified Flow Scheme of MiRO Refinery Crude Oil LPG Iso Isomerisate LPG Gasoline Pool 3 Atm. Dest. Atm. Resid. Naphtha Gas Oil HDS FCCU FCC-Gas HDS HDS 3 Reformer Gas plant Reformate C 3= C 4 -Mix BHC ETBE LPF Benzene HPF Gasoline Pool Gasoline Pool Benzene Gasoline Pool MD Pool Propene Gasoline Pool 3 Vac. Dest. Vac. Resid. VGO HKGO ICN (Naphtha) Slurry Oil (HCGO) PrimeG HDS own consumption Alkylation Alkylate Gasoline Pool n-butane Gasoline Pool MD Pool DC Coke LKGO Calciner Green Coke Calcinate Oxidizer Bitumen Dist.Bitumen (Bunker Oil) Coking.com: Delayed Coking Conference 2008 page 8

9 General MiRO Delayed Coker Data Foster Wheeler Design Closed Coke Handling System Start Up 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 1984 Start Up h Project Automatic Control for DC Cycle Combitool Drilling / Cutting Swivel Type Bottom Head 1994 Preheat Furnace 1997 COP Technology: HKGO-Draw 2000 COP Technology: New Fractionator / FZGO-Draw Hydraulic Operated Crushers 2003 Parallel Onstream decoking 2006 Redundant Slurry Pumps Dewatering Bin Modifications Heater Ceramic Coating Coking.com: Delayed Coking Conference 2008 page 9

10 Coking.com: Delayed Coking Conference 2008 page 10

11 Coking.com: Delayed Coking Conference 2008 page 11

12 Agenda Safety Successful Safety Review with COP Automation - Automatic Control of DC Cycle - Isolation valves remote controlled - Top and Bottom Head remote controlled Coking.com: Delayed Coking Conference 2008 page 12

13 Safety Review 1st Keep hazardous energy contained, specific to the semi-batch coking process, such as interlocks, double blocks. 3 items: double blocks 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 3 rd Items specific to protecting property. Fire proofing of steel structure required Fire monitors and fire fighting equipment issues Coking.com: Delayed Coking Conference 2008 page 13

14 Safety Review Proposal: Cutting deck egress route Coking.com: Delayed Coking Conference 2008 page 14

15 Safety Review Realization: Cutting deck egress route Coking.com: Delayed Coking Conference 2008 page 15

16 Safety / Automation Objectives Safety: Automatic Control of DC Cycle (1) Assist Operator Help avoid operating errors Implement interlock system Optimize drum decoking Operational steps Drum switch - Hydrocarbon purge Cooling - Coke Cutting - Pressure Test - Preheating Coking.com: Delayed Coking Conference 2008 page 16

17 Safety / Automation Safety: Automatic Control of DC Cycle (2) 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 Coking.com: Delayed Coking Conference 2008 page 17

18 Safety / Automation Safety: Automatic Control of DC Cycle (2) 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 Coking.com: Delayed Coking Conference 2008 page 18

19 Safety / Automation 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 Coking.com: Delayed Coking Conference 2008 page 19

20 Safety / Automation Z+J Double Disc Valve in blowdown line - One Z&J isolation valve performs as two conventional block valves (capex savings) - Installed in spring Safe and reliable operation ng in g di end en s tps p ntn e e t t a PP a - No additional maintenance needed Coking.com: Delayed Coking Conference 2008 page 20

21 Safety / Automation Z+J Double Disc Valve in blowdown line - One Z&J isolation valve performs as two conventional block valves (capex savings) - Installed in spring Safe and reliable operation ng in g di end en s tps p ntn e e t t a PP a - No additional maintenance needed Coking.com: Delayed Coking Conference 2008 page 21

22 Safety / Automation Automation: Semi-Automatic Bottom Head 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 Coking.com: Delayed Coking Conference 2008 page 22

23 Safety / Automation Automation: Semi Automatic Bottom Head 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 Coking.com: Delayed Coking Conference 2008 page 23

24 Agenda Process technology COP fractionator revamp - Zero natural recycle Heater improvements - Heater ceramic coating (Cetek / COP) Coking.com: Delayed Coking Conference 2008 page 24

25 ConocoPhillips Process Technology Delayed Coker: Hydrocarbons - Simplified Process Diagram Compressor Gas Plant LPG Gas Gas Plant Naphtha HDS HDS VDU Light gas oil Heavy gas oil Flash Zone gas oil Pre Heat furnace Delayed Coker Fractionator Delayed coker Delayved coke Coker drum Kokskammer Vacuum residue Delayed Cokerfurnace Cutter stock Feed tank Feed tank Coking.com: Delayed Coking Conference 2008 page 25

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 Coking.com: Delayed Coking Conference 2008 page 26

27 Heater Improvements Process Technology: Heater Cetek Ceramic Coating Coker Heater Schematic Coking.com: Delayed Coking Conference 2008 page 27

28 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 page 28

29 Heater Improvements Process Technology: Heater Cetek Ceramic Coating FLIR Systems C FLIR Systems C Before After Coking.com: Delayed Coking Conference 2008 page 29

30 Heater Improvements Process Technology: Heater Cetek Ceramic Coating FLIR Systems C FLIR Systems C After 2 years of operation Coking.com: Delayed Coking Conference 2008 page 30

31 Heater Improvements F-001: TMTs after ceramic coating was applied (adjusted for furnace duty) TMT Increase Rate: 0.35 C/day 0.63 F/day /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 Coking.com: Delayed Coking Conference 2008 page 31

32 Agenda Environment No hydrocarbons to atmosphere Closed coke handling system Coking.com: Delayed Coking Conference 2008 page 32

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) 29 psi(g) 80 psi(g) 25 mbar(g) 5.5 bar(g) 0.36 psi(g) 80 psi(g) Flow rate: 2000 Nm3/h up to 700 m3/h 1.7 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 page 33

34 Environment Coke Delayed Coker furnace Delayed Coker Fractionator Coker - Naphtha Light gas oil Heavy gas oil Coking.com: Delayed Coking Conference 2008 page 34 Gas Delayed coker Delayved coke Coker drum Kokskammer Water tank Coke cutting water Compressor LPG Flash Zone gas oil Typical coke handling system Pre Heat furnace Vacuum residue Cutter stock Feed tank Open Coke Pit Feed tank

35 Environment Coke Delayed Coker furnace Delayed Coker Fractionator Coker - Naphtha Light gas oil Heavy gas oil Coking.com: Delayed Coking Conference 2008 page 35 Gas Delayed coker Delayved coke Coker drum Kokskammer Water tank Watertank Coke cutting water Dewatering Bin Coke silo Compressor LPG Flash Zone gas oil Closed coke handling system Pre Heat furnace Vacuum residue Cutter stock Feed tank Feed tank Slurry pit Slurry pump Loading

36 Environment Coke COKE CUTTING PUMP Benefits 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. COKE DRUM DEWATERING BIN 2 x 2000 t CONVEYING SYSTEM 4 x 1500 t COKE BINS COKE CRUSHER 2 x 2000 t CRUSHER SLUICE WAY PIPE CUSTOMERS CALCINATION COKE SLURRY PIT COKE / WATER PUMPS 1300 m³/h 5700 gpm (CEMENT INDUSTRY) Coking.com: Delayed Coking Conference 2008 page 36

37 Coking.com: Delayed Coking Conference 2008 page 37

38 Environment Coke Reliability Challenges of Closed Coke Handling System COKE CUTTING PUMP Dewatering Bins: Spare capacity Conveying System: Spare capacity COKE DRUM Steady Coke Cutting DEWATERING BIN CONVEYING SYSTEM COKE CRUSHER Reliable Coke Crusher CRUSHER COKE BINS SLUICE WAY PIPE Redundant Slurry Pumps CUSTOMERS CALCINATION COKE SLURRY PIT COKE / WATER PUMPS (CEMENT INDUSTRY) Coking.com: Delayed Coking Conference 2008 page 38

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 Coking.com: Delayed Coking Conference 2008 page 39

40 Automation / Safety / Environment 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 Position of drilling/cutting tool [m] Automatic Coke Cutting (automatic tool) time [min] Coking.com: Delayed Coking Conference 2008 page 40

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 Coking.com: Delayed Coking Conference 2008 page 41

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 Coking.com: Delayed Coking Conference 2008 page 42