an advancedcoke handling process - refining...
TRANSCRIPT
CCSS_English_2016-09_Streich
www.triplan.com
TRIPLAN Technology GmbH
Essostrasse 16
76189 Karlsruhe
Germany
Closed Coke Slurry System
• Environment-Friendly
An Advanced Coke Handling Process
• Safe
• Economical
CCSS_English_2016-09_Streich
Content
Page 2
Topic
A Introduction
B Coke Handling Systems
C Process & Operating Features of CCS System
D Special Design of Selected Components
E Advantages of CCS System
F CCS System Implementation
G Conclusion
CCSS_English_2016-09_Streich
ConclusionG
Page 3
CCSS at a Glance - Features of CCSS vs. Conventional Systems
Items CCSS Conventional Systems
Emission of Coke Fines & VOC
Dewatering Efficiency
Water Consumption
Level of Automation
Operational Safety
Reliability
Plot Requirement
Total Investment (CAPEX)
Operating Costs (OPEX)
very low very high
very high poor
Very low high
high very low
very high low
very high low
moderate high
equal
low
equal
high
CCSS_English_2016-09_Streich
Get rid of the coal mine coal mine coal mine coal mine in your refinery !
Technology for Future, For a cleaner environment
CCSS_English_2016-09_Streich
Introduction – Global Situation in Crude RefiningA
Page 5
Worldwide Shiftto Heavier Crudes
Global Heavy Crude Proc. [mio. b/d]
Source: Oil & Gas Journal 2010
More Stringent Regulationsfor Heavy Fuel Oils
Global Sulphur Limit [% w/w]
Source: MARPOL 73/78
Replacement of Heavy Fuelsby LNG
LNG Demand Marine Sector [bil. m³/a]
Source: GAZPROM 2011
10
12
14
16
18
20
2010 2015 2020
0
50
100
150
200
2015 2020 2030
0
1
2
3
4
5
2010 2012 2020
Focus on
Bottom Upgrading
Processes
CCSS_English_2016-09_Streich
Distribution of Bottom Upgrading Processes Distribution by Coking Technologies
Source: Hydrocarbon Publishing 3Q, 2010
Introduction – Bottom Upgrading
51%
36%
5%3%
3% 2%
Coking RFCC
Fixed-bed hydroproc. Visbreaking
Ebullated-bed Hydrocracking Solvent Deasphalting
78%
8%
8%
6%
Delayed Coking Fluid Coking
Other unspecified
A
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CCSS_English_2016-09_Streich
Delayed Coking Processing (Schematic)
Introduction – Key Process Steps Delayed CokingA
Cutting Water
Coke
Residue
Fra
ctionato
r
Furnace
LPG
CokerNaphtha
LCGO
HCGO
Coke Handling System
Coke Drum
Coke Drum
Coke Drum
Heating in theFurnace
Cracking in theCoke Drum
Generating Petro Coke
Decoking byHydraulic Measures
Coke Handling andShipment
Preheating in theFractionator
RecoveringCracked Products
Directing Vapors tothe Fractionator
Residue
Valuable Distillates, e.g. Transportation Fuels
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CCSS_English_2016-09_Streich
Content
Page 8
Topic
A Introduction
B Coke Handling Systems
C Process & Operating Features of CCS System
D Special Design of Selected Components
E Advantages of CCS System
F CCS System Implementation
G Conclusion
CCSS_English_2016-09_Streich
Pit or Pad System
(95% Coker Units) Railcar Loading System
Allen-Sherman-Hoff Hydrobin System TRIPLAN‘s Proprietary CCSS
Coke Handling Systems – Different SetupsB
Sump
Pit or PadMaze
Coke Drum
Reclaimed bycrane or Front-end Loader
To Clean Water Tank
Sump
Sluiceway
Railcar
Coke Fines
WaterClarification
System
To Clean Water TAnk
Coke Drum
Crusher
Sump
Sump
To Clean Water Tank
Coke Drum
Crusher
Sluiceway
Hydrobin
Coke
WaterClarification
System
Coke Fines
Chute
• Open System
• No In-line Crusher
• Cran or Front-End Loaderfor Coke Transport
• No Further Water Treatment
• Open System
� Crusher
� Slurry Sump
� Hydrobin
� Tanks
• Continuous Process
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• Open System
• Just-In-Time Unloading
• Water Separation byOverflowing & throughHoles in the Car
• Closed System
� In-Line Crusher
� Basins
� Dewatering Bin
� Tanks
• Continuous ProcessSlurry Pump
For Reuse
Slurry Basin
Coke
Coke Fines
Crusher
Coke Drum
DewateringBin
WaterSettling
Tank
Drain WaterBasin
Clean Water Pump
Clean Water Tank
Within DCU
CCSS_English_2016-09_Streich Page 10
Open System and Its Main Disadvantage
System Disadvantage
Open Pit / Pad (Conventional) 1. High Emission of Coke Fines and VOC
to the Atmosphere with Exhaust Steamfrom Pit, Slurry Sump etc.
2. High Water Loss
Due to the Exhaust Steam from Open System
Railcar Loading
Allen-Sherman-Hoff Hydrobin
Coke Handling Systems – Different SetupsB
CCSS_English_2016-09_Streich
Having a look at Conventional Open Pit/Pad System
Coke Handling Systems – Conventional Pit/Pad SystemB
Coke Pile
Slurry Pump
Maze
Coke Drum
Coke Drum
Sum
p
Clean WaterPump Recovery
Water
Coke-FilledBaskets
Water Flow
Top Region Water Removal via
Vaporization (Dry Tip)
Pit FloorMaze Maze
Ground Region Water Accumulation
(Wet Feet)
Middle Region Up-Flow Vapor & Down-Flow Liquid
Page 11
CCSS_English_2016-09_Streich
Disadvantages of Conventional Open Pit/Pad System
Coke Handling Systems – Conventional Pit/Pad SystemB
Page 12
High Emission
� Coke Fines & 20% VOC to the Atmosphere with Exhaust Steam from Open Pit
Separate Coke Crushing Step
� Coke Fines to the Atomosphere
Poor Dewatering
� Unhomogeneous in Different Coke Pile Regions
� Post-Drainage within Load Area / Railcars / Trucks Required
High Water Loss due to the Exhaust Steam from Open Pit
� High Quantity of Make-Up Water
Maze Clogging
� Repeatedly Manual Sludge Disposal
Low Efficiency of Water Clarification System
� Fines in the Cutting Water
Poor Reliability and High Maintenance Cost
� e.g. Bridge Crane & Pumps
CCSS_English_2016-09_Streich
Disadvantages of Conventional Open Pit/Pad System - High Emission, Maze Clogging
Coke Handling Systems – Conventional Pit/Pad SystemB
Page 13
CCSS_English_2016-09_Streich
Content
Page 14
Topic
A Introduction
B Coke Handling Systems
C Process & Operating Features of CCS System
D Special Design of Selected Components
E Advantages of CCS System
F CCS System Implementation
G Conclusion
CCSS_English_2016-09_Streich
Process & Operating Features of CCSSC
Page 15
What can be expected from the
Closed Coke Slurry System…?
Measures to Improve Coke Handling Operation
Low Emission Closed System to “cover” Processing
Continuous Operation In-line Crusher
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 ClarificationWater Filtering and Internal SludgeRecycle
Higher System Reliability Unique Design & Construction
CCSS_English_2016-09_Streich
How the Closed Coke Slurry System works?
Process & Operating Features of CCS SystemC
Page 16
Crusher
CR-001
Dewatering
Bin DB-001
Transition
Piece
TP-001
WaterSettling
Tank
TK-001Ve
nt
Clean Water
TankTK-002
Slurry Pump
P-001
Transport
Water Pump
P-003
Drain Water
Pump
P-002
Slurry Basin
SB-001
Drain Water
Basin
SB-002
Make-Up
Water
9
2
3
4
5
7
Cutting
Water
Pump
Coke
Drum1
8
Sluice Way SW-001
Flushing
Water Pump
P-004
6
10
Flushing
Water
Vent
VentVent
In-Line Crushing during Cutting Operation
Water Feeding for Coke Transport and
Further Cooling
Forwarding Coke Slurry into theDewatering Bin
Water Diffusing through the Voids of theCoarse Material into the Drain Water Basin
Forwarding Drain Water into the WaterSettling Tank for Separation of RemainingCoke Fines (<0.5%)
Flushing Water for Cleaning Equipment and Piping
Coke Product from Dewatering Bin
Quenching Water for Decoking
Cutting water
Make-up water for Compensating Water Losses
Discharging Collected Sludge into theSlurry Basin
1
2
3
4
5
6
7
8
9
11
10
11
CCSS_English_2016-09_Streich
How the Closed Coke Slurry System works?
Process & Operating Features of CCS SystemC
Page 17
Dedicated Crushing Principle...
Holding the Full Coke Drum Inventory Positively Back – No Avalance Outlet
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
CCSS_English_2016-09_Streich
How the Closed Coke Slurry System works?
Process & Operating Features of CCSSC
Page 18
Dedicated Dewatering Principle...
Hydrostatic Pressure enhances Drain Water Velocity
Coarse Material of Coke serves as Filter for Trapping and Retaining Coke Fines
Maximum Fines Retention (Sludge Retention Rate in Dewatering Bin >99,5 %)
CCSS_English_2016-09_Streich
Content
Page 19
Topic
A Introduction
B Coke Handling Systems
C Process & Operating Features of CCS System
D Special Design of Selected Components
E Advantages of CCS System
F CCS System Implementation
G Conclusion
CCSS_English_2016-09_Streich
Proprietary Design
Special Design of Selected ComponentsD
Transition Piece& Crusher
Slurry & Drain Water Pump
Page 20
CCSS_English_2016-09_Streich
Special Design of Selected ComponentsD
Double Roll Crusher
Proprietary Design
√ 80 Tons of Special Material
√Unique Design & Construction Features
√ 50 mm / 2” Wall Casing Thickness
√German Craftsmanship, under 100 %
TRIPLAN Supervision
√ High Torque Direct Drive Each Roll
√ Crushing Ratio till 10:1; 40” --> 4”
√ Safe & Remote Operation
Page 21
CCSS_English_2016-09_Streich
Special Design of Selected ComponentsD
Transition Piece
Proprietary Design
√
Compensation of axial and radial
Expansions caused by the huge
Temperature Differences in Coke Drum
√ Closed System
√Cladded Surface which has Contact with
abrasive Medium - Coke/Water Mixing
Page 22
Bild
Transition Piece
CCSS_English_2016-09_Streich
Slurry Pump - Proprietary Design
√ No Fines Generation at Low Speed 600 rpm
√ Design, Construction and Materials Selection for Long Life Cycle
√ Cavitation Protection by Impeller Design and Material Selection
Special Design of Selected ComponentsD
Page 23
CCSS_English_2016-09_Streich
Content
Page 24
Topic
A Introduction
B Coke Handling Systems
C Process & Operating Features of CCS System
D Special Design of Selected Components
E Advantages of CCS System
F CCS System Implementation
G Conclusion
CCSS_English_2016-09_Streich
Advantages of CCS SystemE
Environment-Friendly, Safe, Efficient & Economical
EF
No Emission of Coke Fines & VOC to the Atomosphere
No Effluent
Minimum Steam Exhaust
S
Safe & Healthy Environment für Fellow Worker
Minimization of Occupational Accidents & Fire Hazard within the DCU
EE
Effective Water Clarification
Extensively Automation / Low Manpower
High Overall System Reliability (≥99.5%)
Less Footprint
Omission of Open Pit/Pad with 17 Meter Walls
Low Make-Up Water Consumption
Low Operation & Maintenance Cost
Page 25
CCSS_English_2016-09_Streich
Content
Page 26
Topic
A Introduction
B Coke Handling Systems
C Process & Operating Features of CCS System
D Special Design of Selected Components
E Advantages of CCS System
F CCS System Implementation
G Conclusion
CCSS_English_2016-09_Streich
CCS System ImplementationF
Retrofit e.g. Replacement for Open PIT/PAD
√ Suitable for Multi-Drum Coker
√ Footprint fits into any Existing Coker Units, Maximum Layout Flexibility
√System Flexibility - Slurry Transport via Pipeline (e.g. 4 Kilometers) for Supplying
remote Power Stations / Gasification Plants / Calciner Plants with Petcoke directly
√Basin Construction in Concrete (above-/underground) or Steel Work
(aboveground)
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CCSS_English_2016-09_Streich
CCS System ImplementationF
Greenfield Installation
√ Ease Permission regarding Environmental Concern
√ Early Involvement for Optimum Project Embedding & Cost Savings
√ Suitable for Multi Drum Coker
√System Flexibility - Slurry Transport via Pipeline for Feeding remote Power
Stations / Gasification Plants / Calciner Plants Petcoke directly
Page 28
CCSS_English_2016-09_Streich
Content
Page 29
Topic
A Introduction
B Coke Handling Systems
C Process & Operating Features of CCS System
D Special Design of Selected Components
E Advantages of CCS System
F CCS System Implementation
G Conclusion
CCSS_English_2016-09_Streich
ConclusionG
Page 30
CCSS at a Glance - Features of CCSS vs. Conventional Systems
Items CCSS Conventional Systems
Emission of Coke Fines & VOC
Dewatering Efficiency
Water Consumption
Level of Automation
Operational Safety
Reliability
Plot Requirement
Total Investment (CAPEX)
Operating Costs (OPEX)
very low very high
very high poor
Very low high
high very low
very high low
very high low
moderate high
equal
low
equal
high
CCSS_English_2016-09_Streich
ConclusionG
Operating Experience with CCSS
Page 31
Best Available Technology (BAT)
√No Dedicated Field Operators Required; Less 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 System
√ No Fire, No Accidents, No ‘Near Miss’ Incidents
√ Free Water Content of Commercially Dry Coke ≤ 10%
25 Years+
at a German Refinery
10 Years Operation
in current configuration
CCSS_English_2016-09_Streich
Get rid of the coal mine coal mine coal mine coal mine in your refinery !
Technology for Future, For a cleaner environment
CCSS_English_2016-09_Streich
Thanks for Your Attention
TRIPLAN Technology GmbH
Essostrasse 16
76189 Karlsruhe
Germany
www.triplan.com
www.triplan.com
Sunil Kulkarni
India
Werner Vermeire
Page 33