Closed Coke Slurry System

Transcription

1 Closed Coke Slurry System An Advanced Coke Handling Process Environment-Friendly Economical Safe TRIPLAN AG Auf der Krautweide Baden Soden Germany

2 Content Topic A B C D E F G Introduction Coke Handling Systems Process & Operating Features of CCS System Special Design of Selected Components Advantages of CCS System CCS System Implementation Conclusion Page 2

3 A Introduction Global Situation in Crude Refining Worldwide Shift to Heavier Crudes Global Heavy Crude Proc. [mio. b/d] More Stringent Regulations for Heavy Fuel Oils Global Sulphur Limit [% w/w] Focus on Bottom Upgrading Processes Source: Oil & Gas Journal 2010 Source: MARPOL 73/78 Replacement of Heavy Fuels by LNG LNG Demand Marine Sector [bil. m³/a] Source: GAZPROM 2011 Page 3

4 A Introduction Bottom Upgrading Distribution of Bottom Upgrading Processes Distribution by Coking Technologies 5% 3% 3% 2% 6% 8% 36% 8% 51% 78% Coking Fixed-bed hydroproc. Ebullated-bed Hydrocracking RFCC Visbreaking Solvent Deasphalting Delayed Coking Other Fluid Coking unspecified Source: Hydrocarbon Publishing 3Q, 2010 Page 4

5 A Introduction Key Process Steps Delayed Coking Delayed Coking Processing (Schematic) Residue Cutting Water LPG Preheating in the Fractionator Coker Naphtha LCGO HCGO Residue Fractionator Coke Drum Coke Drum Heating in the Furnace Cracking in the Coke Drum Furnace Coke Generating Petro Coke from Heavy Tars Directing Vapors to the Fractionator Coke Handling System Decoking by Hydraulic Measures Recovering Cracked Products Coke Handling and Shipment Valuable Distillates, e.g. Transportation Fuels Page 5

6 Content Topic A B C D E F G Introduction Coke Handling Systems Process & Operating Features of CCS System Special Design of Selected Components Advantages of CCS System CCS System Implementation Conclusion Page 6

7 B Coke Handling Systems Different Setups Pit or Pad System (95% Existing Coker Units) Railcar Loading System Coke Drum Chute Reclaimed by crane or Frontend Loader Pit or Pad To Clean Water Tank Maze Sump Open System No In-Line Crusher Crane or Front-End Loader for Coke Transport Sump Sludge Settling in Maze Crusher Railcar Coke Drum Sluiceway Coke Fines Sump To Clean Water Tank Water Clarification System Open System Just-In-Time Unloading Water Separation by Overflowing & through Holes in the Car TRIPLAN s Proprietary Closed Coke Slurry System CCSS Vent Coke Drum Coke Fines Water Settling Tank Clean Water Tank for Reuse Chute Crusher Slurry Basin Slurry Pump Dewatering Bin Drain Water Basin Coke Clean Water Pump Closed System Continuous Process between Cutting & Unloading Page 7

8 B Coke Handling Systems Conventional Pit/Pad System Having a look at Conventional Open Pit/Pad System Coke Pile Water Flow Slurry Pump Sump Maze Coke-Filled Baskets Ground Region Water Accumulation (Wet Feet) Top Region Water Removal via Vaporization (Dry Tip) Middle Region Up-Flow Vapor & Down-Flow Liquid Coke Drum Coke Drum Clean Water Pump Recovery Water Maze Pit Floor Maze Page 8

9 B Coke Handling Systems Conventional Pit/Pad System Disadvantages of Conventional Open Pit/Pad System High Emission Coke Fines & 20% VOC to the Atomosphere 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 Quantity of Make-Up Water 1/3 to 1/2 of Total Water Inventory per Batch Maze Clogging Repeatedly Manual Sludge Disposal Required Low Efficiency of Water Clarification System Fines in the Cutting Water Poor Reliability and High Maintenance Cost e.g. Bridge Crane & Pumps Page 9

10 Content Topic A B C D E F G Introduction Coke Handling Systems Process & Operating Features of CCS System Special Design of Selected Components Advantages of CCS System CCS System Implementation Conclusion Page 10

11 C Process & Operating Features of CCSS What can be expected from the Closed Coke Slurry System? Measures to Improve Coke Handling Operation Low Emission Continuous Operation Efficient Dewatering Low Make-Up Water Consumption Low Manpower Requirement Effective Sludge Management Higher System Reliability Closed System to cover Processing In-line Crusher Special Dewatering Bin (Water Content 8%) Less Exhaust Steam Losses High Level of Automation Internal Sludge Recycle Unique Design & Construction Page 11

12 C Process & Operating Features of CCS System How the Closed Coke Slurry System works? Vent Coke Drum Dewatering Bin Water Settling Tank 8 Clean Water Tank 5 4 Make-Up Water Chute 2 1 Crusher 3 9 Coke Drain Water 6 7 Sludge Slurry Pit Drain Water Basin Slurry Pump Drain Water Pump Clean Water Pump Page 12

13 C Process & Operating Features of CCSS How the Closed Coke Slurry System works? Processing Steps In-Line Crushing during Cutting Operation Water Feeding for Coke Transport and Further Cooling Forwarding Coke Slurry into the Dewatering Bin Water Diffusing through the Voids of the Coarse Material into the Drain Water Basin Trapping and Retaining of Coke Fines ( 99.5%) in Coke Bed Forwarding Drain Water into the Water Settling Tank for Separation of Remaining Coke Fines (<0.5%) Discharging Collected Sludge into the Slurry Pit Converting Clean Water into the Clean Water Tank for Reuse Coke Product Unloading from Dewatering Bin Page 13

14 C Process & Operating Features of CCS System How the Closed Coke Slurry System works? Dedicated Crushing Principle... Chute Raising and Docking to Drum Bottom Valve Remotely Holding the Full Coke Drum Inventory Positively Back Unlimited Crushing Capacity Handling any Type of Coke from Premium Calcinate Grade to Shot Coke Matching any Impact Loads & any Cutting Rates In-line Grinding from 40"/1,000 mm to 2"/ 50 mm in One Single Step Releasing Uniformly Crushed Coke Page 14

15 C Process & Operating Features of CCSS How the Closed Coke Slurry System works? Dedicated Dewatering Principle... Short and Uniform Distances to Screen enable Minimum Water Diffusing Time Hydrostatic Pressure enhances Water Stream Velocity Water Runs Through the Voids of the Coarse Material at High Velocity High Velocity leads to Trapping and Retaining of Coke Fines on the Lumps and results in Maximum Fines Retention (Sludge Retention Rate in Dewatering Bin >99,5 %) Page 15

16 Content Topic A B C D E F G Introduction Coke Handling Systems Process & Operating Features of CCS System Special Design of Selected Components Advantages of CCS System CCS System Implementation Conclusion Page 16

17 D Special Design of Selected Components Proprietary Design Double Roll Crusher Slurry Pump & Slurry Pipe Dewatering Bin Page 17

18 D Special Design of Selected Components Double Roll Crusher with Integrated Chute Proprietary Design 80 Tons of Special Material Unique Design & Construction Features 50 mm / 2 Wall Casing Thickness German Craftsmanship, under 100 % TRIPLAN Supervision Page 18

19 D Special Design of Selected Components Double Roll Crusher with Integrated Chute Proprietary Design High Torque Direct Drive Each Roll Crushing Ratio 20:1; e.g > 2 Safe & Remote Operation Hydraulic Chute Raising & Retracting Docking Automatic to Drum Flange or Bottom Valve Page 19

20 D Special Design of Selected Components Dewatering Bin Screens Circumference Cone Section Fully Slotted Drain Lines Circumference To Drain Water Basin Proprietary Design Closed Drum with Vent Drum Wall and Cone Section Fitted with Special Screens Uniform and Fast Dewatering Non-Clogging Type Screens Controlled Release of Coke Product with Vibration Feeder Page 20

21 D Special Design of Selected Components Dewatering Bin Dewatering Effect over Time 100 Free Water in Coke [% w/w] Dewatering Time [h] Proprietary Design Typical Dewatering Performance for Batch Size from 1,000 up to 1,500 Tons Dedicated Batch Dewatering Permanent Water Removal due to Hydrostatic Pressure Dewatering Time 6h from Cutting to Unloading Free Water Content of Coke Product 8% Page 21

22 D Special Design of Selected Components Dewatering Bin Typical Dewatering Schedule Hours X Drum Decoking/Cutting 3 Coke Crushing ( In-Line ) 3 Instant Coke Dewatering 6 Coke Unloading Total Time from Cutting to Unloading Dry Coke : 6 hours Page 22

23 D Special Design of Selected Components 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 Closed Slurry Pipe - Proprietary Design Design and Construction for Optimum Slurry Transportation Special Material Selection for Long Life Cycle Page 23

24 Content Topic A B C D E F G Introduction Coke Handling Systems Process & Operating Features of CCS System Special Design of Selected Components Advantages of CCS System CCS System Implementation Conclusion Page 24

25 E Advantages of CCS System Environment-Friendly, Safe, Efficient & Economical EF S No Emission of Coke Fines & VOC to the Atomosphere Minimum Steam Exhaust Safe & Healthy Environment für Fellow Worker Minimization of Occupational Accidents & Fire Hazard within the DCU Almost 100% Fines Retention Efficiency ( 99.5% in Dewatering Bin + Remaining in Water Settling Tank) Movable and Interchangeable Crusher for Maintenance Access EE High Overall System Reliability ( 99.5%) Low Operation & Maintenance Cost Fully Automation / Low Manpower Low Make-Up Water Consumption Page 25

26 Content Topic A B C D E F G Introduction Coke Handling Systems Process & Operating Features of CCS System Special Design of Selected Components Advantages of CCS System CCS System Implementation Conclusion Page 26

27 F CCS System Implementation Retrofit e.g. Replacement for Open PIT/ PAD Suitable for Multi-Drum Coker Footprint fits into any Existing Coker Units, Maximum Layout Flexibility System Separably - Slurry Transport via Pipeline (e.g. 4 Kilometers) for Feeding remote Power Stations / Gasification Plants / Calciner Plants directly No Extra Shutdown Required for Execution due to Modular Construction / Prefabrication Basin Construction in Concrete (above-/underground) or Steel Work (aboveground) Page 27

28 F CCS System Implementation Greenfield Installation Ease Authorities Environmental Concerns during Project Approval Phase Early Involvement for Optimum Project Embedding & Cost Savings Shorter Cycle Time enables lower CAPEX. Basin Construction in Concrete (above-/underground) or Steel Work (aboveground) Maximum Layout Flexibility System Separably - Slurry Transport via Pipeline (e.g. 4 Kilometers) for Feeding remote Power Stations / Gasification Plants / Calciner Plants directly Page 28

29 Content Topic A B C D E F G Introduction Coke Handling Systems Process & Operating Features of CCS System Special Design of Selected Components Advantages of CCS System CCS System Implementation Conclusion Page 29

30 G Conclusion CCSS at a Glance - Features of CCSS vs. Conventional Systems Items CCSS Conventional Systems Emission of Coke Fines & VOC Dewatering Efficiency very low very high very high poor Water Consumption Level of Automation Very low high high very low Operational Safety very high low Reliability Plot Requirement Total Investment (CAPEX) Operating Costs (OPEX) very high moderate equal low low high equal high Page 30

31 G Conclusion Operating Experience with CCSS Best Available Technology (BAT) 8 Years Operation at a German Refinery No Dedicated Field Operators Required; Only 4 Technicians per Shift for the Entire Delayed Coker Unit. Maintenance Free; Reliability Factor 99,5% Uninterrupted Operation, Equivalent to Cycles No Deterioration of the Slurry & Cutting Water 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 8% Page 31

32 ThanksforYourAttention TRIPLAN AG Auf der Krautweide Bad Soden Germany India Contact: Sunil Kulkarni China Contact: Zheng-Zhu Streich US Contact: Artur Krueger Page 32