Dcu Revamp For Capacity and Efficiency Increase

DCU REVAMP FOR CAPACITY AND EFFICIENCY INCREASE
Presented By:
Hardeep Singh - Bharat Oman Refineries Limited, Bina, India
Virendra Manral - Chevron Lummus Global, Bloomfield, USA
A Chevron and Lummus Technology Joint Venture

© 2016 Chevron Lummus Global. All Rights Reserved. Company Confidential
Overview
Unit Introduction
DCU Revamp
Objectives
Design Basis
Revamp Feasibility Study
Methodology
Coke Drum
Heater
Equipment Adequacy check
Other Proposed Modifications
Conclusion
© 2015 Chevron Lummus Global. All Rights Reserved. Company Confidential 2
Unit Introduction
Unit Design Capacity : 1.36 MMTPA or 170,000 kg/h (23,500 BPSD)

Refinery : Bharat Oman Refineries Limited (BORL), Bina, India
Commissioned : 2011
Licensor : Chevron Lummus Global (CLG)
Detailed Engineering Company: Engineers India Limited (EIL), New Delhi, India

Unit Introduction
Feed Design Basis :
Feed Property Feed-2 Feed-3

Feed-1 Feed-4
Vacuum (65:35 wt% Arab (45:55 wt% Arab
(100% Kuwait) (100% Oman)
Residue Mix) Mix)
API - Gravity 4.53 4.18 3.77 11.99

Sulfur 5.50 5.19 5.50 2.52
Asphaltenes 21.0 N/A N/A 1.8
CCR, wt% 22.30 23.99 25.04 15.62
Extraneous streams :
a) Filter backwash stream from the hydrocracker
b) Black slop from refinery
c) Refinery sludge from ETP

Unit Introduction
Products :
Coker Fuel Gas
Liquefied Petroleum Gas
Coker Naphtha (C5 - 140°C)
Light Coker Gas Oil (140°C - 370°C)
Heavy Coker Gas Oil (370°C Plus)
Coke

Unit Introduction
Unit Special Design Features :

Two heaters for one pair of coke drums
Provision of on-line pigging
Isolations at inlet and outlet
On-line spalling

DCU Revamp
After successful operation of the DCU at design levels, BORL noted the potential to
further enhance the capacity of the unit
The unit revamp was planned out in the three phases :
Phase I - Revamp Feasibility Study - To identify alternatives and estimate

capacity increase and energy saving - Completed
Phase II – Comprehensive process engineering for phase I and in-depth

mechanical design critical items - Completed
Phase III - Detailed Engineering, Procurement and Construction - On-going

DCU Revamp
Objectives
The main objective was to increase DCU throughput by 30% by :
Utilizing inbuilt equipment design margins
Paying attention to current operating conditions
Other considerations :
Short shutdown period
Low revamp cost

DCU Revamp
Design Basis
Design Basis :
Capacity Increase : 170 MT/h to 220 MT/h (23,500 BPSD to 30,550 BPSD)
On-Stream Factor Increase : 8,000 hours/year to 8,280 hours/year
Turndown 50%
Revamp Feed Case :

Feed Property Feed Case - 1 Feed Case - 2
Vacuum Residue 45:55 Arab Mix 48% Arab Mix (65:35 Blend of Arab
Light : Arab Heavy) + 52% Oman
API Gravity 4.53 7.18
Sulfur, Wt% 6.0 4.12
Asphaltenes, Wt% 12.3 9.1
Con Carbon, Wt% 27.0 22.0

Unit Test Run

Determination of maximum achievable capacity
Validation of the CLG in-house Yield Prediction model
Equipment adequacy
Coke Drum
Thermal rating of Coker Heater
Other Equipment
Plot plan availability
Project schedule
Revamp Total Investment Cost (+/- 30%)

Coke Drum
Original design coke drum overhead pressure : 1.05 kg/cm2g
Due to system hydraulics, a minimum coke drum overhead pressure of 1.52
kg/cm2g is required for 130% throughput, however the superficial velocity exceeds
the design limits at these conditions
To meet the superficial velocity design criteria, a higher coke drum overhead
pressure of 2.5 kg/cm2g is required
Higher pressure coke drum operation will decrease liquid yield and increase coke
make

Coke Drum
C5+ Liquid and Coke yield - 1.52 kg/cm2g vs 2.5 kg/cm2g operation
Yield (wt% of feed)
1.52 kg/cm2g
2.5 kg/cm2g
C5+ Liquid Coke
The increase in pressure results in a C5+ liquid yield loss (~ 2 wt.%) equivalent to
about 12 MMUSD/year
Hence, there was merit in investigating options of retaining lower coke drum
overhead pressure

Coke Drum
To retain lower coke drum pressure, the addition of a single new coke drum vs.
another pair of coke drums was studied
The benefits of adding a new single drum vs. another pair of coke drums are :
Lower investment cost
Less plot area required
Longer decoking time (30-hour), thus no change in the blowdown section
Higher vapor disengagement space in each coke drum
Based on the above, it was decided to install a single new coke drum.
CB&I’s Vertical Plate Coke Drum Technology (VPCD) was selected for the new drum.

Coke Drum

Coke Drum

Coke Drum

Coke Drum

Coke Drum
Coking / Decoking Schedule (45-Hour Cycle)
Key Hrs Operation

15 Coking
S 1 Steamout to Fractionator
B 1.5 Steamout to Blowdown
Q 6 Quench and Fill
D 1.5 Drain
U 1 Open Heads
C 4 Hydraulic Decoking
IDLE 6 Idle Time
P 2 Re-head & Pressure Testing
W 7 Drum Warm-up
45 Total Cycle
Coker Heater
Thermal rating of the Coker Heater was carried out for the revamp conditions
Modifications proposed :
Add roof tubes to each cell to keep the radiant flux within the allowable limit
Change tube number, size, and metallurgy of radiant tubes
Allows an increase in the End of Run (EoR) Tube Metal Temperature (TMT),
leading to an increase in run length
Causes EoR pressure drop to be within the allowable limit, minimizing the
modifications in the heater charge circuit
Replace tube supports

Coker Heater
Modifications proposed (cont.) :
Use two future rows of tubes in the convection section
Replace both forced draft and induced draft fans to accommodate higher flow
and static pressure
Reuse the existing burner with new tip drillings and new oil gun
Preliminary rating of Air Preheater reveals no modification is required. However,
further rating of the APH is to be carried out by the supplier during detailed
engineering phase of the project
Combustion air, flue gas ducts and stack – No modification required

Equipment Adequacy Check
Equipment Adequacy :
Wet Gas Compressor : A new wet gas compressor to be installed in parallel with
existing WGC
Columns : Diameters are adequate, internals require modifications
Pumps : Larger impeller installation was recommended, new pumps if required
Shell and tube heat exchangers : Rated based on simple UA analysis
Air coolers : Rated using CLG in-house rating program
Hydraulics carried out in next phase

Proposed Modifications
Other proposed modifications :
Water Ring Compressor : To be installed on the blowdown overhead circuit to

minimize emission and depressurize the coke drum safely
Fresh Feed Steam Preheater : To be installed on the fresh feed line to

accommodate for temperature fluctuations in the fresh feed to the DCU
Coke Pit/Pad : Extension of pit/pad to allow for increase in coke make
Center Feed Device (CFD) : New coke drum feed piping configuration has been
designed considering the installation of a CFD in the future if deemed necessary

Proposed Modifications
Other revamp feasibility considerations :
Plot plan availability for the new / modified equipment
Revamp project schedule – 40 days
Budgetary TIC cost estimate (+/-) 30%
Based on the results of the feasibility study, BORL has decided to

further pursue the revamp of the unit.

Conclusion
Delayed Coking units add a lot of flexibility to a refinery operation. It is one of the
most versatile units in terms of “its ability to process a broad range of” feed quality.
The refiner can shift the product slate to a different type of coke or to a different
yield structure based on shifts in the market demand, with minimal changes to the
unit infrastructure.
Selecting a revamp option should be done carefully, considering the minimization
of capital investment and maximization of return. This requires a vast knowledge of

the technology and experience in project execution.
A successful DCU revamp must be done in a planned manner, with a close working
relationship between the Licensee, Detailed Engineering Company, and Licensor.

Thank you
A Chevron and Lummus Technology Joint Venture

© 2016 Chevron Lummus Global. All Rights Reserved. Company Confidential

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DCU REVAMP FOR CAPACITY AND EFFICIENCY INCREASE

A Chevron and Lummus Technology Joint Venture

Revamp Feasibility Study

Unit Design Capacity : 1.36 MMTPA or 170,000 kg/h (23,500 BPSD)

© 2015 Chevron Lummus Global. All Rights Reserved. Company Confidential 3

Feed Design Basis :

Feed Property Feed-2 Feed-3

API - Gravity 4.53 4.18 3.77 11.99

© 2015 Chevron Lummus Global. All Rights Reserved. Company Confidential 4

Coker Fuel Gas

Liquefied Petroleum Gas

Coker Naphtha (C5 - 140°C)

Light Coker Gas Oil (140°C - 370°C)

Heavy Coker Gas Oil (370°C Plus)

© 2015 Chevron Lummus Global. All Rights Reserved. Company Confidential 5

Unit Special Design Features :

© 2015 Chevron Lummus Global. All Rights Reserved. Company Confidential 6

further enhance the capacity of the unit

The unit revamp was planned out in the three phases :

Phase I - Revamp Feasibility Study - To identify alternatives and estimate

Phase II – Comprehensive process engineering for phase I and in-depth

Phase III - Detailed Engineering, Procurement and Construction - On-going

© 2015 Chevron Lummus Global. All Rights Reserved. Company Confidential 7

The main objective was to increase DCU throughput by 30% by :

Utilizing inbuilt equipment design margins

Paying attention to current operating conditions

Short shutdown period

Low revamp cost

© 2015 Chevron Lummus Global. All Rights Reserved. Company Confidential 8

On-Stream Factor Increase : 8,000 hours/year to 8,280 hours/year

Revamp Feed Case :

Sulfur, Wt% 6.0 4.12

Asphaltenes, Wt% 12.3 9.1

Con Carbon, Wt% 27.0 22.0

© 2015 Chevron Lummus Global. All Rights Reserved. Company Confidential 9

Unit Test Run

© 2015 Chevron Lummus Global. All Rights Reserved. Company Confidential 10

Original design coke drum overhead pressure : 1.05 kg/cm2g

Due to system hydraulics, a minimum coke drum overhead pressure of 1.52

pressure of 2.5 kg/cm2g is required

© 2015 Chevron Lummus Global. All Rights Reserved. Company Confidential 11

C5+ Liquid Coke

© 2015 Chevron Lummus Global. All Rights Reserved. Company Confidential 12

another pair of coke drums was studied

Lower investment cost

Less plot area required

Longer decoking time (30-hour), thus no change in the blowdown section

Higher vapor disengagement space in each coke drum

© 2015 Chevron Lummus Global. All Rights Reserved. Company Confidential 13

© 2015 Chevron Lummus Global. All Rights Reserved. Company Confidential 14

© 2015 Chevron Lummus Global. All Rights Reserved. Company Confidential 15

© 2015 Chevron Lummus Global. All Rights Reserved. Company Confidential 16

© 2015 Chevron Lummus Global. All Rights Reserved. Company Confidential 17

Coking / Decoking Schedule (45-Hour Cycle)

Key Hrs Operation

Change tube number, size, and metallurgy of radiant tubes

leading to an increase in run length

modifications in the heater charge circuit

Replace tube supports