Başlık

TÜPRAŞ Residuum Upgrading Project (RUP)

Delayed Coker Unit (DCU)

XX.05.2019

Onur Aka
Process Superintendent
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 Başlık Agenda

➢ TUPRAS General Information

➢ RUP General Information

➢ RUP Delayed Coker Unit

➢ Issues Encountered During Precommissioning/Commissioning/Operation

➢ Recommendations

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Başlık TUPRAS General Information

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 Başlık Tüpraş Residuum Upgrading Project (Scope)

➢ Delayed Coker Unit (8,200 m3/d), Foster Wheeler USA

➢ Integrated Unicracking Process Unit (8,800/4,000/1,300 m3/d), UOP

➢ Vacuum Distillation Unit (8,500 m3/d), Shell Global Solutions

➢ Hydrogen Production Unit (160,000 Nm3/h), Technip

➢ Sulphur Recovery Units (420 ton/d, 2 trains), Jacobs

➢ Amine Regeneration Unit (2 trains),

➢ Sour Water Stripping Unit (2 trains),

➢ Cooling Water Systems,

➢ Flare,

➢ Co-generation System (120 MW ISO), GE+Aalborg

➢ Tank Farm (23 tanks, 665,000 m3)

➢ Waste Water Treatment Unit (12,000 m3/d),

➢ Jetty Terminal

➢ GARE Station 4
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 Başlık RUP Financial Figures

➢ Total Investment Cost: ~ 3 Billion$

➢ Increase in TUPRAS EBIDTA: 550 Million$/yr

➢ Decrease in Trade Balance Deficit of Turkey:1 Billion$/yr

➢ TUPRAS Refineries Capacity Utilisation: %75-80 →%100 (Actual ~%105)

➢ Nelson Complexity Index of İzmit Refinery: 7.78 → 14.5

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 Başlık Utilisation
Capacity

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 Başlık RUP Brief Process Flow Diagram
Fuel Gas

Natural LPG
Gas Hydrogen Production Unit Hydrogen Integrated
Unicracking Light Naphtha
(160,000 Nm3/h)
Process Unit
Heavy Naphtha
(8,800/4,000/
1,300 m3/d) Jet Fuel

LVGO Diesel
Atmospheric Vacuum Fuel Gas
Residue
Distillation Hydrocracker Bottom
HVGO
(8,500m3/d)

LPG

Vacuum Residue
Delayed Coker Naphtha

Coker Unit
Vacuum Residue (8,200m3/d) Light Coker Gas Oil

Heavy Coker Gas Oil

Petroleum Coke

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 Başlık RUP Delayed Coker Unit

➢ Licensor: Foster Wheeler USA

➢ SYDEC Process (Selective Yield Delayed Coking)
➢ Capacity: 51.578 BPSD
➢ Furnace Outlet Temperature: 925-9400F
➢ Coke Drum Pressure:15 Psig
➢ Coke Drum Vapor Temperature: 810-8250F
➢ Throughput Ratio: 1.07

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 Başlık Technology Partners (Vendors)

➢ Furnace: FW Fired Heater Division (FWFHD)

➢ Coke Drums: Sumitomo Heavy Industries
➢ Coke Cutting System: Flowserve
➢ Unheading System: DeltaValve
➢ Coke Handling: Taimweser and McLanahan
➢ DCS/ESD/Fire&Gas Systems: Yokogawa
➢ Main Contactor: Tecnicas Reunidas
➢ Subcontractor: Tekfen İnşaat

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 Başlık Issues Encountered - 1

➢ Fractionator Bottoms Revisions

➢ Coke Drum&Critical Piping Const. Review

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Başlık Issues Encountered-2

➢ Coke Drum Quench&Antifoam Nozzles Installation

➢ Coke Drum Insulation Revision

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 Başlık Issues Encountered - 3

➢ Coke Pit Dewatering Problem

➢ What was wrong?

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 Başlık Issues Encountered - 4

➢ Coke Chute Support Damage

➢ What happened?

➢ What was wrong?

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 Başlık Recommendations

➢ Consider all activities related with Coke Structure as priority

➢ All construction teams should be aware of expected movement of coke

drums and overhead piping

➢ Consider Lube oil and hydraulic oil flushing as long lead items

➢ Extensive Classroom and Onsite Training for operators is mandatory 14

Başlık

THANK YOU.
ANY QUESTIONS? 15