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PLANT DESCRIPTION
Date of Rev. : 01/04/2023

3.1 Process Chemistry

Carbonization Theory/Reaction
Carbonization is the thermal conversion of organic materials to carbon and graphite. The overall
transformation involves a complex series of chemical reactions and diffusion processes in both the
liquid and solid state. The reaction sequence consists of the elimination of substituent atoms and
groups from the organic molecule, aromatization, and subsequent polymerization to a large
aromatic carbon framework.
Petroleum coke can be formed by two basically different mechanisms.
a) High molecular weight compounds, such as asphaltenes and resins, tend to dealkylate to
straight chain compounds and CH2 groups when subject to high temperatures. A residue of
carbon is left behind. Graphitization is difficult to accomplish for this type of coke at high
temperature.
b) Dehydrogenation of heavy oils followed by the polymerization or condensation of free radicals
forms high molecular weight compounds, which proceed eventually to coke. This type of coke
exhibits superior quality and is easily graphitized. Commercially, synthetic carbon and graphite
are prepared from aromatic starting materials, such as coal tar pitch and heavy petroleum
residues. These raw materials consist largely of mixtures of compounds containing aromatic
hydrocarbon and heterocyclic structures.

Chemical Reactions of Carbonization

There are three types of thermal reaction processes, which are important:
1) Dehydrogenation
2) Rearrangement, and
3) Polymerization
These reactions do not proceed in distinct steps, but occur continuously throughout the
coking process.
The thermal reactions taking place are both endothermic and exothermic. Heat is applied to the
material in the coking heater to initiate the cracking reaction. As polymerization proceeds in the
coke drum, the exothermic reactions provide the heat to continue the dehydrogenation process.
1. Dehydrogenation
The initial reaction in carbonization involves the loss of a hydrogen atom from an aromatic
hydrocarbon and leads to the formation of an aromatic-free radical intermediate.
2. Rearrangement Reactions
Perhaps the most complicating features of the early stages of carbonization are the thermal
rearrangement reactions. They often make it impossible to predict from the starting structure
whether a given compound will produce a well-graphitizing or a disordered carbon. Thermal
rearrangement usually leads to a more stabilizing aromatic ring system, which can then become
the building block for graphite growth.
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3. Polymerization of Aromatic Radicals

The formation of carbon involves the polymerization of aromatic-free radicals. These
polymerizations usually are initiated in the liquid phase and lead to aromatic polymers. This is an
important stage in the graphitization process. Unlike conventional polymerization, which rapidly
increases the molecular size, the aromatic polymerization appears to proceed in steps. Non planar
radical intermediates lead to disordered aromatic polymers which never truly graphitize.

Brief Process Flow Description

The delayed coking process is essentially a thermal cracking process to minimize refinery yields
of residual fuel oil by conversion to gas, naphtha, gas oil and coke. The Coker feed is vacuum
residue. The feed stream is preheated by HCGO product and pump around streams and charged to
the bottom section of the main Fractionator where it mixes with the heavy recycle liquid from the
bottom tray. The combined Coker feed and heavy recycle liquid is pumped to the coking heater
where it is rapidly heated to temperatures above the coking point. This heater charge is quickly
pushed through the heater in order to prevent significant coke formation in the heater tubes.

The heater effluent is charged to the Coke Drum where further cracking reactions and subsequent
polymerization take place to form coke. Vapor products leave the top of the Coke Drum where
they are immediately quenched with a slip stream of HCGO pumparound. Quenching stops the
cracking and polymerization reactions.

The quenched Coke Drum effluent is charged to the Main Fractionator where light gas, naphtha,
LCGO, HCGO and heavy recycle liquid are separated. The LCGO and HCGO steams are stripped
in their respective strippers to meet product specifications before cooling and final routing to the
battery limits.

Vapor from the Coker Fractionator is partially condensed and collected in the Coker Fractionator
Overhead Receiver, which separates vapor, hydrocarbon liquid and sour water. Vapor is routed to
the Vapor Recovery Section. A portion of the hydrocarbon liquid is pumped to the Main
Fractionator top tray as reflux, and the remaining portion is pumped to the Vapor Recovery
Section. Sour water goes to OSBL for treatment.
The Vapor Recovery Section separates the light products to Stabilized Naphtha and fuel gas.
The wet gas from the Coker Fractionator Overhead Receiver is compressed in a two-stage Wet
Gas Compressor. The compressor Vapor discharge is partially condensed and separated in the
Recontact Drum. The Vapor is charged to the Absorber, where it is contacted by a naphtha stream
(Lean Oil) in order to limit loss of LPG with fuel gas. The overhead gas from the Absorber is sent
to the Sponge Absorber for contact with a LCGO stream as sponge oil in order to minimize loss
of naphtha range material with the Sour Coker Gas. Liquid from the Recontact Drum is treated in
the Stripper to remove C2 and lighter components. Hydrocarbon liquid from the bottom of the
Stripper is then pumped to the Debutanizer Column. Sour water from the Compressor Interstage
Drum and the Recontact Drum recycle to the Coker Fractionator Overhead Receiver. Hydrocarbon
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liquids from the Recontact Drum are routed to the Debutanizer to separate C3 and C4 components
from Stabilized Naphtha.

3.2 Detailed Process Flow Description

From the operational point of view, the above process can be classified into the following sections:
 Feed Surge Drum and Feed Preheat
 Coker Furnace and Coke Drums
 Coker fractionator
 Vapor Recovery Section
 Coke Drum Steamout /Blowdown
 Decoking Green Coke Handling
The detailed description of each of these above sections is given in the following paragraphs. For
an easier follow up of the detailed process description, refer drawing nos. 14-0101 to 109.

3.2.1 Coker Feed System, Coking and Primary Fractionation

Design feed to the Delayed Coker Unit consists of straight run vacuum residue. The feed is
received in the Coker Feed Surge Drum 14-VV-00-101 and is pumped by the Coker Unit Feed
Pumps 14-PA-CF-101(N) A/B.
Coker feed is preheated in a steam heated exchanger, 14-EE-00-1001 from 173 oC to 220oC and
then successively preheated against Heavy Coker Gas Oil (HCGO) product in 14-EE-00-101A/B
and with HCGO Pump-around in 14-EE-00-102A/B. The preheated feed then flows into the
bottom of the Coker Fractionator, 14-CC-00-101(M). The feed mixes with bottoms liquid of the
fractionator, which is a gasoil heavier than HCGO that condenses in the wash section of Coker
Fractionator and then overflows into the bottom. The combination of bottoms liquid, called
Recycle Oil, and the fresh feed becomes Coker Heater feed. Introduction of relatively cool Coker
feed into the fractionator bottoms reduces the tendency for coke formation in the tower bottoms.
Fractionator bottoms liquid level is maintained by regulating the flow rate of Coker feed from the
Coker Feed Drum. To remove accumulated coke fines, a slipstream of fractionator bottom liquid
is continuously circulated through the Fractionator Bottoms Strainers, 14-GN-00-101A/B, by the
Fractionator Bottoms Recirculation Pump, 14-PA-CF-103A/S.
The Coker Heater** feed is pumped by the Coking Heater Charge Pumps, 14-PA-CF- 102 (M)
A/B, to the Coker Heater, 14-FF-00-101(M) A/B. The Coker Heater features four passes with
individual flow controls on each pass. A controlled quantity of HP steam is injected into each
heater pass to maintain a sufficient velocity to minimize coke formation in the tubes. The prime
function of the Coker Heater is to quickly heat the feed to the required reaction temperature while
avoiding premature coke formation in the heater tubes.
A steam coil, above the process convection section in the heater, superheats MP steam. This steam
is utilized for stripping LCGO and HCGO in their respective stripper column. Coker Heater
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combustion air is also preheated against flue gas in the convection section to improve heater
efficiency.
The Coker Heater is fired with fuel oil or fuel gas or combination of both fuels. A Heater Fuel Gas
K.O. Drum, 14-VV-00-109, separates any condensable liquids in the fuel gas before they reach
the Coker Heater.
The heater 14-FF-00-101(M)A/B has a total of four passes. Two heater coils have a common
convection section and the other two heater coils have their own common convection section. Air
preheat system*, grade mounted Stack, and ID fan are common for all four heater coils.
The heater is to be designed for a configuration that allows one half of the heater to be offline
while the other half remains online – so that the offline half can be decoked by pigging. Such
configuration would allow decoking half the furnace – without having to shut down the entire unit.
Such configuration is termed “Split Heater” configuration for this project. During pigging of the
offline half of the furnace, thermal efficiency of the online half of heater would reduce - due to
possibly reduced air preheat.
The coke drum feed leaves the heater at approximately 503-507°C and 4.0-4.5 kg/cm2g. The coke
drum inlet switch valves divert the hot Coker feed into the bottom of the filling (‘coking mode’)
Coke Drum, either 14-RB-00-101A, 14-RB-00-101B, or 14-RB-00-1001. In the coke drum, the
hot feed cracks and polymerizes to form coke and cracked products. One coke drum is designed
for filling with coke to a safe operating level within a 15-hour period. An anti-foam chemical is
injected into the filling Coke Drum when a foam front is encountered. This intermittent injection
of antifoam continues until the end of coking cycle as well as during steam-out to the fractionator
and blowdown system. The main objective of antifoam injection is to prevent foam carryover to
the Coker Fractionator.
The cracked products leave the top of the Coke Drum as a Vapor stream at approximately 450°C
and 1.52 kg/cm2g. Hot coke drum Vapor effluent is immediately quenched to 426°C or less with
recycle HCGO to stop the cracking and polymerization reactions and to thereby prevent coke
formation in the line to the Coker Fractionator.
The Coker Fractionator separates the coke drum effluent into light gas, Naphtha, Light Coker Gas
Oil, Heavy Coker Gas Oil, and a heavy recycle stream. The column is provided with 25
fractionation trays and a spray zone, and is divided into two major sections by the HCGO draw
pan. The upper section consists of valve type fractionating trays; the lower section contains spray
chamber with the redistribution deck. The quenched coke drum Vapor effluent flows upward
through the redistribution deck, with cooling accomplished by contact with down-flowing reflux
liquid. Heavy recycle liquid is condensed and overflows the bottom packed section to mix with
fresh Coker feed in the tower bottom section as described earlier.
Net product Vapor flows to the upper tower section through Vapor risers in the HCGO draw-off
pan. This Vapor consists of the products, reflux, and steam. Heat removal and fractionation are
accomplished in the upper section of the Coker Fractionator.
All HCGO draws are taken from the same draw tray. The Reflux and the HCGO Pumparound are
pumped by common pumps, 14-PA-CF-104A/B. Reflux returns to the tower on flow control.
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The HCGO Pumparound improves the Coker Fractionator’s heat recovery and has three services.
The pumparound first exchanges heat against fresh feed in 14-EE- 00-102A/B, and then it provides
heat to generate steam in the MP steam generator 14-EE-00-105. A bypass around the steam
generator controls the temperature of the pumparound return to the Coker Fractionator.
Cooled HCGO PA from 14-EE-00-105 goes to reboil the Debutanizer in 14-EE-00- 108(N). A
Debutanizer bottoms stream circulates through the shell side of this 14- EE-00-108(N) exchanger
by thermosiphon action, and a bypass on the HCGO PA side controls the duty to maintain a
temperature set point in the Debutanizer.
A HCGO quench stream is taken out from the cooled HCGO PA returning from 14- EE-00-108(N).
This HCGO quench goes to the reactor overhead line under flow control. The cooled pumparound
stream returns to the tower, also under flow control. HCGO product draw from the Coker
Fractionator flows under level control by gravity flow to the HCGO Stripper, 14-CC-00-103. It is
steam stripped in the stripper and Vapors are returned to the Fractionator. The stripped HCGO
product is pumped by the HCGO Product Pump 14-PA-CF-106A/B and then cooled against fresh
feed in 14-EE-00-101A/B. It is then used to generate steam in the MP Steam Generator 14-EE-00-
103* and to preheat BFW in the BFW Preheat Exchanger 14-EE-00-104A/B.
*Bypass provision is given for 14-EE-00-103 on HCGO product side to avoid unnecessary cooling
of HCGO and also for maintenance purpose as per MOC no. DCU-16-1882
Thereafter, the HCGO product stream is cooled to 80°C in the HCGO Product Air Cooler 14-EA-
00-101, and is routed as “Cold” HCGO Product to the battery limit. The temperature of the “Cold”
HCGO product outlet is controlled by adjusting the air cooler’s blade pitch (Manual). The HCGO
Product Air Cooler 14-EA-00-101 can be bypassed to route “hot” HCGO product directly to the
battery limit. A dedicated temperature controller on the “hot” HCGO product manipulates the
quantity of “cold” HCGO mixing into the “hot” HCGO - to control the “hot” HCGO temperature
at 170°C.
Light Coker Gas Oil is withdrawn from the chimney tray below Tray 16 of the Coker Fractionator
and gravity flows under level control to the Light Coker Gas Oil Stripper 14-CC-00-102. It is
stripped with MP Superheated Steam, and the stripped LCGO product is then pumped by Lean
Sponge Oil/LCGO Product Pump, 14-PA-CF-107(M)A/B, to cool it successively with 14-EE-00-
113, Lean Sponge Oil/Rich Sponge Oil Exchanger, 14-EA-00-104, LCGO Lean Sponge Oil Air
Cooler, and with cooling water in the LCGO Lean Sponge Oil Trim Cooler, 14-EE-00-114(N).
The LCGO product stream is cooled down to 40°C and then splits to form two streams - as Lean
Sponge Oil to the top tray of Sponge Absorber column, 14-CC-00-106(M), and as the “cold”
product stream that goes to the unit battery limit under flow control. The LCGO Product Air
Cooler, 14-EA-00-104, can be bypassed to route “hot” LCGO product directly to the battery limit.
A dedicated temperature controller on the “hot” LCGO product manipulates the quantity of “cold”
LCGO that is mixed with the “hot” LCGO - to control “hot” LCGO temperature at 100°C.
The LCGO Coalescer (14-VV-00-112), coalesces the free water in the Cold LCGO stream,
to reduce the water content before LCGO goes off sites to the tankage. A set of LCGO Salt Driers,
14-LZ-00-113A/B are provided on the Hot LCGO product stream, in order to reduce the Hot
LCGO water content to 200 ppmw. A 2” interconnection line as per MOC No. CDU/VDU/DCU-
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12-1377 is provided at B/L for transferring Cold LCGO to Cold HCGO product in case of
insufficient ullage in LCGO storage tanks. As per MOC MS Block/DCU-12-1286, pre-filter 14-
GN-00-109 A/B is provided before LCGO Coalescer.
Cold HCGO product in case of insufficient ullage in LCGO storage tanks The salt driers operate
with one operating and the other in standby mode. Each salt drier is designed for a run length of
15 days after which the drier would require re-filling by fresh salt. Typically, Lummus provides
salt driers on ‘cold’ LCGO product as water removal is best at lower temperatures. For the BPCL
BR Coker, salt driers on Hot LCGO have been provided as specific BPCL BR requirement.
Normally it remains in bypass condition.
Overhead Vapor from the Coker Fractionator is cooled and condensed in the Coker Fractionator
Overhead Condenser, 14-EA-00-102, and the Coker Fractionator Overhead Trim Condensers, 14-
EE-00-106(N)A/B/C/D. It enters the Coker Fractionator Overhead Receiver (14-VV-00-102)
where, Vapor, hydrocarbon liquid, and condensed water are separated. Vapors from the overhead
receiver is routed to the Vapor Recovery Section.
The Fractionator Reflux Pumps, 14-PA-CF-111(M)A/B pump a portion of the hydrocarbon liquid
back to the Fractionator top tray as reflux under flow control reset by the tower overhead
temperature. This indirectly controls the naphtha endpoint temperature. The Fractionator Overhead
Liquid Pumps, 14-PA-CF-110(M)A/B, pump the net wild naphtha stream to the Vapor Recovery
Section. The Sour Water Pumps, 14-PA-CF-109A/B, pump the condensed water to the Battery
Limit. The low-pressure sour water streams from the Vapor Recovery Section recycle to the Coker
Fractionator Receiver to take advantage of this sour water pump. A portion of the sour water is
recycled under flow control to the inlets of the Compressor Interstage Coolers (14-EE-00-
109A/B/C/D and 14-EE-00-1006A/B) as wash water.
*To facilitate Heater APH washing activity APH drain line has been provided with a caustic
dosing arrangement and is routed to nearest peripheral drain through MOC, DCU-17-2002
** As per OISD guidelines Provision of Pressure gauze in emergency steam line of heater before
NRV have been provided through MOC DCU-17-2045, Installation of PM analyzer done for
better monitoring & to comply statuary requirement. Refer MOC DCU-15-1754. As per MOC
MS Block/DCU-13-1589, Heater-A/B burner gas tip orientation changed to get proper heat flux
and to avoid high TST of heater tubes*

3.2.2 Vapor Recovery Section

The Vapor recovery section separates the combined Vapor and liquid overhead products from the
Coker Fractionator into sweet Coker gas, LPG and Coker Naphtha.

3.2.3 Wet Gas Compression

Wet gas from the Coker Fractionator is compressed by two compressors operating in parallel. The
Wet Gas Compressor, 14-KA-CF-101, is a HP steam turbine driven centrifugal compressor (100%
condensing type) that takes on 60% of the wet gas mass flow. The Wet Gas Compressor II, 14-
KA-CF-1001, is an electric motor driven centrifugal compressor that takes on the remaining 40%
of the wet gas mass flow.
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The wet gas is compressed in two stages. The first stage discharges the Vapor at 3.5 kg/cm2g. The
Vapors from 14-KA-CF-101 is cooled to 40°C by the Compressor Interstage Cooler, 14-EE-00-
107A/B/C/D, while the discharge from 14-KA-CF-1001 is cooled to 40°C by the Compressor
Interstage Cooler II, 14-EE-00-1002A/B. The s subsequently enters the Compressor Interstage
Drum, 14-VV-00-103, and the Compressor Interstage Drum II, 14-VV-00-1002. The
uncondensed, and condensed hydrocarbon liquid and water are separated in the Interstage drums.
The condensed sour water recycles under its own pressure, back to the inlet of the Coker
Fractionator Condenser, 14-EA-00-102(M) as wash water. The Compressor Interstage Liquid
Pump, 14-PA-CF-112A/B, and the Compressor Interstage Liquid Pump II, 14-PA-CF-1001A/B,
pump the hydrocarbon liquid to the inlet of their respective Compressor Discharge Coolers (14-
EE-00-109A/B/C/D and 14-EE-00-1006A/B) where it joins the second stage discharge stream
from their respective Wet Gas Compressor. For sampling of VV-103 and VV-104 boot sour water,
close loop sample point provision is given across boot level control valve. * (refer MOC DCU-16-
1905 and DCU-16-1906)
The second stage of the Wet Gas Compressors compresses the Vapor from the interstage drums to
13.9 kg/cm2g, where the Vapor combines with the interstage drum hydrocarbon liquid and the
recycled sour water from the Coker Fractionator Overhead Receiver. In the Wet Gas Compressor
(14-KA-CF-101) train, these combined streams are cooled and condensed in the Compressor
Discharge Cooler, 14-EE-00-109A/B/C/D, and then enter the Recontact Drum, 14-VV-00-104. In
the Wet Gas Compressor II train, the combined streams are cooled and condensed in the
Compressor Discharge Cooler II, 14-EE-00-1006A/B, and then enter the Recontact Drum II, 14-
VV-00-1004.
Hydrocarbon liquids from the Recontact Drum (14-VV-00-104) are pumped to the Stripper
column, 14-CC-00-105, via the Stripper Feed Pumps 14-PA-CF-113A/B on flow control with level
reset. Similarly, the hydrocarbon liquids from the Recontact Drum II (14-VV-00-1004) are
pumped to the Stripper column via the Stripper Feed Pumps II (14-PA-CF-1002A/B), also on flow
control with level reset. Sour water from the Recontact Drums are withdrawn under level control
and are routed to the inlet of their respective Compressor Interstage Coolers.

3.2.4 Absorber, Stripper and Sponge Absorber Columns

Vapor from the Recontact Drum, 14-VV-00-104, and Recontact Drum II, 14-VV-00-1004, flows
to the bottom of the Absorber column, 14-CC-00-104(M). The Absorber column has 30 trays. A
cooled sponge Naphtha (Coker Naphtha) from the Debutanizer bottoms is fed to top of the
Absorber primarily to reduce the loss of LPG in the Coker Gas stream. The Absorber Overhead
Vapor is routed to the downstream Sponge Absorber. The Absorber Bottom Pump II, 14-PA-CF-
121(N)C, operating with the Absorber Bottoms Pumps 14-PA-CF-121A/B on standby, return the
rich sponge oil from Absorber bottoms back to the Recontact Drum and Recontact Drum II, under
level control from the bottom of the Absorber Column. Before re-entering the Recontact Drums,
the Absorber bottoms are cooled via Compressor Discharge Cooler, 14-EE-00-109A/B/C/D, and
Compressor Discharge Cooler II, 14-EE-00-1006A/B.
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The liquid from Tray 15 of the Absorber is pumped via the Absorber Intercooler Pump, 14-PA-
CF-122(N)A/B, through the Absorber Intercooler, 14-EE-00-118(N), into the Absorber Water
Separator, 14-VV-00-113. The hydrocarbon liquid flows from top of the Separator back to the
column, entering on Tray 17. Water from bottom of the separator flows under interface level
control on its own pressure back to the Coker Fractionator Overhead Receiver.
The Stripper column, 14-CC-00-105(M), strips ethane and lighter components from the LPG and
naphtha. It receives the liquid from Recontact Drum (14-VV-00-104) and Recontact Drum II (14-
VV-00-1004) via Stripper Feed Pump (14-PA-CF-113A/B) and Stripper Feed Pump II (14-PA-
CF-1002A/B) on its top tray, Tray 30. The stripping section is configured with three reboilers. At
the bottom of the column, liquid from the bottom sump enters the shell side of the Stripper Lower
Reboiler (14-EE-00-111) by thermosiphon action. Hot Debutanizer Bottoms Stream is used as the
heating medium in this lower reboiler. The balance of reboiling duty requirement is provided by
the Stripper Upper Reboiler, 14-EE-00-110, and Stripper Reboiler, 14-EE-00-1005, which both
use MP steam as the heat source. The MP steam flow to the Stripper Reboiler is controlled by a
flow controller at a constant set point, while the MP steam flow to the Stripper Upper Reboiler is
controlled by the fifth Stripper tray from the bottom of the column.
Vapor from the top of the Stripper column flows to the Recontact Drum via the Compressor
Interstage Cooler, 14-EE-00-109. Stripper bottoms liquid flows by its own pressure to the
Debutanizer (14-CC-00-107) under flow control reset by level control in the bottom of Stripper
column. A PDI across the stripper column has been provided for operation point of view as per
MOC NO. MS Block/DCU-12-1268.
A Water Trapout Drum 14-VV-00-105 is provided towards the top portion of the Stripper column,
to remove any condensed water*. Absorber overhead Vapor flows to the bottom of the Sponge
Absorber, 14-CC-00-106, which has 21 trays. Cooled, lean sponge-oil (Light Coker Gas Oil) from
the Light Coker Gas Oil Stripper is fed to the top of the Sponge Absorber primarily to reduce the
loss of naphtha in the Stripper Overhead Vapor stream. Flow of the lean sponge oil has been
discussed previously with the flow of the LCGO product. The Sponge Absorber Overhead Vapor
(Sour Coker Gas) is routed to the Battery limit. Rich sponge oil from the Sponge Absorber bottoms
is used to cool the lean sponge oil (Light Coker Gas Oil) in the LCGO Lean/Rich Sponge Oil
Exchanger, 14-EE-00-113 and is returned to the Coker Fractionator.

*An interface type level transmitter has been provided to VV-105through MOC-MS Block/DCU-
13-1600

3.2.5 Debutanizer
The Debutanizer column, 14-CC-00-107(M) is provided with 39 trays to separate the feed into an
overhead product of Coker LPG and a bottom product of Coker Naphtha. Overhead Vapor is totally
condensed in the Debutanizer Overhead Condensers, 14-EE-00-15(M)A/B/C/D/E/F/G/H, and then
routed to the Debutanizer Overhead Receiver, 14-VV-00-107. From there, the Debutanizer Reflux
Pumps, 14-PA-CF-108A/B, pump the reflux back to the top tray on flow control reset by
Debutanizer’s top Vapor temperature. A part of the reflux pumps’ discharge is drawn off as Coker
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LPG product under the receiver’s level control and is routed to the battery limit. Pressure is
controlled in the receiver by throttling the overhead condenser’s hot Vapor bypass control valve.
The column has two thermosiphon reboilers, 14-EE-00-108(M) and 14-EE-00-119(N). Heat to 14-
EE-00-108(M) is provided by the circulating HCGO pumparound stream under the Coker
Fractionator. The Debutanizer bottoms stream is pumped by Debutanizer Bottoms Pumps (14-PA-
CF-105(M)A/B) to supply Stripper reboiler duty in 14-EE-00-111. Thereafter, the Debutanizer
bottoms stream is cooled to 40°C by the Debutanizer Bottoms Air Cooler (14-EA-00-103) and the
Debutanizer Bottoms Trim Cooler 14-EE-00-112(N) in series. It is then routed as “Cold” Naphtha
Product to the battery limit. The Debutanizer Bottoms Air Cooler can be bypassed to route “Hot”
Naphtha product directly to the battery limit. A dedicated temperature controller on the “hot”
Naphtha product manipulates the quantity of “cold” Naphtha that is mixed with the “hot” Naphtha
- to control “Hot” Naphtha temperature at 100°C.

3.2.6 Coke Drum Steamout and Blowdown

Coking is a semi-batch operation and the BPCL BR unit is anticipated to operate under a 45-hour
coke drum cycle for the normal operation after implementation of unit revamp. Each drum will be
on-line for 15 hours of filling and off-line for 30 hours during the subsequent decoking mode of
operation. *MOC: MP steam quench line TT are provided on coke drum drain line to ensure dry
steam injection in coke drum. Refer MOC MS Block/DCU-13-1592*The total cycle for each drum
from oil-in to oil-in will thus be 45 hours as shown below:

Operation Hours
Coking 15.0
Steamout to Coker Fractionator 1.0
Steamout to Blowdown System 1.5
Slow Water Cooling 1.5
Fast Water Cooling 4.5
Drain Coke Drum 1.5
Remove Top and Bottom Heads 1.0
Hydraulic Coke Boring/Cutting 4.0
Reheading/Pressure Testing 2.0
Drum Heat-up 7.0
Idle 6.0
Total 45.0

Following completion of a drum filling cycle, Coker Heater effluent is diverted to one of the other
(empty) coke drums by means of the Inlet Switch Valves. Steam is then injected into the bottom
of the coke-filled drum for 60 minutes, with volatile light hydrocarbons purged to the Coker
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Fractionator. During the next 90 minutes, steam rate is increased and the resultant Vapors (mostly
steam) are routed to the bottom of the Blowdown Tower.
The Blowdown Tower, 14-CC-00-108, cools and condenses the steam and hydrocarbon Vapors
evolved from the Coke Drum during the steaming, water cooling, and drum re-heating operations.
It has 12 shed trays to contact the incoming Vapors from the Coke Drum with a stream of
recirculating quench oil to condense the high boiling-point hydrocarbons. The quench oil
circulation rate is adjusted to maintain the Blowdown Tower bottom temperature approximately
180°C in order to prevent water condensation in the tower.
The Blowdown Tower overhead Vapors, consisting of mostly steam with some light hydrocarbons,
are condensed in the Blowdown Overhead Condenser, 14-EA-00-106. The partially condensed
stream from the outlet of the condenser flows to the Blowdown Overhead Receiver, 14-VV-00-
111. Condensed water separates by gravity settling and is pumped by the Blowdown Water Pump
14-PA-CF-115 A/B to OSBL sour water stripping. The condensed hydrocarbon liquid is pumped
by the Blowdown Overhead Oil Pump 14-PA-CF-116(M)A/B as quench oil to the coke drum
overhead and is also pumped back to the bottom of the Blowdown Tower. The Blowdown Quench
Oil Pumps, 14-PA-CF-114A/B, pump out the tower bottoms.
There is a 3-way split at the discharge of the pumps. Net recovered liquid, which contains no free
water, goes back to the Coker Fractionator Column on flow control for product recovery, joining
the fresh feed after 14-EE-00-102A/B. To keep the Blowdown Tower warm, part of tower bottoms
circulates back through the shell side of the Blowdown Quench Oil Heater, 14-EE-00-116, on flow
control to join the feed to the tower. A temperature controller on the bottoms stream from the tower
regulates steam flow to the tube side of 14-EE-00-116. Ahead of this exchanger, the Coke Drum
Condensate Stream joins the recirculating bottoms stream to be heated before entering the tower.
The third branch takes the bottoms stream to the top of the tower via the Blowdown Quench Oil
Cooler, 14-EA-00-105. This stream, which is on flow control, is circulating quench oil that was
mentioned at the beginning of the process flow description for this tower. The level control at the
bottom of the tower resets the net flow of the bottoms liquid which is on flow control.
The non-condensable Vapor from the Blowdown Overhead Receiver goes to the Water Ring
Compressor, 14-LZ-00-1005, and then is routed to the suction of the Wet Gas Compressor for
recovery. Alternatively, this overhead Vapor can go to the flare when the need arises.

3.2.7 Decoking
Coke is removed from the Coke Drums by hydraulic decoking in two steps. First, a hole about 1
meter in diameter is bored down through the coke bed. For the second step, the coke bed is cut in
layers as the operator lowers the tool. The hydraulic cutting tools are mounted at the end of a
hollow drill stem that is suspended from a swivel joint. A motor rotates the drill stem. A hoist on
the platform raises and lowers the drill stem within a structure built over the Coke Drums.
Cutting water is supplied by the Coke Cutting Pumps, 14-PA-CF-120A/B, at approximately 280
kg/cm2g. A special hydraulic bypass control valve is used to avoid frequent starting and stopping
of the pump. After the coke is removed, the drum remains idle until it is ready to be re-headed,
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steam purged to remove any air, and pressure tested with steam. The drum is then heated with the
Vapors from the on-line Coke Drum, which is being filled.
The Vapor /liquid mixture, which forms as the overhead from the live coke drum is cooled in the
empty drum, flows to the Coke Condensate Drum, 14-VV-00-108, where the Vapor and liquid
separate. Initially the Vapor goes to the Blowdown Tower and later to the Coker Fractionator. The
Coke Condensate Pump, 14-PA-CF-117, pumps the condensate to the Blowdown System until it
is "dry" (i.e., at a temperature above 160°C), then to the Coker Fractionator. When the Coke Drum
is adequately heated, it is ready to go on-stream for the Coke Drum filling step.

3.2.8 Coke Handling

Green coke is cut from three (3) Coke Drums, two (2) existing Coke Drums 14-RB-00-101A/B
and one new Coke Drum 14-RB-00-1001, according to the Coking /Decoking Schedule shown in
Figure 3.2-1 on the next page. A high pressure water jet system is used in the coke cutting process.
During coke cutting operation coke of various sizes along with high temperature water discharges
from the Coke Drum to the chute system below and by gravity flow discharges to the coke pit, 14-
AU-00-101(M). Water with coke fines drains to the inlet weir and flows through the maze. The
maze traps most of the coke fines and will require periodic cleanout.
Coke will be removed from the coke pit below each Coke Drum using the Coker Bridge Crane 14-
LZ-00-115R and will be transported to another location on the coke pad for dewatering for
approximately 24 hours. The same Bridge Crane is used to lift the coke that has been dewatered
from the coke pit to a stationary Coke Hopper with Grizzly 14-LZ-00-108. The Hopper opening
is equipped with a grizzly to limit the maximum coke size to 250 mm x 250 mm. Smaller sizes
pass through the Grizzly openings to the Vibro Feeder which in turn discharges to the Coke
Transfer Conveyor which is part of the OSBL coke handling system.
Coke lumps larger than 250 mm x 250 mm will fall by gravity from the sloped Grizzly to the coke
pit below. The coke pile will also contain larger lumps. The Bridge Crane clamshell bucket may
also be used to break up the lumps prior to transferring to the Coke Hopper. The Bridge Crane will
also be used to clean the maze by removing the coke fines accumulated in the maze. Coke fines
up to one meter in depth are expected to accumulate in the maze. The coke fines are transferred to
the coke pit to become part of the coke product.
Decanted water from the Maze is pumped out by the Maze Pumps, 14-PA-CF-119A/B through a
Hydrocyclone, 14-GJ-00-101, for further removal of entrained coke fines. The overflow water
from the Hydrocyclone then goes to the Clear Water Tank, 14-TT-00-101, from where the Coke
Cutting Pumps, 14-PA-CF-120A/B, can take suction to use this water as Coke cutting water.
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3.2.9 Process Flow Diagrams

PFDs are marked-up to show the extent of modifications done for the revamp Case. Each change
on the PFDs is identified with an item number that is used as an identifier in the modification
schedule shown on the next page below.

PFD Title Drawing No.

Coker Fractionation 14-0101
Coker Heater 14-0102
Coke Drums 14-0102A
Coker Fractionator Overhead System 14-0103
Wet Gas Compressor (New Parallel) 14-0103A
Absorber/Stripper, Sponge Absorber 14-0104
Debutanizer 14-0105
Blowdown 14-0107
Decoking Section 14-0108
Miscellaneous 14-0109

3.3 Process Variables

Operating Variables are the parameters available to the Plant Operator for manipulation so as to
meet the requirements of Product quality and Yields. The key coking operating variables include
recycle ratio, pressure, and temperatures.

3.3.1 Feedstock Characteristics

The feedstock characteristics have a significant influence on Coker Yields. Amount of Coke
produced is directly proportional to the CCR in the feedstock. Increase in the CCR of the feed
results in increase of Coke, Gas and Naphtha yields and decreased yields of Gas Oil. Also, as the
API gravity of the feed increases, there is a reduction in the Coke yield, increase in the yield of
gas oil and a minor reduction in the yield of Gas & Gasoline.
Though the plant operator, in strict sense, has no control on this variable, a clear understanding of
the effect of feed stock quality is essential.

3.3.2 Recycle Ratio

Recycle is the high boiling material in the Coke Drum vapors that condense at the base of the
fractionator. Increase in recycle increases the cracking reaction; thereby resulting in production of
more Gas, Naphtha & Coke and Lesser Gas Oil.
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The recycle ratio is maintained by controlling the flow rate of HCGO reflux (wash) to the bottom
section of the fractionator.
At a constant heater charge rate, increasing this reflux rate will increase the recycle rate and reduce
the fresh feed rate; decreasing this reflux rate will decrease the recycle rate and increase the fresh
feed rate.

(Furnace feed rate - Fresh feed to unit)

-------------------------------------------------- X 100
(Fresh feed to unit)

The throughput ratio for the post revamp operation is specified in order to meet the main objective
of maximizing C5+ liquid yield. The throughout ratio is estimated to be at a minimum of 7% for
the production of a heavy Coker gas oil (HCGO) product that can meet a maximum Conradson
Carbon specification of 1.0 wt%.

3.3.3 Coke Drum Pressure

At constant temperature and recycle ratio, an increase in the coke drum pressure will cause more
coke yield, more gas yield and lesser C5+ liquid distillates make. This is so as heavier hydrocarbon
materials are retained in the drum and thus cause an increase in the coke yield. The quality of the
coke also improves i.e. it becomes spongier in nature.
Since the objective of this unit is also to maximize the liquid distillate for the Hydrocracker, it has
been designed with the minimum coke drum pressure as possible but at the same time restricting
the off gas compressor to two stages.
The key pressure controlling instrument is the pressure controller which maintains a constant
pressure in the suction of the Wet Gas Compressor. This pressure controller should be set so that
the pressure of the coke drum overhead is 1.52 kg/cm 2(g). However, the suction pressure should
not be set below atmospheric pressure.

3.3.4 Coker Heater Outlet Temperature

The heater outlet temperature is maintained at 507°[Link] operating range of the coke drum Vapor
temperature is between 425°C and 449°C.
Increasing the outlet temperature of the heaters will decrease the yield of coke. The green coke
produced will have a lower Volatile Combustible Material (VCM) content and will be harder to
cut from the coke drum. The higher temperature will compensate for the shorter residence time of
the coke formed in the top section of the coke drum.
Lower temperature will not allow the coking reaction to proceed to completion and will give rise
to a semi-coked mass or pitch type of material in the drum. This can further cause a severe carry
over problem. Additionally, the formed pitch type material in a Coke bed is extremely difficult to
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cool to a safe temperature thus creating a significant fire hazard when the Coke Drum is opened to
the atmosphere.
A low operating temperature produces a green coke with very high VCM.

3.3.5 Turbulizing Media

The Coker Heater has been designed considering the injection HP steam (Velocity steam) or
Boiler Feed Water (BFW) as turbulizing media in the furnace coils. When velocity steam is not
in use BFW injection in the heater coils provides the velocity and turbulence necessary in the
tubes to minimize the coke deposits.
Increasing the turbulizing media rate will minimize the chances of coke deposits in the reaction
coils but will lead to energy loss due to extra firing. Also, it would have an undesirable effect
upon Coke quality as the generated steam potentially may result in forming an unstable Coke bed
structure within the Coke Drum.