Scribd
Upload
84 views32 pages

Understanding Petroleum Coke and Its Uses

Petroleum coke is a solid carbon material derived from oil refining processes. It has a higher energy content than coal. There are two main types - fuel grade coke which is used directly in power generation but requires further processing to reduce sulfur emissions, and anode grade coke which is processed to remove sulfur and metals for use in aluminum and steel production.

Uploaded by

zamijaka
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
84 views32 pages

Understanding Petroleum Coke and Its Uses

Petroleum coke is a solid carbon material derived from oil refining processes. It has a higher energy content than coal. There are two main types - fuel grade coke which is used directly in power generation but requires further processing to reduce sulfur emissions, and anode grade coke which is processed to remove sulfur and metals for use in aluminum and steel production.

Uploaded by

zamijaka
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
  • Petroleum Coke
  • Crude Oil Refinery in Glance
  • Thermal Cracking
  • Delayed Coking
  • SNOX Process

Petroleum coke

Petroleum coke (often abbeviated Pet coke) is a carbonaceous solid derived from oil refinery coker unit [delayed coker unit]
The coke formed from the condensation of polynuclear aromatics has a H/C ratio of 0.73. The coke formed through other reactions might have the formula CH where = 0.20.8

Petroleum coke
Petcoke has a higher energy content than coal and emits between 30~80% more CO2 than coal per unit of weight The coke can be either be : [1] Fuel grade (high in sulfur and metal) called as green coke [2] Anode grade (low in sulfur and metal) called as calcined coke

Fuel grade (green) coke


1. The raw coke directly out of the delayed coker is referred as green coke. In this context, green means unprocessed 2. This coke is used in fuel application for power generation such as utility boiler and cement kilns 3. Due to high content of sulfur and metal that can be harmfull for enviroment, then to meet current tighther enviromental regulation, some form of sulfur capture process is required which is known as SNOX process

Anode grade (calcined) coke


1. The further processing of green coke by calcining in a rotary kiln to removes residual volatile matter and also metal from the coke 2. This coke is used to make anodes for aluminium, steel and titanium smelting industry

Crude oil refinery in glance

Feed for Cracking Unit [Catalytic, Thermal Cracking]

Crude oil refinery in glance

Feed for Thermal Cracking [Delayed Coking, Visbreaking]

Crude oil refinery in glance

Catalytic Cracking [FCC, Hydrocracker Unit]

Thermal Cracking [Delayed Coker, Visbreaking Unit]

Thermal cracking
As the term implies, thermal cracking reaction are those that occur when the temperature is raised to a point at which bonds that hold a molecule together are broken. This breaking of bonds result predominantly in an increase in smaller molecules. However, breaking of bonds also leads to free radical formation that can also result in subsequent polymerization or condensation reactions. These reactions form larger, more condensed molecules. As applied to the refining industry, thermal cracking is used to produce smaller molecules from larger one. As such, it is an endothermic reaction when considered on an overall basis; however, some of the condensation reactions that eventually lead to coke are exothermic. Thermal cracking process designed to handle heavy residues with high asphaltene, resin, metal and sulfur contents. These residue can not fed to catalytic cracking unit because their impurities can deactivate and poison the catalyst

Thermal cracking
In thermal cracking generally 2 [two] types of reactions take place : [1] Primary reaction by decomposition of larger molecules to smaller one [2] Secondary reaction by which active product from primary cracking reaction further crack or react to form other molecule or polymerize to generate heavy product (coke)

Thermal cracking
Various thermal cracking processes : [1] Visbreaking : it is a thermal cracking process producing gas, distillates and visbroken residue (471~493oC at 50~200 psig) [2] Delayed cooking : continuous thermal cracking which generates coke and produces various distillates in fractionator from vacuum residue. Coke drum temperature remains around 482~516oC at 90 psig [3] Fluid coking : continuous coking process where residue is sprayed on to fluidized bed of hot coke particles. Here cracking takes place at much higher temperature than delayed coking (up to 565oC) [4] Flexi coking : continuous coking process like fluid coking which includes gasification section of coke produced in fluid coking operation Among the above, Delayed Coking is most popular Goal for delayed coker operation is to maximize the yield of distillates and minimize of coke (as byproduct). The main products of delayed coking is off gas (from which LPG is recovered), naphta, light coker gas oil (LCGO) and heavy coker gas oil (HCGO) Most typical of delayed coking feedstock is vacuum residue (+530oC)

Delayed coking

Delayed coking
Some of well known process licencors of Delayed Coker Unit are as under : [1] Foster Wheeler [2] KBR [3] Lummus Technology [4] Conoco Philips [5] Exxon Mobil, etc

Delayed coking licenced by Foster Wheeler/UOP

Delayed coking licenced by Foster Wheeler/UOP

Delayed coking licenced by Foster Wheeler/UOP

Delayed coking licenced by Foster Wheeler/UOP

Delayed coking licenced by Foster Wheeler/UOP

Delayed coking licenced by Foster Wheeler/UOP

Delayed coking licenced by Foster Wheeler/UOP

Delayed coking licenced by Foster Wheeler/UOP

Delayed coking licenced by Foster Wheeler/UOP


Operating condition : typical ranges are [1] Heater outlet temperature : 900~950oF [2] Coke drum pressure : 15~100 psig [3] Recycle ratio, equivalent fresh feed : 0~1 Note : (1) Increasing coking temperature decrease coke production, increase liquid yield and gas oil end point (2) Increasing pressure and/or recycle ratio increase coke production decrease liquid yield and gas oil end point Economic : Investment (basis 65,000~100,000 bpd) 2Q 2005 US Gulf : 6,700~13,600 US$/barrel Utilities, typical per bbl feed [1] Fuel : 120,000 BTU [2] Electricity : 3 kWh [3] Steam : 35 lb [4] Cooling water : 36 gallon Currenly, 52 delayed coker installed worlwide with total capacity over 2,5 million bpsd

Delayed coking licenced by kbr

Experiences, KBR has provided process technology for more than 15 cokers.

Delayed coking licenced by lummus technology

Delayed coking licenced by lummus technology


Operating condition : typical ranges are [1] Heater outlet temperature : 900~950oF [2] Coke drum pressure : 15~90 psig [3] Recycle ratio, equivalent fresh feed : 0~100% vol/vol feed Economic : Investment (basis 20,000 bpd) 2008 US Gulf Coast : 8,000 US$/barrel Utilities, typical per bbl feed [1] Fuel : 123,000 BTU [2] Electricity : 3.6 kWh [3] Steam : 1 lb [4] Cooling water : 58 gallon [5] Boiler feed water : 38 lb [6] Condensate : 24 lb Currenly, 60 delayed coker installed worlwide

Delayed coking conoco philips

Delayed coking conoco philips

Delayed coking conoco philips


Operating condition : typical ranges are [1] Heater outlet temperature : 920~945oF [2] Coke drum pressure : 15~25 psig [3] Recycle ratio, equivalent fresh feed : 15~20% vol/vol feed Economic : Investment (basis 60,000 bpd) Year 2000 : 3,000 US$/barrel Utilities, typical per bbl feed [1] Power : 13,940 BHP [2] Fuel : 361 x 106 BTU/hr [3] 600# Steam : 13,400 lb/hr [4] 475# Steam : 52,000 lb/hr [5] 150# Steam : 7,350 lb/hr [6] Condensate : 25 gallon/minute [7] Boiler feed water : 140 gallon/minute

flexicoking exxon mobil research & engineering

Fluidized bed coking with integrated steam gasification technology to covert heavy HC to lighter liquid product, clean fuel gas with minimum coke

Cyclic process of delayed coking

Cyclic process of delayed coking

Cyclic process of delayed coking

Snox process
The SNOX process is a process which removes sulfur dioxide, nitrogen dioxide and particulates from flue gases. The sulfur is recovered as concentrated sulfuric acid and the nitrogen oxides are reduced to free nitrogen The SNOX process developed by Haldor Topsoe has been specifically designed for power and steam generation plants to remove sulfur and nitrogen oxides from combustion of heavy residuals, petroleum coke, sour gas or other waste products from refineries The SNOX process includes the following steps:
[1] Dust removal [2] Catalytic reduction of NOx by adding NH3 to the gas upstream the SCR DeNOx reactor [3] Catalytic oxidation of SO2 to SO3 in the oxidation reactor [4] Cooling of the gas to about 100 C whereby the H2SO4 condenses and can be withdrawn as concentrated sulfuric acid product

Snox process

Petroleum coke Petroleum coke (often abbeviated Pet coke) is a carbonaceous solid derived from oil refinery coker unit [del
Petroleum coke Petcoke has a higher energy content than coal and emits between 30~80% more CO2 than coal per unit of weight
Anode grade (calcined) coke 1. The further processing of green coke by calcining in a rotary kiln to removes residual volat
Crude oil refinery in glance Feed for Cracking Unit [Catalytic, Thermal Cracking]
Crude oil refinery in glance Feed for Thermal Cracking [Delayed Coking, Visbreaking]
Crude oil refinery in glance Catalytic Cracking [FCC, Hydrocracker Unit] Thermal Cracking [Delayed Coker, Visbreaking
Thermal cracking As the term implies, thermal cracking reaction are those that occur when the temperature is raised to a po
Thermal cracking In thermal cracking generally 2 [two] types of reactions take place : [1] Primary reaction by decompositio
Thermal cracking Various thermal cracking processes : [1] Visbreaking : it is a thermal cracking process producing gas, di
Delayed coking

You might also like