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Baker
Discussion Topics
1. Coker economics and impact of fouling on DCU and refinery operations 2. Coker heater fouling mechanisms 3. Stages of fouling 4. Design of custom MILESTONE additive programs 5. Coking Stability Index (CSI) 6. Case histories 7. Summary
TM
$/Bbl
Resid Fuel
Cokers are making a lot of money, and refiners want new ways to increase unit throughput!
US Gulf Coast (Harts Downstream Energy Services)
2007 Baker Hughes Incorporated. All Rights Reserved.
Conversion Losses
1% ~ $3 MM
De-coking Costs
$25 50 M/coil
Reduced Flexibility
Can be > $5 MM
E, H & S Concerns
Content of solids/inorganics
Corrosion by-products Filterable solids and salts Sodium concentration
Caustic
NaOH injections into desalted crude
Asphaltene Destabilization
Disruption of asphaltene resin interaction Thermal cracking conditions (>750F) cause progressive loss of asphaltene solubility in the bulk oil phase Asphaltenes lose paraffinic side-chains and naphthenic portions are de-hydrogenated to aromatic rings
+
Solubility Loss, Precipitation, Dehydrogenation, Coke Formation
N-
Heat
Coke Formation
High temperature destabilizes asphaltenes They become more aromatic and less soluble in the bulk liquid
Asphaltene Precipitation
Stress Asphaltene Destabilization & Disruption of Resins
Aggregation
Deposition Degradation
Stages of Fouling
Initial layer formed on tube surface
Metal catalyzed coking Fast - at the startup of the unit when coils are clean and metal is exposed
Stages of Fouling
Initial Fouling S teady State Fouling Bulk Fouling B u lk Pressure Drop Heat Transfer Coefficient U
Initial
Time
S h u tdow n Shutdow
1200
Slope for first 30 days is 3.9 degrees F / day Slope for day 31 until end is 1.3 degrees F / day
1150
1100
1050
Days on Line
Coker Feed
CSI
West Coast Refiner Midwest Refiner Furnace Feed Canadian Refiner Furnace Feed
1000
800
INTENSITY
More Stable
600
400
200
CSI
Interacts with metal surfaces to reduce catalytic effects on surface coking reactions Stabilizes asphaltenic compounds in the feedstock to inhibit their precipitation Disperses organic & inorganic particles
Summary
Delayed coker furnace fouling is a complex phenomenon involving heavy hydrocarbon compounds and inorganic materials Two stages of fouling: initial catalytic stage and thermal or steady-state stage Costs of delayed coker furnace fouling can be significant especially when throughput is restricted either during operation or during de-coking cycles
Summary
The Baker Petrolite research group has developed a successful mitigation program for delayed coker furnace fouling A new, multi-component program is utilized to combat the various mechanisms of heater fouling Treatment programs have been used in several applications with significant economic benefits