Furnace: Study and Application of Process Simulation Technology On Coking

Study and Application of Process Simulation
Technology on Coking Furnace

The 1
st
Saudi-Chinese
Oil Refinery Forum 2013
China University of Petroleum
xiaojiazhi@sina.com
October 28 ,2013
Contents
Preface
Study on Coking Mechanism
PSS Development & Applications
Cooperation Expectation
2010 coker processing capacity
Delayed coking is the important means to
upgrade heavy oil, have capacity of more
than 100 million tons, and account for
more than 30% of heavy oil processing
capacity, the second in the world.
Preface
The role of Delayed Coking in heavy oil processing
Unit:10
4
ton
Preface
Delayed coking & Our research field
The coking furnace is the core of delayed coking unit
which determines the operation performance, period and
economy benefit of the whole unit.
Coking
Furnace
Energy Saving
Long-Period
operation
Product Distribution
Optimization
Commercial demand for coking furnace
Preface
Coking Furnace
Tube
inside
Tube
outside
Tube
coking
Heat flux
Coking mechanism
Process simulation
Experimental apparatus
Numerical simulation
Wall-Fired
Preface
Our research
Preface Principle
Heavy oil flows through the tubes
quickly before the coke precursor is
formed at a low conversion and at the
same time gets enough heat, then
finishes its deep conversion in the
coke drum
The technical key point is to provide
the enough heat for coking reaction
and at the same time reduce the
coking rate.

Technical key point
Preface
1. Design and build a coking laboratory
apparatus for investigating coking
characteristics of different
feedstocks;
2. Study and development of coking
mechanism for different feedstocks;
3. Utilization and development of eight
mathematical models for obtaining
series of designing and operational
parameters.
PSS Based on three important stand points
Coking mechanism in Tube
1. Basic conceptions
2. Coking mechanism inside tube
3. Criteria for designing the coking furnace
Outline
Tube coking mechanism -Basic conceptions
The Coke Precursor (C.P.)
In PSS, we define Toluene insolubles (TI),
not asphaltenes as Coke Precursor.
The Maximum Thermal Conversion Severity (MTCS)
MTCS is an important property of a
certain oil that must be investigated by
special experiments.
The Reason of Forming MTCS: Cage Theory
Tube coking mechanism -Basic point
When the thermal conversion is
lower, the coke precursor(C.P.)
is surrounded by oil colloid, that
is to say the oil colloid system is
not destroyed, The colloid acts
like a cage. When the
operational thermal conversion
is higher than the Maximum
Thermal Conversion Severity
(MTCS), The cage is destroyed
and the C.P. increases steeply.

The Operational Thermal Conversion Severity (OTCS, Xout)
OTCS is an important operating parameter of oil at
tube exit that must be determined by PSS.
Wave Flow
Bubble Flow
Plug Flow
Stratified Flow
Spary Flow
Slug Flow
Annular Flow
Two Phase Flow Pattern

This chart shows the difference of two phase flow
patterns in the horizontal tube. The key tube in coking
heater should be the spray flow pattern.
The Fundamental Boundary Conception (Film Theory)
No matter what flow pattern it is, there always is a boundary
close to the tube wall, where the coking takes place.
The Sensitive Coking Temperature (SCT )
The film temperature
determines the coking rate.
The SCT is the film
temperature with an upper
limit, obtained from PSS.
it is equal to:
Tube coking mechanism -Conclusion
Coking Rate =Coke Forming Rate Coke Diffusing Rate
Coke Forming Rate
=F( coking factor, film
temperature )
Coke Diffusing Rate
=F( boundary layer thickness ,
coke precursor concentration
gradient )
Result-1: similar to the real situation
Coke Precursors partly diffuse to the bulk flow and
partly deposit on the tube wall at the same time.
Result-2: the ideal situation
All coke precursors diffuse to the bulk flow.
Result-3 : the worst situation
All coke precursors deposit on the tube wall.
Tube Coking Mechanism- Criteria for Designing the Coking Furnace

The Conventional Design Criteria
Design Criteria in Certain Country
New Criteria Based On Our Research

The Content
Conventional Design Criteria has 2 par.:
Cold Oil Velocity
(1200 1800kg/m
2
s
2.12.2 m/s
Heat Flux Intensity
(29 32kW/m
2
)
Design Criteria In Certain Country has 2 Par.
Oil Residence Time in Tube
Thermal Conversion at Outlet Tube
You can not find a way how to deal with heavy oil
from this Design Criteria directly.

New Criteria Based On our Research
ensuring that the two phase flow in the key tubes is
the spray flow;
ensuring that the thermal conversion severity at
exit of the heater is less than the maximum thermal
conversion severity of a definite feedstock;
estimating the coking tendency by the peak oil film
temperature and coking factors.
This system takes account of both coke diffusing rate and
forming rate for a definite feed, especially for heavy oils.
PSS Development & Application

1. Model development for PSS (process simulation software)
2. Specially designed experimental apparatus
3. PSS Precision Check
4. PSS Applications
5. Work done

the catalogue
Eight Models Functions
product distribution for
heavy oil cracking
To predict the oil composition at certain
arbitrary tube section
Coking rate inside tubes To predict coking quantity in tubes
Vapor-liquid equilibrium
model
To predict vaporization fraction at any cross
section
Two-phase flow model To determine the pressure in tubes
enthalpy and reaction
heat model
To predict the profile of the main stream
temperature along the tubes
Radiation transfer model

To get the heat intensity distribution along
tubes
Turbulent flow model To predict turbulent exchange coefficients
Fuel combustion model To predict combustion velocity
PSS Model
Model development for PSS
A 12-lump thermal reaction model for calculating the residence time
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E/R, K
Statistical test
Notes
Regression
coefficient
R
F Test
Cracking reaction 32963.107 0.9609 240.62
Condensation reaction 65422.485 0.5994 11.22
Twelve lumped reaction model
Gases 32054.019 0.9851 654.03
Model of this study
<210C 33968.002 0.9879 809.95
210~240C 33451.673 0.9855 673.61
240~270C 33770.680 0.9866 728.68
270~300C 34473.317 0.9907 1061.20
300~330C 33100.602 0.9846 633.99
330~360C 35726.691 0.9895 940.93
360~390C 34460.689 0.9886 861.18
390~420C 33395.897 0.9672 289.84
420~450C 30751.582 0.8980 165.15
450~480C 28629.761 0.8730 187.11
480~510C 34724.206 0.8204 400.07
Four lumped reaction model Gas + <210C 33509.313 0.9876 791.32 Model of Toru
Takatsuka
210~300C 33864.114 0.9922 1268.22
300~390C 34501.615 0.9867 737.66
390~510C 28215.431 0.8251 167.94
The Database for 12-lump thermal reaction model constant
The endothermic and exothermic reactions occur at same time
2. Specially designed lab apparatus
It is difficult that the reaction temperature is
controlled at the expected temperature
s
So, Special Laboratory Apparatus is Designed for Controlling smoothly
The apparatus is aimed at obtaining the product distribution, kinetic
constants of 12 lumped reactions and the maximum thermal conversion
severity. Besides, this special apparatus can do a lot of research in the
delayed coking field, such as coking factors, operation optimization
evaluation etc.
2. Specially designed lab apparatus
Comparisons of results from experiments and PSS
Experiment
Value
Weight of cracked gas (g) 12.3 / 9.6 / 5.3 /
Weight of cracked oil(g) 7272.5 / 6446.6 / 3113.4 /
Gas yield(m%) 0.1688 0.178 0.1489 0.13 0.1699 0.112
Overall thermal conversion % 4.28 2.86 2.738 2.083 2 1.808
<210C fraction yield at exit (m%) 0.16 0.25 0.265 0.183 0.125 0.158
210-330C fraction yield at exit (m%) 2.38 0.828 0.482 0.603 0.119 0.518
330-510C fraction yield at exit (m%) 14.34 13.98 14.59 13.61 14.33 13.47
Experiment 1 Experiment 2 Experiment 3
Experiment
value PSS value
Experiment
value PSS value PSS value
It is difficult to acquire operation thermal conversion severity (OTCS)
data at outlet from commercial heater. The OTCS and product
distribution was checked by special designed experiments, The results
of PSS simulation and experimental data are basically alike.
Comparisons of flue gas temperature from commercial heater and PSS value
Lobo-Evans

Monte Carlo
Flue gas temperature 789.3 782.95 783.74 858.44
absolute error 0 -6.35 -5.56 69.14
Flue gas temperature 779 863.12 856.74 867.83
absolute error 0 84.12 77.74 88.83
absolute error 0 28.37 27.74 101.26
Flue gas temperature 769.2 817.3 803.4 765.63
absolute error 0 48.1 34.2 -3.57
absolute error 0 36.04 26.18 0.68
Item
cokingheater
operating
data
PSS value
Heater 1
Heater 1
Heater 1
Heater 2
Heater 2
This is a comparison of flue gas temperature from commercial
heater and PSS values with different models. It can be found that the
heat flux distribution how to influence the key parameter, operation
thermal conversion severity (OTCS), during PSS development.
Comparisons of inlet pressure from commercial coking heater and PSS value
This is Comparisons of inlet pressure from commercial coking
heater and PSS value. The outlet pressure is the given value.
4. PSS Applications
The PSS Capability
The PSS Function
The PSS Case Study
the list

PSS Applications in series commercial heater in China
NO. ITEMS CONTENT REMARK
1 Operating Calibration Obtaining fundamental data Shijiazoung Ref.
2
Statistic technological
operation data analysis
2Shi+1Zun+1Chong+1An
+1J in+1Shen:7cycles
2800007data
3
Cokin g heater tube
coke conductivity
investigation
Obtaining relation between coke
conductivity and temp
Shijiazoung Ref
4
Sampling and analysis
of coking heater tube
coke
Obtaining tube coke distribution, coke
density, and composition
Shijiazhoun, Shengli
5
Lab apparatus
development and
reaction model
coupling
For generalization of PSS Shengli, ShenuaLiaohe
6
Coking at high heat
intensity
Coorelating tube coking model
Supported by Sneng
Hua Ref.
7
Operation accident
analysis
Techncal analysis of accident
Chong zhou, Shengli,
Chilu, Da qin
8
One and double side
heating heater s tube
simulation
Softwaref For design company
9
Steam injection
guiding

10
Diagnosis of tube
coking

4. PSS Applications
For technological design of coking heater
Including the configuration
of radiant section, the pass
number of radiant tubes
and its arrangement,
the diameter and length of
radiant tubes, the number
and arrangement of fire
nozzles, and all operation
parameters, etc.
4. PSS Applications The PSS Capability
For assessing the existing coking heater
Obtaining the parameters,
such as the real residence
time of the feed medium in
the tubes, the real thermal
conversion, the peak oil
film temperature, two
phase fluid flow pattern,
etc., judging that whether
the fluid medium in the
tube is at the normal
delayed status or not;
finding out the weak point
in the operation, and giving
suggestion for improving.
For optimizing the operation conditions for an existing coking heater
Finding out the measures
for decreasing the coking
phenomena inside the
tubes; for realizing longer
working time, for higher
light distillate yield, as
well as for safety
operation.
Key Parameters along the Tube
4. PSS ApplicationsThe PSS Function
Temperature, Pressure, Film Temperature, Thermal Conversion, etc.
Two Phase Flow Pattern at Any Section
Controlling Coking Parameters
OTCS, Heat Flux, Flue Temperature, Two Phase Flow Pattern, etc.
4. PSS Case study
Improvement of 40 existing coking heater performance and
cooperation with designer for 16 new coking heaters, successfully.
The representative case studies are as follows
Design of large scale coking heater;
Revamping of existing heater;
Determining operation condition for a new feedstock;
Judging tube coking status and its prediction;
Multi-steam injection for increasing light oil yield;
Judgment of accidents;
Operation Optimization;
Heavy oil processing.
The List
Design of large scale coking heaters
4. PSS Applications Case study
Participated the design and
operation of the large scale
coking heater in Shanghai,
Nanking, Shandong, and others.
Cooperated with SINOPEC SEI, by
using PSS successfully.
Increasing 40-60% capacity in
comparison with the conventional
design method.
Revamping of existing heaters
Participated the revamping of
Shijiazhuang and other six refineries,
increasing 50% capacity of coking
heater, without changing the main
structure and dimensions of the
heater by using PSS.
Participated the energy saving of
Changzhou and other two refineries,
decreasing the energy consumption
by 10% by using PSS.
Determining operation conditions for a new feedstock
According to the conventional
operation, the exit temperature,
and steam injection quantity and
recirculation ratio are determined
by experience;
For new coking heater and new
feed, the above three parameters
are difficult to be determined;
With PSS, a new concept of
heat required for coking is
suggested, thus helped Hunan
and other several refineries
successfully started up.
Judging tube coking status and its prediction
By using PSS, diagnosis of the
fluid medium inside tubes is made
whether its status is normal or not;
investigate the influence of the
outside tube temp., fire wall temp.
and pressure drop on the inside
tube coke thickness in time. For
example, Shengli refinery solved
this problem in time.
Multi steam injection for increasing the light oil yield
With PSS, Hunan
refinery use the
multi steam
injection method,
thus increased the
light oil yield by 2%.
Judgment of accidents
Zhenhai Refinery imported
foreign feed, without too
high asphaltene content,
but at the beginning of
start-up, the tubes coked
seriously, then the
operation shut down; With
PSS , the accident cause
was found, and suitable
measures were adopted ,
thus putting to normal
operation
Operation Optimization
The Operation optimizing grade analysis
0
5
10
15
20
25
30
Unt 1 Unit 2
Apparatus Data(A)
Operation(B)
Difference(A-B)
The coke yield from Experimental
and commercial heater
J udging whether commercial unit is
operated at optimization
conditions, i.e., whether the light
oil yield is sufficient high for a
certain feed;
For many refineries, such as Hubei
refinery, for a certain unit 1, the
coke yield reached 25%, for unit 2,
the coke yield was 20%; it seems
the unit 2 is operated better, but
according to experimental data,
unit 1 is better.
Heavy oil processing
Coking Factor
For heavy oil processing, based on
specially designed apparatus for
investigating the definite feed
coking characteristics, with
mathematical models, and
utilization of coking mechanism,
PSS solved successfully the heavy
feed coking processing by using
special heater construction and
suitable feed ratios.
The feeds have higher coking
factor than Brazil.
A 12 lumped thermal reaction
model constant database is set up;
Special laboratory apparatus is
designed successfully;
Coking factor database is set up;

Summary of work done
5. Work Done the list
Special experiments are designed:
Kinetic experiments for
obtaining coking rate,
Industry tube coke thermal
conductivity,
Product distribution
database at the same reaction
condition;
A series of precision check for PSS
Operating Thermal Conversion
Severity is verified by special exper.,
the rule of coking rate is validated by
commercial heater data,
the pressure drop, flue gas temp. etc.
are verified by commercial data;
A series of application for PSS have
been done and case study presented .
19851988 The study on the law of radiation and
flow outside tubebackground research
19891991 The study on the heavy oil thermal
cracking background research
19911995 The study on technical design method
of coking heater background research
19961997 Maximum throughput of single side
coking heaterapplication research
19982000 Eliminate the bottleneck for single
side coking heaterapplication research

0001 Study the introduced new techniques for
double Side Coking Heaterapplication Research
0102 Design double Side Coking Heater in China
0002 Investigate parameters for 12 lumped models
background research
0203 Research on the large capacity coking heater
0203 Quick measurement for feedstock coking
tendency background research
The Cumulated Thickness of Codes of PSS is about 400 mm
All the code that has been edited by our group for 20 years
is packed up by this photo
Cooperation Suggestion
Research cooperation
Technological cooperation
Designing cooperation
Manufacturing cooperation
List
Provide apparatus equipped with controlling device and data software
Cooperation Suggestion Research cooperation
A specially designed
laboratory coking
apparatus is
purchased by client,
for determining the
feed stock coking
characteristics for
simulating the
coking process, etc.
laboratory coking
engineer sent by
the client would
come to our
laboratory and be
trained for using the
apparatus.
Before it, a confidential
agreement and buy-
selling agreement have
to be made. However,
the client may not buy
the apparatus, but ask
us to do the above
mentioned work.
Provide PSS and coking apparatus
Cooperation Suggestion Technological cooperation
Visit with each
other , face to face,
to make clear the
principle and to
grasp the measures
and technics for
using the PSS
software.
Provide PSS and coking apparatus
Cooperation Suggestion Technological cooperation
Seller would submit
PSS software code ,
training the
utilization of PSS
for buyers experts.
Provide necessary parameters
Cooperation Suggestion Designing cooperation
Buyer may not buy either
the lab apparatus or PSS ,
but ask seller to do the
work on experiment and
calculation to give the
necessary parameters to
buyer.
Provide necessary Designing cooperation
Cooperation Suggestion Manufacturing cooperation
Buyer may buy the lab
apparatus and PSS , and ask
SINOPEC SEI to make
design drawing, for building
or revamping the coking
unit.
Manufacturing cooperation
Cooperation Suggestion Manufacturing cooperation
Besides, buyer may buy
part or the complete of
the equipment,
and the seller would
participate the start up
of the unit.
Warm Welcome to China
Warm Welcome to
China University of Petroleum
Please feel free to contact us
for cooperation.
Thanks for
Your Attention

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Two Phase Flow Pattern

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