Sim Romero
Rio Oil & Gas 2010
13-16 September 2010 Riocentro Convention Center Rio de Janeiro, Brazil
IBP2714_10
2010 KBC Advanced Technologies plc. All Rights Reserved.
polymerization
Liquids
0 500
Coke
1500 2000 2500 3000
Boiling Point, F
The polymerization or coking kinetics are a function of; Feed quality (i.e. asphaltenes, concarbon, sulfur etc) Feed contaminates (i.e. sodium, iron oxides/sulfides, general inorganic solids) Heater operating conditions time at temperature and heat flux
Delayed coker furnace fouling is a complex function of the thermal kinetics
PROPRIETARY INFORMATION 3
Heat Flux
Coke formation occurs at the boundary layer where the velocity is low and the temperature is high.
Q = Surface x Heat
Area Flux
The coke thickness acts as an insulation to heat transfer causing the tube wall temperature to increase.
Fouled Conditions
Outside Tube Wall Temperature Significantly Greater Than Boundary Layer Temperature Thermal Resistance Due To Metal Wall And More Importantly The Coke Deposited On The Tube
PROPRIETARY INFORMATION
Analysis of Ash
Silicon (dry, ppm) Iron (dry, ppm) Vanadium (dry, ppm) Nickel (dry, ppm) Aluminum (dry, ppm) Calcium (dry, ppm) Sodium (dry, ppm) Magnesium (dry, ppm) 10,270 241,100 1,699 1,023 251 7,799 5,439 2,764 15,240 169,400 2,140 1,607 111 12,230 7,227 3,196 14,190 272,700 1,760 1,393 2,385 9,225 3,954 2,107 5,623 301,900 19,910 15,880 2,645 10,130 7,004 842 4,551 312,000 8,577 3,037 2,506 15,910 19,800 3,519
Crude Unit Desalter Performance Significantly Affects The Delayed Coker Heater
7 PROPRIETARY INFORMATION
18,000 BTU/Hr/SqFt
12,000 BTU/Hr/SqF t
Double fired heater design reduces the peak flux and allows for higher average flux rates the average flux should, in a new design, still be limited
PROPRIETARY INFORMATION 8
Location of Thermowell
Perpendicular to pipe location results in a short thermowell and can lead to errors in measurements Poor insulation around the TW can cause poor measurements Return bend location gives better performance Decoking methods need to be considered with the location of the thermal wells Metallurgy or special hardening should be required to prevent erosion Some locations are using the process temperature two to four tubes back in the process
Straight run out of heater short thermowell longer thermowell First 90 bend out of heater
General practice is to online spall and pig decoke when the opportunity arises
PROPRIETARY INFORMATION
Fouling rates and monitoring heater operations Design should be for less than 1.5F/day Greater than 3F/day implies an operational problem or excessively high heat flux 3F/days = 3 month run 1.5 /day = 6 month run Use a linear regression to filter out variables Infrared scans should be done to verify or check tube metal skin temperatures
General practice is to online spall and pig decoke when the opportunity arises
PROPRIETARY INFORMATION
PROPRIETARY INFORMATION
DCS
Acoustic pyrometry is a relatively new technology for measuring gas temperature in a furnace. This method involves determining the temperature of flue gas by measuring the speed of sound waves as they pass through the gas. A detailed mapping of the gas temperature is possible with a matrix of sound transmitters and receivers. Acoustic pyrometry provides a continuous monitoring of the heat flux in the fire box
PROPRIETARY INFORMATION
Sonic Meter
New technology very low maintenance and good reliability No obstruction in flow path Pressure drop equal to an equivalent length of straight pipe Unaffected by changes in temperature, density or viscosity Corrosion/erosion -resistant Accuracy about 1% of flow rate
Coriolis Meter
New technology some maintenance and startup issues Good reliability Excellent accuracy- better than +/-0.1% with an turndown rate more than 100:1. The Coriolis meter can also be used to measure the fluid density.
PROPRIETARY INFORMATION
A great man once said if you cant measure it, you cant manage it
Muito Obrigado
Sim Romero KBC Advanced Technologies, Inc. +1 832 494 0441
www.kbcat.com sromero@kbcat.com
PROPRIETARY INFORMATION
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