COKE DRUM
Shivangi Ruparel, Asst.Prof, K.J.Somaiya College of Engineering, Vidyavihar, Mumbai400077, ruparelshivangi@gmail.com
Sangita bansode, Asso.Prof, K.J.Somaiya College of Engineering, Vidyavihar, Mumbai400077, sangitabansode@yahoo.com
Paresh Tulankar, Engineer, Toyo Engineering India Limited, Mumbai, India
tulankarp@toyoindia.com
Abstract
One of the primary reasons leading to failure of the delayed coke drum is the severe temperature gradient due to
cyclic temperature variation. Based on the two dimensional heat conduction theories, an analytical solution of
the transient temperature stresses in the coke drum is obtained, which is then compared with Finite element
analysis done using Ansys Software. Various working temperature conditions are discussed. Numerical results
show that the present theoretical model can describe basic features of the transient temperature field in the coke
drum. A transient thermal-stress analysis is developed which gives temperature distribution and stress
parameters for given values of boundary temperatures.
Notations
Bi Biot number
Cp Specific heat [J/Kg-K]
E
Modulus of elasticity [N/mm2]
Fo
Fourier number
K
Diameter ratio = ro/rl
In modern industry, the heat conduction problem in pipes and pressure vessels subjected to
variation in thermal conditions can be described as the transient temperature field in thick
hollow cylinders. The shell of the coke drum can be simplified as a cylinder for the analysis
purpose as suggested by Zihui Xia, Feng Ju(2010). Vollbrecht(1974) has analysed the stresses in
both cylindrical and spherical walls subjected to internal pressure and stationary heat flow.
Kandil (1975) has studied the effect of steady-state temperature and pressure gradient on
compound cylinders fitted together by shrink fit. The finite element method has been used by
Sinha (1978) to analyse the thermal stresses and temperature distribution in a hollow thick
cylinder subjected to a steady-state heat load in the radial direction. Naga (1986) has
presented the stress analysis and the optimization of both thick-walled impermeable and
permeable cylinders under the combined effect of steady-state temperature and pressure
gradient.
Although a lot of studies were conducted on transient temperature field of infinite cylinders
under constant thermal boundary conditions, only few studies involved dynamic thermal
boundary conditions. McNeill and Brock (1971) presented a simple analytical solution for a
straight pipe subjected to a linear thermal shock using discrete technique, and Marie (2004)
proposed an extension of this solution for any variation of the fluid temperature. Kandil
(1995) solved the radial temperature distribution within a cylinder under dynamic internal
temperature gradient based on the finite difference technique. Shanani and Nabavi (2007)
considered the thermal problem of an infinite cylinder subjected to time-dependent thermal
boundary condition using finite Hankel transform.
To deal with the problem of the coke drum, it is necessary to understand the character of
temperature field in the drum wall. Due to severe thermal operational conditions, it is nearly
impossible to get the exact temperature distribution by field surveys. At present, the
temperature in the drum wall is obtained by calculating it from the measured temperature of
the outer surface, or by FEM simulation. Most of the studies in the literature on coke drums
were based on field surveys and FEM analysis as concluded by Zhi-hua and LIU (2010). The
main aim of this paper is to study the transient variation of thermal stresses within thick
cylinders subjected to different operating conditions. The temperature distribution within the
cylinder wall is determined using numerical methods.
ANALYSIS OF TRANSIENT STRESSES
Following are the assumptions taken into consideration during the analysis:
(i) The ends of the cylinders are assumed to be unrestrained.
(ii) The longitudinal strain developed as a result of the stress is uniform and constant, i.e.
plane strain with = 0.
(iii) The temperature of the cylinder is considered to vary only in the radial direction and is
time-dependent, i.e. T = T(r, t).
(iv) There is no source of heat generation within the cylinder thickness.
(v) The outside surface of the cylinder is exposed to ambient conditions which are large
enough so that its temperature can be assumed to remain constant. Therefore, the mean value
of the convective heat transfer coefficient is used in the calculations.
(vi)The thermal conductivity of the cylinder material, the coefficient of linear expansion,
modulus of elasticity and Poisson's ratio are assumed to be independent of temperature.
Temperature distribution
The differential equation of time-dependent heat flow in the radial direction is given
according to Kandil (1995) in polar coordinates as
1
(1)
This equation can be solved numerically on the basis of the forward finite difference
technique. The cylinder is discretized into a cylindrical mesh using an equidistant sized grid.
The transient finite difference equation at any node of interest is derived by making an energy
balance on the volume of material associated with each node. A set of algebraic equations for
temperature is obtained for a number of nodal points through the thickness of the cylinder.
The temperature at an interior node (m), as shown in Figure. l(a), after a time interval t is
given by the equation:
= 0
1,
1 +
, +1
+1 + 1 20
(2)
For the non-interior node (n) (at the outside surface) as shown in Figure. 1 (b), the equation
of temperature is given by
= 20
1,
1 + 0 + 1 20
1,
(3)
Figure. 1. Thick cylinder model: (a) interior node, (b) non-interior node.
Then, the temperature distribution is obtained by solving these equations at specified time
intervals t. It is worth mentioning that for small values of radial interval (r) and of Fourier
number (Fo) the mesh density increases and therefore the calculation time increases.
However, the calculation accuracy also increases. Taking advantages of computer facilities in
the calculations, r is chosen to be small enough so that its effect on the accuracy of the
resulting temperature is negligible. The relevant time interval (t) should be determined to
verify the stability of Equations (2) and (3):
=
where the following condition is satisfied,
0.5 > 0 <
0 2
(4)
1,
(5)
There are four different kinds of working conditions possible for the temperature at the
boundary of the inside surface of the cylinder. These are as follows:
(i) The temperature of the inside surface is suddenly changed from to and remains
constant during the operating time, i.e.
, =
(6)
(ii) The temperature of the inside surface is linearly increased within a so-called heating time
( ) up to the operating temperature and then remains constant over the operating time.
, = +
, =
0
7
(iii) The temperature of the inside surface during the operating time is oscillating according
to the harmonic function, i.e.
, = + sin 2
(8)
(iv) The temperature of the inside surface takes an arbitrary periodic form over the operating
time, i.e.
, = +
=1
sin 2
(9)
ln
( )
ln
(10)
where T(r) is the temperature at radius r, and are the inner and outer radii, with as the
inside wall temperature.
=0
(11)
The total strain is made up of two strains. The first one is dependent on the induced stresses
and the other one is due to free thermal expansion. Thus, the relation between thermal
stresses and strains follows the thermo elasticity formulae given below:
1
+ =
+ =
= +
1
= +
1
= +
+ = 0
(12)
(13)
(14)
+ = 0
(15)
Substituting (12) and (13) into Eqn (15) and using Eqn (11), yields
1
3
3 = 1
(16)
Solving Equation (16) with the boundary condition at the inside and outside surfaces, (r =
and r = ), gives:
1
= 1 2
2 +2
2 2
. +
. . 2
(17)
2 +2
2 2
= 1 2
= 1
2
2 2
(18)
(19)
. =
. =
, .
, .
(20)
(21)
conditions are used at the radial and bottom planes. Since the cylinder being modelled is
long, nodes are coupled to enforce a constant axial strain condition.
Table 1: Material, Geometry and Load data for analysis
Material Properties
E = 30 x 106 N/ m2
= 0.3
= 15.12 x 10-6 /K
= 7861.09 kg/m3
c = 418.6 J/kg-K
Geometric Properties
a = 9500 mm
b = 9545 mm
h = 42900 mm
Loading
Tf = 370 C
To = 38C
CONCLUSIONS
A theoretical study of thermal stress analysis has been carried out for thick-walled cylinders
subjected to a transient temperature gradient with different operating conditions. The analysis
reveals that the maximum effective stress always occurs at the inside surface of the cylinder,
and its peak value takes place at the start of the operating temperature.
In order to reduce the effective stress in the coke drum, the inner surface should be heated
gradually up to the operating temperature. The transient time after which the temperature of
the drum reaches the steady-state condition is proved to depend on both the diameter ratio
and the heating time. The solution is in a close form, and can be easily applied to discuss the
effects of the parameters of the coke drum on the transient temperature distribution.
Acknowledgement
The authors are grateful to Mr.Mangesh Shirpurkar, Joint Manager, Heat Transfer & Applied
Technology department, Toyo Engineering India Limited for his encouragement and help in
the preparation of this paper. Technical assistance for analyzing temperature distribution in
coke drum was provided by TOYO Engineering India Limited.
REFERENCES
[1] Thomas, J. W. API survey of coke drum cracking experience. Proceedings-Refining
Department, American Petroleum Institute, 46th Midyear Meeting, Chicago, Illinois,
141153 (1981)
[2] Bagdasarian, A. et al. Integrity of coke drums (summary of 1998 API coke drum
surver). ASME, Pressure Vessels and Piping Division (PVP) , 265270 (2000)
[3] Zihui Xia, Feng Ju Pierre Du Plessis, , Heat Transfer and Stress Analysis of Coke
Drum for a Complete Operating Cycle, Journal of Pressure Vessel Technology by
ASME, Vol. 132 / 051205-12, (2010)
[4] H. Vollbrecht, Stress in cylindrical and spherical walls subjected to internal pressure
and stationary heat flow, Verfahrenstechnik 8, 109-112 (1974)
[5] A. Kandil, Investigation of stress analysis in compound cylinders under high pressure
and temperature, M.Sc. Thesis, CIT Helwan (1975)
[6] R. N. Sinha, Thermal stress analysis of a hollow thick cylinder by the finite element
method. J. Inst. Eng. (India) Mech. Eng. Division, (1978)
[7] S. A. R. Naga, Optimum working conditions in thick walled cylinders, d. Eng. Mater.
TechnoI, Trans. ASME. 108, (1986)
[8] McNeill, D. and Brock, J. Engineering Data File Charts for Transient Temperatures
in Pipes, Heat/Piping/Air Condition Eng., 107119 (1971)
[9] Marie, S. Analytical expression of the thermal stresses in a vessel or pipe with
cladding submitted to any thermal transient. International Journal of Pressure Vessels
and Piping 81(4), 303312, (2004)
[10] Kandil, A., EL-Kady, A., and EL-Kafrawy, A. Transient thermal stress analysis of
thick-walled cylinders. Int. J. Mech. Sci. 37(7), 721732 (1995)
[11] Shahani, A. R. and Nababi, S. M. Analytical solution of the quasi-static
thermoelasticity problem in a pressurized thick-walled cylinder subjected to transient
thermal loading. Appl. Math.Modelling 31(9), 18071818 (2007)
[12] Zhi-hua NING, Ren-huaiLIU, Analysis of transient temperature field in coke drums,
Appl. Math. Mech. -Engl. Ed. 31(3), 291304 DOI 10.1007/s10483-010-0303-7,
(2010)
[13] Wang, Zheng et al. Numerical simulation of the transient heat transfer of coke drums
and study on the characteristic of stress filed, Pressure Vessel 22(10), 2327 (2005)
[14] Kardomateas, G. A. Transient thermal stresses in cylindrically orthotropic composite
tubes. ASME J. Appl. Mech, 411417 (1989)
[15] Yee, K. C. and Moon, T. J. Plane thermal stress analysis of an orthotropic cylinder
subjected to an arbitrary, transient, asymmetric temperature distribution. ASME J.
Appl. Mech., 632640 (2002)