Delayed coking process.

Delayed coking is widely used in oil processing industry. As coke is obtained

in the form of particles, its sorting becomes easier (particles size are 25 mm or
more).
The technological scheme of unit is simple and recirculation of heavy liquid
products are used in the unit. The yield of coke is higher than other processes. Tar,
cracking residue, asphalt, extract are used as a feedstock.
The unit consists of four section coke camera (reactor), two tube furnaces,
rectification column and heat regeneration system.
Coke gradually fills the chamber during the process after stopping the raw
transfer, it is blow up with water vapours then it is cooled with water, then it is
refilled from coke camera with help of hydrocuts.
The technological regime of the unit: the entering temperature of feedstock to
coke camera 500-510ºC; removing temperature of vapours from the chamber 440-
450ºC; pressure in the coke camera 0,2-0,3 mPa; filling of chamber with coke-24
hours.
Raw material (tar) is pumped to the heat exchangers, heated to the definite
temperature at the heat of expense of light and heavy gas-oil fractions obtained in
this unit, then raw material is heated till 350-380ºC in the furnaces and fed to the
surface of reverse tray in lower part of rectification column, reaction products
removed from the upper part of coke chamber is sent to the bottom of reverse tray
in the rectification column.
In this section raw material contacts with vapour coking products removed
from two parallel working chambers. As a results of this heavy part of vapours are
condensated and mixed with raw material.
Thus, reverse flow is created. The heavy particles are condensated to raw
material as a result of contact, lighter particles are evaporated and mix with
reaction products.
 The mixture of raw material with recirculate is formed and this is called
second raw material. When the raw material consists of light fractions, it contacts
with vapour coming from coke camera and evaporates, then goes to the upper part
of rectification column. Second raw material from the lower part of rectification
column is pumped to the furnace, heated till 500-510ºC. To prevent the coking of
furnace tubes heated water vapour is fed to the furnace. The amount of heated
water vapour due to the second raw material is 3%. Heated water vapour increases
the rate of flow through the reaction tubes.
Vapour-liquid mixture with help of valves enters to the 2 parallel working
chambers. Other coke chambers are prepared for work cycle. Heat raw material
gradually fills the camera. The volume of chamber is large, the residence time of
raw material is much, so the cracking of raw material takes place in the cameras.
Vapours of decomposition products are continuously removed from the upper part
of the chambers and pass to the rectification column, the heaviest residue is
remained in the chamber.
The polycondensation reactions characteristic of coking process proceed with
the emission of heat, but decomposition reactions proceed with absorption of heat.
The heat effect of the process is negative, in contrast to the heat effect of these
reactions. Therefore the temperature of reaction vapour removed from the reaction
chamber is 30-500C less than the entering temperature of raw material to the
chamber.
Reaction products are parted different fractions in rectification column. Gas,
gasoline and water vapour removed from the upper part of rectification column is
condensed in condenser-cooler, then enter to the gas seperator. Obtained gases are
sent to the gas seperating units. Some part of gasoline is returned to the top of
column as a reflux, other part is sent to the rectifier.
Light and heavy gasoline fractions are removed from the sides of rectification
column, enter to the additional evaporating columns, evaparated with the water
vapour. Light gasoil fraction are purified from gasoline fraction, heavyl gasoil
fraction from light gasoil fraction with water vapour. Then these fractions enter to
the heat exchangers, heat the raw material, then enter to the coolers, cooled till 30-
350C and removed from the system.
Experimental exploitation of delayed coking units indicates that the process is
carried out in two stages. The first heat is mainly used to heat the reaction chamber
and to evaporate obtained condensate. This consumption of heat causes a decrease
of decomposition reactions. At this stage the evaporation of heavy fractions
exceeds the cracking reactions.
At the second stage of coking the volume of coke is constantly increases,the
quantity and quality of the obtained products are stabilized. As the amount of coke
increases, the volume of free reaction medium decreases and at the same time the
average temperature of coking increases.In this case the quality of the distillates
can be changed again. The layer of obtained coke is more durable and and contains
less volatile substances. When raw material is heated more in the furnace, the less
fear of flooding it in the chamber and the better quality coke is obtained.
 Picture 1. Delayed coking process.
1 - reactor; 2 – 4 way cranes; 3,4 – furnace; 5,7,11,12,14,20,23 – pumps; 6 – rectification column;
8,21 – condenser-cooler; 9 – evaporating column; 10 – water separator; 13 – water reservoir; 15,19-riboiler;
16 – fractionating absorber; 17,25 – cooler; 18 - rectifier; 22 – reflux reservoir; 24 – additional absorber
 The coke chamber is a cylindrical apparatus placed vertically. The pressure is
0.18-0.6Mpa. The internal diameter of the camera is 4.6-5.5m and its height is 27-
28m. Coke is filled to 4/5 of its height and depending on the productivity of the unit
lasts 24-36 hours. After the chamber is full it is emptyed through the valve without
disturbing continuous supple of the raw material.
To unload the chamber it is blowed up with water vapour during 30-60 min .
The purpose of this to desorb the absorbed oil vapours from the surface of coke. This
vapour first is sent to rectification column, then at the end of the evaporation thrown
to the atmosphere. When the temperature reaches 200-2500C at the top of the
chamber, cooling is continiued with water. The transfer of the water to the chamber
continues until its evaporation is completed (If the water vapour isnt removed from
the top of the chamber, the temperarure in the chamber wil be below 100ºC).
The hydraulic method, based on the force of the flow of water at high pressure, is
used to unload coke from the chamber. After cooling the chamber, the hatches open
from above and below the chamber. Then the coke is unloaded using a hydraulix ax.
Heating and cooling of the chamber and unloading of coke takes 48 or 60 hours
depending on the type of raw material.
 Picture 2 .Reactor (Coke chamber)
Factors affecting the coking process can be measured by pressure, temperature
and the volume velocity of raw material. Coke chamber is designed to work under
two pressures. When the quantity of tar is small in the feedstock the pressure is
≈0.4mPa, when the quantity of tar is large in the feedstock the pressure is 0.18mPa.
High aromatized distillate raw material is used to obtain “needle” coke.
The heating temperature of raw material in the furnace also affect to the quality
of obtained coke. When the entering temperature of the chamber is very high, the
amount of volatile substances in the obtained coke is increased and the mechanical
strength of coke increases.