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Decoke Procedure Modification Vinod Mishra Ingenero
Decoke Procedure Modification Vinod Mishra Ingenero
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Presentation Outline
• Introduction
• Need For Decoke Modification
• Basis for Decoke Modification
• Methodology Adopted
• Case Study – Ethylene Plant
• Conclusion
• Q&A
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Introduction
Coke deposition in furnace coils is inherent to the process
• During normal operation, coke slowly deposits in the radiant coils and
transfer line exchanger tubes
* Primary Transfer Line Exchanger (PTLE), Secondary Transfer Line Exchanger (STLE), Tertiary Transfer Line Exchanger, etc.
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Effect of Coke Deposition
Coke deposition limits production
• Reduced heat transfer to the process fluid resulting high TMT (tube metal
temperature) shut down to prevent tube failure
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Furnace Operating Parameters
To get desired yield from the cracking furnaces, operating
parameters are continuously measured and monitored
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Decoke Operation
Furnace operation is typically terminated and decoking
done when specific criteria is reached
•Maximum TMT of any coil reached to the design limit of coil metallurgy
(1050 ºC)
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Need for Decoke Modification
Decoking procedures differ; getting it wrong is expensive
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Basis for Decoke Modification
A holistic and scientific approach should be used to develop
a specific decoke procedure for every Ethylene plant based
on furnace type, feed, severity and TLE fouling
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Methodology Adopted
Ingenero combines best of breed technology into a single
software tool for Ethylene producers for this purpose and
other optimization
Sample Software Combined and/or results utilized:
Furnace Side / Hot Side
• Convection section modeling (e.g. FRNC 5)
• CFD
• Fire Box Modeling (geometry / heat flux models)
• Yield models
• ANN
• LP Model
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Burner Adjustment for Controlling TMT
Fire box (geometry / heat flux) models allows individual
burner management
= Fully open valve =Partially shut valve =Primary fuel line =Secondary fuel line
BURNER =Low capacity burner BURNER = High capacity burner
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FRNC to Monitor Convection Section
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Methodology Adopted
Specifically for decoking optimization those key operational
and decoking parameters are analyzed
• Deviations of individual coil CPR, TMT and TLE outlet temperatures are
tracked and trended for individual furnaces for daily review and analysis
• Analysis of furnace parameters, Feed trims, COT trims and Burner
management provides daily guidance to control CPR and TMT of coils as
well as TLE outlet temperatures
• Fouling trends of individual radiant coil and TLE in the furnace from
HTRI/ HTFS software is incorporated into the daily output
• With historical analysis and predictive modeling, the appropriate decoke
steps and modifications in decoke procedure are achieved
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Case Study
Software allows deviation of furnace radiant coils CPR to be
controlled through management of burner and other furnace
operating parameters to minimize coking
CPR deviation trends of Furnaces
Delta Average CPR
0.10
FURNACE1 FURNACE2 FURNACE3 FURNACE5
0.09
0.08
0.07
0.06
Increase in CPR
0.05
deviation
0.04 CPRdeviation reduction after operation
0.03 optimization
0.02
0.01
0.00
-0.011-Dec 11-Dec 21-Dec 31-Dec 10-Jan 20-Jan 30-Jan 9-Feb 19-Feb 1-Mar 11-Mar 21-Mar 31-Mar 10-Apr 20-Apr 30-Apr
-0.02
-0.03
-0.04
-0.05
-0.06
-0.07
-0.08
-0.09
-0.10
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Case Study
TLE fouling is reduced by modifying Decoke procedure
TLE fouling trends before and after Decoke procedure modifications
TLEfouling trends
0.0018
PTLE-1 PTLE-2 PTLE-3 PTLE-4 PTLE-5 PTLE-6
0.0016
Before decoke procedure modification
0.0014
0.0012
After decoke procedure modification
0.001
0.0008
0.0006
0.0004
0.0002
0
17-Jun-07 22-Feb-08 29-Oct-08 06-Jul-09 13-Mar-10 18-Nov-10 26-Jul-11 01-Apr-12
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Case Study: Improve Furnace Run-length
Run length met design quickly and then was greatly
exceeded
Furnace Run-length
120
110
100
Time (Days)
80
60 55
40 33
20
0
Original Design Achieved
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Impact on Plant Performance
Yield improved about 3% from 76.6% by Decoke procedure modification
& optimization
Net Ethylene Made (Tons) 386,000 437,000 565,709 531,996 500,466 577,772 538,069 551,112
excl. CH4
Feed Processed (Tons) 504,000 548,000 702,226 670,034 621,904 722,327 680,342 696,515
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Conclusion
Applying a systematic and careful analysis of decoking
process and variables associated with coking can have
dramatic effects
Example Client:
• Furnace run length improvement (33 days to 105 days)
• Delimited TLE maximum outlet temperature
• 3 Furnace decoke operations were avoided during the year.
• Equivalent to extra Ethylene production 1055 tons
• Other intangible benefits - Increased Furnace Coil life/ reliability due to
reduction in decoke cycle
• Energy saving due to reduced decoke cycle
• Prediction and planning for mechanical cleaning of TLE
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Confidential & Proprietary 18
Ingenero – Team Member’s Profile
Vinod Mishra
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Questions
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