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Delayed Coker Unit (DCU): Process Overview The Delayed Coker Unit is a refining process that converts heavy, complex hydrocarbons into lighter, more valuable products. The process involves: 1. Feedstock preparation: Heavy residual oils from crude oil refining are heated and mixed with steam. 2. Coking: The heated feedstock is fed into the coker drum, where thermal cracking occurs, converting heavy hydrocarbons into lighter ones. 3. Coke formation: Carbon-rich residue forms and settles at the bottom of the coker drum. 4. Product separation: Lighter products (gasoline, diesel, jet fuel) are separated from the coke. DCU Configuration 1. Single-stage coking: One coker drum. 2. Two-stage coking: Two coker drums in series. 3. Flexicoking: Combination of coking and gasification. Key Equipment 1. Coker drums: Vertical or horizontal vessels where coking occurs. 2. Furnaces: Heat the feedstock to 450-500°C (842-932°F). 3. Heat exchangers: Recover heat from product streams. 4. Separators: Separate products from coke. 5. Coke handling system: Handles and transports coke. Products 1. Gasoline 2. Diesel 3. Jet fuel 4. Fuel oil 5. Petroleum coke (petcoke) Advantages 1. Converts low-value feedstock into high-value products. 2. Increases refinery profitability. 3. Flexibility in product slate. 4. Reduces waste generation. Disadvantages 1. High capital and operating costs. 2. Complexity of operation. 3. Environmental concerns (coke formation). 4. Requires specialized maintenance. Design Considerations 1. Feedstock quality. 2. Process conditions (temperature, pressure). 3. Coker drum design. 4. Materials selection. 5. Environmental regulations. Manufacturers 1. UOP (Honeywell). 2. ExxonMobil. 3. ConocoPhillips. 4. Shell Global Solutions. 5. Fluor Corporation. The Delayed Coker Unit is a complex process requiring careful design, operation, and maintenance. Understanding its intricacies helps optimize performance, minimize issues, and ensure safe operation. Delayed Coker Units (DCUs) are classified into two main types based on feed injection location: 1. Side Feed DCU 2. Center Feed DCU Side Feed DCU Characteristics: 1. Feed injected through nozzles or quills located on the side of the coker drum. 2. Feed distribution is radial, promoting even coke formation. 3. Suitable for high-viscosity feeds. Advantages: 1. Better feed distribution. 2. Reduced coking time. 3. Increased yield of liquid products. Disadvantages: 1. Higher capital costs. 2. Complex feed injection system. Center Feed DCU Characteristics: 1. Feed injected through a central nozzle or quill. 2. Feed distribution is axial, potentially leading to uneven coke formation. 3. Suitable for low-viscosity feeds. Advantages: 1. Lower capital costs. 2. Simplified feed injection system. Disadvantages: 1. Potential for uneven coke formation. 2. Longer coking time.

Delayed Coker Unit (DCU): Process Overview The Delayed Coker Unit is a refining process that converts heavy, complex hydrocarbons into lighter, more valuable products. The process involves: 1. Feedstock preparation: Heavy residual oils from crude oil refining are heated and mixed with steam. 2. Coking: The heated feedstock is fed into the coker drum, where thermal cracking occurs, converting heavy hydrocarbons into lighter ones. 3. Coke formation: Carbon-rich residue forms and settles at the bottom of the coker drum. 4. Product separation: Lighter products (gasoline, diesel, jet fuel) are separated from the coke. DCU Configuration 1. Single-stage coking: One coker drum. 2. Two-stage coking: Two coker drums in series. 3. Flexicoking: Combination of coking and gasification. Key Equipment 1. Coker drums: Vertical or horizontal vessels where coking occurs. 2. Furnaces: Heat the feedstock to 450-500°C (842-932°F). 3. Heat exchangers: Recover heat from product streams. 4. Separators: Separate products from coke. 5. Coke handling system: Handles and transports coke. Products 1. Gasoline 2. Diesel 3. Jet fuel 4. Fuel oil 5. Petroleum coke (petcoke) Advantages 1. Converts low-value feedstock into high-value products. 2. Increases refinery profitability. 3. Flexibility in product slate. 4. Reduces waste generation. Disadvantages 1. High capital and operating costs. 2. Complexity of operation. 3. Environmental concerns (coke formation). 4. Requires specialized maintenance. Design Considerations 1. Feedstock quality. 2. Process conditions (temperature, pressure). 3. Coker drum design. 4. Materials selection. 5. Environmental regulations. Manufacturers 1. UOP (Honeywell). 2. ExxonMobil. 3. ConocoPhillips. 4. Shell Global Solutions. 5. Fluor Corporation. The Delayed Coker Unit is a complex process requiring careful design, operation, and maintenance. Understanding its intricacies helps optimize performance, minimize issues, and ensure safe operation. Delayed Coker Units (DCUs) are classified into two main types based on feed injection location: 1. Side Feed DCU 2. Center Feed DCU Side Feed DCU Characteristics: 1. Feed injected through nozzles or quills located on the side of the coker drum. 2. Feed distribution is radial, promoting even coke formation. 3. Suitable for high-viscosity feeds. Advantages: 1. Better feed distribution. 2. Reduced coking time. 3. Increased yield of liquid products. Disadvantages: 1. Higher capital costs. 2. Complex feed injection system. Center Feed DCU Characteristics: 1. Feed injected through a central nozzle or quill. 2. Feed distribution is axial, potentially leading to uneven coke formation. 3. Suitable for low-viscosity feeds. Advantages: 1. Lower capital costs. 2. Simplified feed injection system. Disadvantages: 1. Potential for uneven coke formation. 2. Longer coking time

💡 Why are Shell and Tube Heat Exchangers the Industry’s Go-To Solution? In the demanding world of petroleum refining, efficiency and durability are paramount. That’s why shell and tube heat exchangers have become the backbone of heat transfer processes in refineries. These systems are not just robust but versatile, capable of handling extreme temperatures and pressures with ease. 🔑 Key Takeaways: 1️⃣ Discover how their modular design adapts to various flow patterns like counterflow for maximum heat transfer. 2️⃣ Learn why fixed tube sheets, floating heads, and U-tube configurations are essential for different operational needs. 3️⃣ Explore common refinery applications, from preheating crude oil to steam generation and product cooling. 📊 Did You Know? Shell and tube heat exchangers can operate under intense conditions, making them crucial for handling corrosive fluids and significant temperature differentials. With the right maintenance, they last longer, improving refinery efficiency. 🔧 Fouling, corrosion, and thermal fatigue are challenges every refinery faces. However, with regular cleaning, corrosion-resistant materials, and proactive monitoring, these issues can be managed effectively. 💬 What are your biggest challenges with heat exchangers? Share your thoughts and experiences below! ⬇️ 👉 Want more insights? Subscribe to Industrial Insight Nexus for free and get expert knowledge delivered straight to your inbox!

Pressure vessels are essential in the oil and gas sector, used in various applications, from production to product storage. They contain fluids under significant pressures, ensuring a safe environment for critical operations. In the oil sector, pressure vessels are commonly used in refineries to separate and process different components of crude oil, such as gases, liquids, and solids. They are also employed in units for cracking, distillation, and chemical recovery. Additionally, these equipment play a vital role in the transportation and storage of petroleum products, such as gasoline, diesel, and liquefied petroleum gas (LPG). Regarding gas, pressure vessels are essential in operations for the production, processing, and distribution of natural gas and other combustible gases. They are used in compression units, gas treatment, and liquefaction, as well as in storage and distribution facilities. Given the volatile nature of operations in the oil and gas sector, the integrity of pressure vessels is of paramount importance. Failures in these equipment can result in leaks, explosions, and other serious incidents that pose risks to the safety of people, the environment, and the company's assets. Therefore, rigorous standards in the design, manufacturing, and maintenance of pressure vessels must be followed, ensuring their safe operation in all phases of the process.

WHY IS STRIPPING STEAM IMPORTANT FOR CRUDE DISTILLATION? In the world of crude oil distillation, achieving optimal separation of hydrocarbons is crucial for refining efficiency and product quality. One key technique that enhances this process is the use of stripping steam. But how does it work? Let's dive in! 💠What is Stripping Steam? Stripping steam is water in vapor phase that is injected at the bottom or at specific points within the distillation column. Its usually of high pressure and temperature and it’s primary purpose is to remove lighter hydrocarbons from the heavier liquid fractions. This technique significantly improves the separation process. 💠How Does It Work? 1. Reduces Partial Pressure: By injecting steam, we increase the total pressure in the vapor phase. This reduces the partial pressure of hydrocarbons, promoting their volatilization. This is supported by Dalton’s law of partial pressure and Raoult’s Law. Where the total pressure of the system is a function of the partial pressure of each component and the partial pressure of each component is a function of its mole fraction and vapor pressure. 2. Stripping Action: This involves injecting steam into the distillation column, which rises through the column and interacts with the descending liquid hydrocarbons. As the steam ascends, it reduces the partial pressure of the hydrocarbons, promoting their volatilization. This action effectively "strips" lighter hydrocarbons from the heavier liquid fractions, facilitating their separation and improving the purity of the distillates. 💠Why is it Important? 1. Improved Product Quality: Reduces contamination of heavier products with lighter hydrocarbons. 2. Increased Recovery: Maximizes the recovery of valuable light hydrocarbons. 3. Operational Efficiency: Balances energy use and operational conditions for optimal performance. Managing the quality and quantity of steam is crucial to avoid over-stripping or operational issues. Heat Balance: Integrating steam injection effectively within the overall heat management of the distillation process is key. Stripping steam is a powerful tool in the refinery arsenal, driving efficiency and quality in crude oil processing. Understanding and leveraging this technique can lead to significant operational benefits and energy savings. Curious to learn more about refinery processes or have insights to share? Let's connect and discuss! #OilAndGas #Refining #ProcessEngineering #EnergyEfficiency #Hydrocarbons #ChemicalEngineering

Interesting and useful article in #oil #gas industry. #gasengineering #engineering #refinery #processengineering It is a great experience to be an engineer, especially in oil&gas! I recommend to the young people live this experience! A lot of Knowledge you can reach! I am very proud!

Crude oil refinery : Brief explanation about the various processes From the outside, an oil refinery may look like an endless maze of pipes, chimney stacks, steel columns, and vessels. The fact is, however, oil refineries are highly sophisticated industrial facilities transforming crude oil into valuable products used in an array of applications. Unprocessed oil is not very useful in its original form. An oil refinery or petroleum refinery is an industrial process plant where crude or “unprocessed” oil is processed and refined into more useful products such as petroleum naphtha, gasoline, diesel fuel, asphalt base, heating oil, kerosene, and liquefied petroleum gas. The issue with crude oil is that it contains hundreds of different types of hydrocarbons all mixed together. They have to be separated into different fractions to produce anything of value. This is where an oil refinery comes into play. Today, pipelines, trains, tankers, and trucks transport crude oil to refineries where it is transformed into the products we use every day. The crude oil can be processed in two ways. The most common way is a process called fractional distillation and the newer techniques use chemical processing. Fractional Distillation: is used for separating a mixture of substances with narrow differences in boiling points, and is the most critical step in the refining process. Chemical Processing: Breaks longer chains into shorter ones (cracking). Or by combining smaller pieces to make larger ones (unification).

*NGL* fractionation train edit The NGL fractionation process treats offgas from the separators at an oil terminal or the overhead fraction from a crude distillation column in a refinery. Fractionation aims to produce useful products including natural gas suitable for piping to industrial and domestic consumers; liquefied petroleum gases (Propane and Butane) for sale; and gasoline feedstock for liquid fuel blending. The recovered NGL stream is processed through a fractionation train consisting of up to five distillation towers in series: a demethanizer, a deethanizer, a depropanizer, a debutanizer and a butane splitter. The fractionation train typically uses a cryogenic low temperature distillation process involving expansion of the recovered NGL through a turbo-expander followed by distillation in a demethanizing fractionating column. Some gas processing plants use lean oil absorption process[27] rather than the cryogenic turbo-expander process. The gaseous feed to the NGL fractionation plant is typically compressed to about 60 barg and 37 °C.] The feed is cooled to -22 °C, by exchange with the demethanizer overhead product and by a refrigeration system and is split into three streams: condensed liquid passes through a Joule-Thomson valve reducing the pressure to 20 bar and enters the demethanizer as the lower feed at -44.7 °C. some of the vapour is routed through a turbo-expander and enters the demethanizer as the upper feed at -64 °C. the remaining vapor is chilled by the demethanizer overhead product and Joule-Thomson cooling (through a valve) and enters the column as reflux at -96 °C. The overhead product is mainly methane at 20 bar and -98 °C. This is heated and compressed to yield a sales gas at 20 bar and 40 °C. The bottom product is NGL at 20 barg which is fed to the deethanizer. The overhead product from the deethanizer is ethane and the bottoms are fed to the depropanizer. The overhead product from the depropanizer is propane and the bottoms are fed to the debutanizer. The overhead product from the debutanizer is a mixture of normal and iso-butane, and the bottoms product is a C5+ gasoline mixture.

Steam Loss in Oil Process Steam comprises approximately 30% of the energy consumed in a typical petroleum Refinery. The results of the various steam trap performance assessment programs reveal that approximately 20% of the steam leaving a main boiler plant is lost via leaking traps in distribution network. In Petroleum Refineries the cost of steam loss through steam distribution network is insignificant as compared to production loss still the energy consumption leads to new awareness because of considerable environmental impact. Steam network performance is vital for process plant reliability, safety and product yield. Therefore, process plants need effective ways to reduce the amount of energy consumed by their steam network. Regular industry practice is to replace faulty traps by upgrade technology ones based on expert reports. However, this can induce further failures in case of insufficient preventive maintenance of steam network. In such cases, simple repairs and maintenance or one to one replacement of traps will not be the suitable choice because of severe pipeline corrosion and/or previous water and steam hammer effects on the traps and pipelines. Also, it malfunctions new technology traps which otherwise might be able to perform better. Source: https://lnkd.in/dYQa6E3t #oil #storage #steam #safety #petroleum #refinery #boiler #process #heattransfer #storage #oilandgas #oilandgasindustry #learning #effectiveness #learning #training #thermodynamics #heating #cooling #engineers #plants #facilitiesmanagement

Essential for safety and efficiency, Swing Check Valves play a crucial role in the petrochemical industry. Widely employed in power plants, gas transmission, and refineries, these valves ensure the one-way flow of liquids or gases, preventing hazardous leaks or fires. Trust in Steelstrong's Swing Check Valves for robust and reliable flow control in critical petrochemical applications. #SteelStrong #ValveManufacturers #IndustrialValves #GateValve #GlobeValve #BallValve #SwingcheckValve #ForgedValve #IndustrialValvesManufacturers #ChemicalIndustry #ValveSuppliers #PetrochemicalIndustry #Petrochemicals #Petroleum