COKER Introduction:A coker unit is an oil refinery processing unit that converts the residual oil from the

vacuum distillation column or the atmospheric distillation column into low molecular weight hydrocarbon gases, naphtha, light and heavy gas oils, and petroleum coke. The process thermally cracks the long chain hydrocarbon molecules in the residual oil feed into shorter chain molecules. A delayed coker is a type of coker whose process consists of heating a residual oil feed to its thermal cracking temperature in a furnace with multiple parallel passes. This cracks the heavy, long chain hydrocarbon of the residual oil into coker gas oil and petroleum coke. The yield of coke from the delayed coking process ranges from about 18 to 30 percent by weight of the feedstock residual oil, depending on the composition of the feedstock and the operating variables. Feed: Vacuum Residue, Short Residue (from AVU) (hot) Circulating Lube Oil (from FCC) (cold) RCO from OSBL Tanks Equipments: Feed surge drum Heat exchangers Fractionator Stripping column Furnace Reactors Quench column Air pre-heater Hydrocarbon recovery vessel Process:Feed enters the SURGE VESSEL at 80-85 0C with the help of pump provided. From surge vessel it enters the first HEAT EXCHANGER at 1100C with the help of pump and heat is exchanged with hot kero (product) and leaves the heat exchanger at 1400C. And then feed goes to second heat exchanger where heat is exchanged with the LDO and

attains a temperature of 1800C. In the third heat exchanger the heating is done by LDO CR and the temperature reached by the feed is 2200C. The hot feed now enters the FRACTIONATOR at two different passes to control the temperature. Pumping the incoming residual oil into the bottom of the main fractionator, rather than directly into the furnace, preheats the residual oil by having it contact the hot vapors in the bottom of the fractionator. At the same time, some of the hot vapors condense into a high-boiling liquid which recycles back into the furnace along with the hot residual oil. In fractionator different cuts are obtained .the top product is off gases which are send to the FD fan coolers and then to condensers which follow to vessel containing boot drums. The vessel separates the material and we get gases and naphtha which are sent to LRU. The boots in the vessel separate the water and is called sour water. The next cut from the fractionator is kero which is send to the kero stripper and the after cooling is sent to run down. Below kero we get LDO(Light Diesel Oil) which is sent for stripping and cooling and then to R/D. The next lower cut is that of CFO which after being sent to the The bottom product of fractionator is send to the furnaces with the help of pumps. Boiler Feed Water is added to the furnace because the temperature inside the furnace is sufficient enough for the crude to crack and form coke. BFW is added to prevent the deposition of coke on walls of the tubes in the furnace. The heated crude from furnace is now sent to the reactors through a 4-way valve. In the reactors the remaining cracking is completed so the coke formed here is called delayed coke and the vapors from the reactor are sent to the quench column where the vapors are quenched and the suspended coke particles are also settled .The down product is cooled and taken out as RFO. The vapors from top are sent to the fractionator for the purpose of providing heat and also it atomizes the feed. The solid coke is deposited and remains in the coke drum in a porous structure that allows flow through the pores. Depending upon the overall coke drum cycle being used, a coke drum may fill in 16 to 24 hours. After the drum is full of the solidified coke, the hot mixture from the furnace is switched to the second drum. When the process of coke deposition is completed the reactor is first cooled by steam from 470oC to 250oC.The vapors released during this process is sent to the hydrocarbon recovery vessel which are provided with umbrella vessel and gas oil is scrubbed with the help of LDO already present in the vessel auto one-third level . After steam water is used, first low range and then high range. When temperature of 80oc is reached then the reactor is provided with coke cutting equipment where water is drilled .

The top and bottom heads of the full coke drum are removed, and the solid petroleum coke is then cut from the coke drum with a high pressure water nozzle, where it falls into a pit, pad, or sluiceway for reclamation to storage. The reactor is washed and then the chamber is assembled and a pressure test is done to check for leakage. Finally the chamber is filled with steam to avoid thermal shock of the feed entering the reactor. Now the reactor is ready for the process again.

Quality control, or QC for short, is a process by which entities review the quality of all factors involved in production. This approach places an emphasis on three aspects:[citation needed] 1. Elements such as controls, job management, defined and well managed processes,[1][2] performance and integrity criteria, and identification of records 2. Competence, such as knowledge, skills, experience, and qualifications 3. Soft elements, such as personnel integrity, confidence, organizational culture, motivation, team spirit, and quality relationships. Controls include product inspection, where every product is examined visually, and often using a stereo microscope for fine detail before the product is sold into the external market. Inspectors will be provided with lists and descriptions of unacceptable product defects such as cracks or surfaceblemishes for example. The quality of the outputs is at risk if any of these three aspects is deficient in any way.

Quality control emphasizes testing of products to uncover defects and reporting to management who make the decision to allow or deny product release, whereas quality assurance attempts to improve and stabilize production (and associated processes) to avoid, or at least minimize, issues which led to the defect(s) in the first place.[citation needed] For contract work, particularly work awarded by government agencies, quality control issues are among the top reasons for not renewing a contract. [3]

Use of an Ignition Quality Tester (IQT) This is a method that measures the time delay between the start of fuel injection and the start of significant combustion through auto-ignition of a pre-measured amount of diesel in a constant volume chamber. The time delay is used with a formula to calculate the Derived Cetane Number (DCN) which correlates to the D613 cetane engine. This is a relatively lower cost (less than one third of an engine), very reliable, high accuracy, faster, easily operated, and maintainable device.

Use of a Near Infra-Red (NIR) Analyzer This method uses a Near InfraRed (NIR) analyzer to obtain the absorption spectrum of diesel which then is fed to a chemometric model to estimate cetane. Its reproducibility is an order of magnitude better than an engine; the reproducibility is the same (because we use the engine as the referee). It is very reliable and low maintenance if the chemometric property prediction

model is set-up in accordance with ASTM E1655 practice and run as per ASTM D6122. The cost is the same as a cetane engine, but it measures 10 to 15 diesel properties simultaneously every 1 to 2 minutes.

MON (Motor Octane Number) is determined by burning fuel in a test engine running under severe and sustained high load, high speed conditions, and comparing the results to the reference fuels. (R+M)/2 (Pump Octane Number) as the name implies, is determined by adding together a fuel's RON and MON ratings and dividing by two. This is the common rating found on pumps in North America.