EUROPEAN ACADEMIC RESEARCH
Vol. X, Issue 4/ July 2022
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ISSN 2286-4822
www.euacademic.org
Evaluation and simulation of different crude oil in
Delayed Cocker Unit (DCU) in Khartoum Refinery
SALMA ABDALLA MOHAMED IBRAHIM
College of Graduate Studies and Scientific Research
Karary University, Khartoum, Sudan
BABIKER KARAMA ABDALLA
Professor, Karary University Khartoum, Sudan
ADIL ALI MOHAMED
Assistant Professor, Karary University Khartoum, Sudan
HAIDER ABDELGADIR ELBASHER
Assistant Professor, MASAD Khartoum, Sudan
Abstract
In this study, a computer simulation and salutary analysis was conducted for
two types of crude oil produced in Sudan in order to reach the goal of the ideal mixing
ratio between the heavy crude (Dar / Fula) to be used as a substitute for crude oil (Fulla
blend) in the delayed coke production unit at the Khartoum Refinery in Sudan which is
now use only fulla blend. Based on the results of laboratory testing and computer
simulations and lab analysis performed, blending 50% of DAR blend with 50% of Fula
blend ore in the delayed coke production unit achieved a good improvement in the
specifications and quantities of the products such as xyz which is better than that
achieved by using fulla blend in DCU with the potential for a certain negative impact
and limitations according to the variance in the physical and chemical properties of the
two types of ore used that must be consider.
Keywords: coke, refinery, DCU, blend, crude oil.
1. INTRODUCTION
Crude oil is one of the raw materials that formed under the layers of the
earth according to specific conditions and composed of hydrocarbon materials
which are distilled to recover many types of products which have wide range
of use in the life, according to a range of molecular weights (e.g. petrol and
diesel)[1]. The heavier bottom component of crude oil is generally vended
into the burner energy or cellarage energy request (for shipping) as a Heavy
Energy oil as fuel (HFO). Therefore, only a cut of the crude oil after refining
can be distilled to serve the automotive energy needs. It's still possible using
a process called delayed coking to crack the heavy petroleum remainders to
lighter products, thereby supplementing the product of automotive energies
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Abdelgadir Elbasher– Evaluation and simulation of different crude oil in
Delayed Cocker Unit (DCU) in Khartoum Refinery
and producing a solid carbon called coke. Delayed coking is one of the
chemical engineering unit processes used in numerous petroleum refineries.
The main idea of the delayed coking unit is to convert the residual products
with low value to lighter products have high value and to produce a coke
product. The coking process consists of thermal cracking, condensation, and
polymerization process that do both in sequence and contemporaneously. The
coker furnace supplies the necessary heat to initiate vaporization and
cracking, while the cracking and polymerization process are completed in the
coke reaction vessel, therefore the term (delayed coking). The high- molecular-
weight gasoil cut and asphaltene materials are cracked into small cuts of
hydrocarbons and heavy carbon products (coke). The light intermediate
products formed during the cracking process are further cracked, producing
low- molecular- weight components, similar as hydrogen, a wide range of
other light gaseous component, and light liquids in the gasoline and distillate
boiling range. Due to high coke reaction vessel (known as cocker drum)
temperatures, the liquids vapors and gas products pass above to the
fractionator, leaving the solid coke in the coke vessel. The structure of the
green coke product is dependent upon the residue or feedstock form
transferred to the Coker. In brief, the process heats the residual oil from the
vacuum distillation unit in a petroleum refinery to its thermal cracking
temperature in the heat transfer tubes of a furnace. This incompletely
vaporizes the residual gasoil and initiates cracking of the long chain
hydrocarbon components of the residual oil painting into hydrocarbon gas,
coker naphtha, and coker gasoil and petroleum coke. The heater effluent
discharges into veritably large perpendicular vessels( called" coke drum")
where the cracking process continue to completion, forming solid petroleum
coke which deposits out and accumulates in the coke drums from which the
product coke is latterly removed.[2][3] This study conducted in Khartoum
refinery in Sudan which use one type of blend of crude oil for DCU, this
study amid to make new mix from this type of blend produce in Sudan to
ameliorate the specifications of final product.
1.1 Literature review of the delayed coking process
Delayed coking evolved steadily over the early to mid-1900s to enable refiners
to convert high boiling, residual petroleum fractions to light products such as
gasoline. Pound for pound, coking is the most energy intensive of any
operation in a modern refinery. Large quantity of energy are needed to heat
the thick, poor-quality petroleum residue to the 900 - 950 degrees F required
to crack the heavy hydrocarbon component into lighter, more valuable
products. One common misconception of delayed coking is that the product
coke is a disadvantage. Although coke is a low valued (near zero economic
value) byproduct, compared to transportation fuels, there is a significant
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Abdelgadir Elbasher– Evaluation and simulation of different crude oil in
Delayed Cocker Unit (DCU) in Khartoum Refinery
worldwide trade and demand for coke as it is an provident fuel. Coke
production has increased steadily over the last ten years, with farther
increases read for the foreseeable future. Current domestic production is near
111,000 tons per day.
A major driving force behind this increase is the steady decline in
crude quality available to pollutants. Crude slates are anticipated to grow
heavier with advanced sulfur contents while Crude slates are anticipated to
grow heavier with advanced sulfur contents while environmental restrictions
are anticipated to significantly reduce the demand for high- sulfur residual
energy oil products. Light sweet crudes will continue to be available and in
indeed lesser demand than they're moment. Refineries will be faced with the
choice of get light sweet crudes at a preferential price, or adding bottom of
the barrel elevation capability, through new investments, to reduce the
product of high- sulfur residual energy oil and increase the product of
distillate fuel with low- Sulphur[4] . A alternate disadvantage is that liquid
products from cokers constantly are unstable, i.e., they fleetly form gum and
sediments. Because of intermediate investment and operating costs, delayed
coking has increased in fissionability among refiners worldwide. Grounded on
the 2000 Worldwide Refining Survey published in the oil and Gas Journal
December 2000 issue, the coking capacity for 101 refineries around the world
is 2937439 barrels/ timetable day.. These cokers produce,154607 tons of coke
per day and delayed coking accounts for 88% of the world capacity.
The delayed coking charge capacity in the United States is1, 787,860
b/cd. In general, coking belongs to a class of thermal corruption, free radical
chemical reactions that have been considerably studied, except for the last
stages of coke conformation itself. The engineering of thermal processes has
been well developed. Recent mind efforts to minimize the environmental
impacts of furnace processes have lead to significant advancements. As the
coke product has declined in value, alternate coking processes have been
developed to consume the coke produced in- house (e.g., burn it). The values
of these processes are privately associated with the mileage requirements of a
particular refinery. Delayed coking is still the favored process in new
construction. [5]
1.2 Delayed coking process
The first delayed coker was erected by Standard Oil of Indiana at Whiting,
Indiana in 1929[6], [7]. The development of hydraulic decoking came in the
late 1930's. Shell Oil at Wood River, Illinois presented a paper on hydraulic
decoking4.0 m( 13 ft) periphery Dobbs units and stated that they had patents
along with Worthington Pump Company on hydraulic decoking bits and
snoots[ 8]. Standard Oil of Indiana had patents on the original cutting nozzles
used by Pacific Pump [9].
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Abdelgadir Elbasher– Evaluation and simulation of different crude oil in
Delayed Cocker Unit (DCU) in Khartoum Refinery
A veritably analogous nozzle is presently used in the new compact
combination coke cutting unit. A pilot hole is drilled down through the coke in
the vessel using high pressure water, and then the coke is cut out with a
drilling bit with horizontal water nozzles. Roy Diwoky while at Standard Oil
Whiting was one of the crucial people in developing the hydraulic decoking in
the 1930's. Diwoky in May 1952, while Administrative Vice President of Pan
Am SouthernCorp. (Possessed by Standard Oil of Indiana), worked with Great
Lakes Carbon Corporation to produce the first needle coke in a delayed coker.
Bernard Gamson, the Director of Research and Development for Great Lakes
Carbon at the time, stated in a report that Diwoky was “the father of delayed
coking [ 7].
“Delayed coking combined a number of the features and
advancements from the development of the thermal cracking process. The use
of pressure as well as heat for cracking and separating the heater from the
coker and the use of two cans enabled the delayed coker to operate on a
nonstop base. The number of cokers erected before 1955 was small, with a
swell in delayed coker construction between 1955 to 1975 at 6% and an 11%
growth rate during the 1965 to 1970 period [10]. The growth of delayed
cokers was in step with the growth of fluid catalytic cracking and rapid-fire
decline in thermal cracking. A fluid coker, suchlike to a fluid catalytic cracker
except that fluid coke is circulated rather of catalyst, was first erected in 1954
at Billings, Montana. Five further fluid cokers were erected in the late fifties,
and one in 1970.
Fig.1. Typical schematic diagram of a delayed coking unit [3]
In 1958, the head of petroleum refining engineering at Colorado School of
Mines, J.O. Ball, stated that there would not be any further belated cokers
erected. Ball allowed all new cokers would be fluid cokers, and that a delayed
coker was just a scrap can in the refinery, the delayed coking process was
developed to minimize refinery yields of residual energy oil painting by severe
thermal cracking of stocks similar as vacuum residuals, aromatic gas oils, and
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Abdelgadir Elbasher– Evaluation and simulation of different crude oil in
Delayed Cocker Unit (DCU) in Khartoum Refinery
thermal tars [10]. In early refineries, severe thermal cracking of similar
stocks redounded in unwanted deposit of coke in the heaters. By gradational
elaboration of the art it was set up that heaters could be designed to raise
residual stock temperatures above the coking point without significant coke
conformation in the heaters. This needed high rapidity (minimal retention
time) in the heaters. furnishing an insulated swell barrel on the heater
effluent allowed sufficient time for the coking to take place before posterior
processing, hence the term “delayed coking”.
2. STATEMENT OF THE RESEARCH PROBLEM
In the Khartoum refinery using only the crude from Fulla field in Sudan as
feed stock for DCU unit and all design set depending on the fulla blend, now
the Fulla crude Decreased from 40000 barrel/day to 20000barrel/day for some
reasons . this work planned to study possibility of Blending fulla crude with
other crude available in Sudan ( Dar blend)with ideal ratio should be
considered to guarantee amount of feed stock without any change or major
change in the unit design.
2.1 Location
Khartoum Refinery Co., Ltd, which is located 75 Km North of Khartoum -
Sudan country
3. OBJECTIVES
3.1 General Objectives:
The main objective of this thesis is to reach the ideal blending percentage
between Dar Blend /Fula heavy crude mix in order to be used as the
alternative to Fulla crude oil in Khartoum refinery DCU.
3.2 Specific Objectives:
1. Evaluation and simulation studies to estimate the possibility processing
different ratios of Dar Blend /Fula heavy crude mix.
2. To disquisition of the effects on some physic-mechanical properties of heavy
and light crude oil.
4. MATERIAL AND METHODS
Khartoum Refinery Company is the biggest Refinery in Sudan which is
located about seventy-five kilometers north of Khartoum; the engineering
construction was completed in January 2000. In May 2000 the refinery
started production.
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Abdelgadir Elbasher– Evaluation and simulation of different crude oil in
Delayed Cocker Unit (DCU) in Khartoum Refinery
The study method has two step included lab scale run done for different
mixing ratio between Dar blend /Fulla blend the result used as input data for
simulation program (hyses) which descripted in the below:
4.1 Sampling
The sampling taken from the inlet of DCU unit and the sample was free of
any disposal. The sample was observed to be semi-liquid at room temperature
and it was shaking to homogenization, and then a representative portion of
the sample was taken and tested.
4.2 Distillation:
The Distillation Apparatus used is:
i-FISCER C FR467 V1.72 (10/22/08)
The distillation procedure is carried out according to the following:
[A] ASTM D2892 [11]:
(1) The distillation cut from (IBP – 165) ℃ are separated at Vacuum 1,
pressure (100 Torr).
(2) The distillation cut from (165 – 220) ℃ are separated at Vacuum 2,
pressure (10 Torr).
(3) The distillation cut from (220 – 280) ℃ are separated at Vacuum 2,
pressure (10 Torr).
(4) The distillation cut from (280 – 350) ℃ are separated at Vacuum 3,
pressure (2 Torr).
[B] ASTM D5236 [11] (POTSTILL Method)
(1) The distillation cut from (350 – 410) ℃ are separated at Vacuum pressure
(1 Torr).
(2) The distillation cut from (410 – 500) ℃ are separated at Vacuum Pressure
(0.1 Torr).
4.3 Fractions and Lab Analysis:
The products as Naphtha, kerosene, diesel fraction, vacuum distillation
fraction, atmospheric distillation residue fraction and vacuum distillation
residue fraction by true boiling point distillation instrument and then tests
the properties of crude and these fractions under ASTM and GB standard.
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Abdelgadir Elbasher– Evaluation and simulation of different crude oil in
Delayed Cocker Unit (DCU) in Khartoum Refinery
4.4 Theoretical Evaluation and Simulation
4.4.1 Simulation software:
In this project we are using aspen Hysys (v8.8) which is one of best simulation
software in the field of downstream processing.
Fig.2. Aspen Hysys software input data
Fig.3. Aspen hysys software fractionation distillation
Fig.4. Aspen Hysys software DCU simulation
4.4.2 Material balance:
An overall material balance will be calculated for the whole process using the
simulation software. And a correlation method will be used to predict the
products yields manually.
4.4.2.1 Material balance by Prediction:
Estimation of product yields can be carried out using correlations based on
the weight percent of Conradson carbon residue determine the trend of coke
production [12] (wt% CCR) in the vacuum residue.
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Abdelgadir Elbasher– Evaluation and simulation of different crude oil in
Delayed Cocker Unit (DCU) in Khartoum Refinery
Diesel wt% = 64.5 %* Gas oil wt
HCGO wt% = 35.5 % * Gas oil wt
5. RESULTS AND DISCUSSION
1. DCU in Khartoum Refinery is designed for Fulla crude, which is
characterized by the followings:
a) High acid number
b) Heavy crude oil (0.93 specific gravity)
c) High Calcium content (about 1200ppm)
d) High Viscosity (117mm²/s at 100 °C)
e) Sweet crude (sulfur content 0.15% wt)
2. Dar blend crude is also a heavy crude (0.91specific gravity), sweet (0.11%
wt sulfur content), and low calcium content, more paraffinic than Fulla (its
pour point 38°C while Fulla about 5 ° C), both (Fulla and Dar) blend are high
TAN No., (˃ 4 mgKOH/g). Several test runs were carried in Khartoum
refinery DCU with different Dar blend ratio 23% , 26% and 36% respectively
in the past during period from February 2012 up to May 2016 and the results
were as in Table .1.
Table 1. Result of blend with different ratios comparing with pure Fula
blend.
Item FULA 100% 16% 23% 26% 36%
Diesel +Gasoline 64.98 67.8 68.3 68 67.4
Coke 14 13 15 16 14.6
Wax oil 16 12.2 9.8 10.48 12.6
LPG 1.6 2.9 2.9 1.84 2
Dry gas 3 3.6 3.6 3.18 3
Loss 0.42 0.5 0.4 0.4 0.4
Total 100 100 100 100 100
Middle distillate yield (Diesel+Gasoline+HCGO) 80.98 80 78.1 78.58 80.98
5.2 Simulation results:
In the simulation program using input data as in fig 5.1 and fig 5.2 with
mixing ratio 50% for each blend Fula and Dar after applying input the
simulation result below as in Fig. 5, Fig. 6. Fig.7.and Fig. 8. the results for
mixing ratios of 50/50 for Fula and Petrodar shown in Table .1.
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Abdelgadir Elbasher– Evaluation and simulation of different crude oil in
Delayed Cocker Unit (DCU) in Khartoum Refinery
Fig .5. Hysys operating condition
Fig.6. Hysys feed properties input
Fig.7. Hysys simulation properties results
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Abdelgadir Elbasher– Evaluation and simulation of different crude oil in
Delayed Cocker Unit (DCU) in Khartoum Refinery
Product
Fig.8. Hysys simulation cuts results
Table 2. Mixing ratio 50% Fula blend and 50% Dar blend
Yield Flow Rate
Name m% kg/hr
Fula blend 50% 125,000
input Dar blend 50% 125,000
Subtotal 100% 250,000
Diesel + Gasoline 66.2 165,500
Coke 12.82 32,050
Wax oil 13.3 33,250
Output
LPG 3.44 8,600
Dry Gas 4.27 10SSS675
Loss 0
5.3 Delayed Coker Yield Prediction:
5.3.1 Using correlation [11]
Gas wt% = 7.8 + 0.144 * (wt% CCR) Gas wt% = 7.8 + 0.144 * 4.4 =8.4336 %.
So mass flow of the gas = 250000 * 0.084336 = 21084 kg/h Naphtha wt% =
11.29 + 0.343 * (wt% CCR)
Naphtha wt% = 11.29 + 0.343 * 4.4 = 12.8 %
So mass flow of the naphtha = 0.128 * 250000 = 32000 kg/h Coke wt% = 1.6 *
(wt%CCR)
Coke wt% = 1.6 * 4.4 = 7.04%
So mass flow of the coke = 0.0704 * 250000 = 17600 kg/h Total gas oil = 100 -
Gas wt% - Naphtha wt% - coke wt% Total gas oil= 100 - 7.04 - 12.8 - 8.43 =
71.73 %
Total gas oil = 0.7173 * 250000 = 179325 kg/h HCGO wt% = 0.355 * total gas
oil
= 0.355 * 179325 =63660 kg/h
Diesel % = 0.645 * 179325 = 115664 kg/h
5.4 Discussion:
1. All GDHT stream to DCU calculated and segregated from DCU material
balance, about 26% of DCU LPG and 21% of DCU dry gas comes from
GDHT, considerable amount should be taken in account during
material balance calculation.
2. As seen from table (5.1) material balance, total liquid yield (naphtha+
diesel+ heavy coker gas oil) is slightly increased with the increasing Dar
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Abdelgadir Elbasher– Evaluation and simulation of different crude oil in
Delayed Cocker Unit (DCU) in Khartoum Refinery
blend crude ratio and coke yield also slightly decreased, the reason is that
the liquid component of Dar blend crude is little more than Fulla crude
based on both crudes TBP assay.
3. Distillates (naphtha+diesel) are increased from 64.98% to 67.4%～68%
compared with before processed Dar in 2014 test run , but slightly
decreased compared with different blending Dar ratio because the IBP of
wax oil for 36% Dar blend crude is 247℃ while the IBP of wax oil for 26%
is 254℃.
4. Coke yields decreased as Dar CCR less than Fulla., also Coke quality
changed (see table-4), ash and calcium content decreased due to lower
calcium content in Dar blend.
5. Naphtha paraffinic content increased, and diesel cetane number
improved number due to the paraffinic nature of Dar blend (see Table.2.).
6. For rich gas quality, only H2S concentration increased (about 4200 ppm
during the test, before around 2000 ppm) , so during processing
Dar Blend more chemical(MDEA) is needed to treat H2S to the
required value (0.5 ppm).
7. Refer to table 5.2 the study proved that the mixing ratio 50% from each
blend fulla and Dar blend resulted in product with in the range of DCU
products and expand the chance of filling the gap of fulla blend decrease
to keep refinery work as normal conditions and the became clear in hysys
result for simulation of products specifications such as (sulfur, nitrogen,
vanadium) content and other properties approved by refinery as
standard. Fig 9. Below shows the comparison between different mixing
ratio and the mixing ratio under study (50%/50% fulla & Dar blend).
Fig.9. Comparing of output between different mixing ratios of fulla and Dar
blend
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Abdelgadir Elbasher– Evaluation and simulation of different crude oil in
Delayed Cocker Unit (DCU) in Khartoum Refinery
6. CONCLUSION & RECOMMENDATION
6.1 Conclusion:
According to the lab test and simulation results, blending of 50% Dar crude
with Fula crude in DCU achieved a good improvement in term of product
qualities and quantities with the probability of certain negative impact and
limitations according to the differences in physical &chemical properties of
the two crude oils used.
6.2 Recommendation:
1. KRC could increase the percentage of Dar /Fula blending processing in
DCU up to 50% with close monitoring for operation parameters and
product specification
2. Increase Dar ratio more than 50% Dar /Fula is affecting to some extend
positively on the product but also may affect negatively on the equipment
load.
3. Dar is classified as medium crude oil , the light content is obviously much
higher than Fulla crude ,the negative expected impact that should be
considered during operation of 50% Dar ratio as follows:
a. Change many operating conditions to minimize the negative
impact (to some extend effective).
b. Starvation at fractionator bottom level and surge drum
c. High load at the top of the fractionator.
REFERENCES
[1] JAMES.G .2017.Handbook of petroleum refining .ISBN9781466591608.
[2] J.H. Gary and G.E. Handwerk (1984). Petroleum Refining Technology and Economics, 2nd
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[3] W.L. Leffler (1985). Petroleum refining for the nontechnical person, 2nd Edition. PennWell
Books. ISBN 0-87814-280-0.
[4 Meyers R A, Handbook of Petroleum RefiningProcesses, McGraw-Hill, 1997.
[5] Michael Volk, Jr. PI, Keith D. Wisecarver Co-PI, Charles M. Sheppard Co-PI .Fundamentals of
Delayed Coking Joint Industry Project, University of Tulsa, July 2002
[6] Gamson, Bernard W., “Reflections,” Great Lakes Carbon Cororation Research and Needle Coke
Production, Private Letter, September 15, 1983.
[7] Peters, C.F., “Additional Reflections,” Great Lakes Carbon Corporation, Research and Needle
Coke Production, Private Letter, October 14, 1983.
[8] Court, W.F., “Hydraulic Decoking of Coke Chambers,” Refiner & Natural Gasoline Manufacturer,
Vol.17, No.11, November 1938, A Gulf Publishing Company Publication, pp. 568-573.
[9] Purton, Robert M. , Ingersoll-Dresser Pump Company, Telephone Conversation, January 1998.
[10] Conners, J.W., “Changes in Petroleum Coke Quality and Future Prospects,” Union Oil
Company of California, February.12, 1981.
[11] https://webstore.ansi.org/standards/ASTM/ASTMD289220.
[12] Khartoum Refinery, Delayed Coking Unit Operation Manual, Chapter Two.
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