Gastight Coke Drum System Preventing Steam Emissions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing closed coke slurry systems are not emission-free, as they release substantial amounts of steam and coke fines into the environment, and there is a need for cost reduction in installation and operation.
Innovation Solution
A closed, gastight system is designed to extract sellable petroleum coke pieces from solidified coke in a coke drum unit, featuring a coke crushing unit, a closed sluice way, a dewatering bin unit, a closed drain water basin, a cooling water line, and a heat rejection heat exchanger to prevent steam generation and emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a conventional open slurry system is used to discharge quench water and coke fines, then the system structure is simple, but substantial amounts of steam and coke fines are released into the environment causing emissions
Solution Approach 1:
The harmful component (steam and coke fines) is extracted from the discharge stream by separating the quench water discharge into two pathways: a closed gastight system for water-containing streams that prevents steam emission, and an open pathway for dry coke fines that no longer generates steam emissions
Solution Approach 2:
A cooling water line is introduced as an intermediary element that mixes cooling water with hot quench water in the draining line, reducing the temperature of quench water before it enters the slurry basin, thereby preventing steam generation at the slurry basin surface
2Object-affected harmful factors
If quench water is cooled by mixing with cooling water in the slurry basin, then steam generation is prevented, but the slurry basin becomes an open system allowing emissions
Solution Approach 1:
The cooling action is performed preliminarily in the hot quench water draining line before the quench water enters the slurry basin. By mixing cooling water with hot quench water upstream, the temperature is reduced in advance, preventing steam generation when the water reaches the slurry basin, thereby eliminating the need for an open cooling system
3Object-affected harmful factors
If the quench water draining line is kept open for simplicity, then the system is easy to operate, but steam and hydrocarbon vapors are released into the environment
Solution Approach 1:
The harmful hydrocarbon vapor emissions are extracted from the quench water discharge stream by implementing a closed gastight draining line configuration, separating the water-containing stream (handled in closed system) from the dry coke fines stream (handled in open system), thereby eliminating hydrocarbon vapor release
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively prevents steam generation and emissions of coke fines and water into the environment, reduces operational costs, and allows for precise temperature and pressure control, ensuring efficient cooling and processing of petroleum coke.
Implementation Method 1
a cooling water line leading from the water tank, namely from an intermediate portion thereof, to the hot quench water draining line, namely to a joining point in the hot quench water draining line at a position above the closed slurry basin, configured to feed cooling water from the water tank to the hot quench water in the hot quench water draining line, in order to prevent steam generation within the slurry basin
Implementation Method 2
a heat rejection heat exchanger is provided in the cooling water line, configured to reduce the temperature of the cooling water flowing through the cooling water line, against a secondary heat exchange medium, particularly environmental air
Implementation Method 3
a mixing unit, in particular a static mixer, is provided in the hot quench water draining line, at the position of the joining point of the cooling water line, or at a position downstream of the joining point of the cooling water line
Implementation Method 4
a dewatering bin unit configured to receive the petroleum coke slurry from the slurry basin, to collect the sellable petroleum coke pieces, and to act as a filter leading runoff drain water from a lower area thereof as filtered water and petroleum coke fines out of it
Data Source
Figure 1
AI summary
A closed, gastight system for gaining sellable petroleum coke pieces out of solidified petroleum coke in a coke drum unit according to the invention is configured to be connected to a coke drum unit (X) containing solidified petroleum coke and comprises a coke crushing unit (C) for crushing the petroleum coke into sellable petroleum coke pieces, configured to be connected to the coke drum unit (X), particularly by means of a flexible transition piece (A); a line, particularly a closed sluice way (D) leading petroleum coke slurry to a closed slurry basin; a closed slurry basin (E); a dewatering bin unit (G) configured to receive the petroleum coke slurry from the slurry basin (E), to collect the sellable petroleum coke pieces, and to act as a filter leading runoff drain water from a lower area thereof as filtered water and petroleum coke fines out of it; a closed drain water basin (I), separate from the slurry basin (E), configured to receive the filtered water and the petroleum coke fines from the dewatering bin unit (G); a single water tank (L) configured to receive the filtered water from the drain water basin (I); a hot quench water draining line (2) configured to receive hot quench water from the coke drum unit (X) and to lead the same to the closed slurry basin (E); and a cooling water line (3) leading from the water tank (L), particularly from a intermediate portion thereof, to the hot quench water draining line (2), in particular to a joining point (IP) in the hot quench water draining line (2) at a position above the closed slurry basin (E), configured to feed cooling water from the water tank (L) to the hot quench water in the hot quench water draining line (2), in order to prevent steam generation within the slurry basin (E).