Sidewall Injection Charging System for Delayed Coking Drum Maintenance

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Solution Overview

Problem

The delayed coking process in the petroleum industry faces challenges due to the need to disassemble the charging line during each coking cycle, leading to operational risks, increased maintenance, and reduced efficiency, as the lower flange of the drum must be disassembled to allow coke discharge, which is hazardous and time-consuming.

Innovation Solution

An injection charging system that decouples the lower flange of the delayed coking drum without disassembling the charging line by redirecting the hydrocarbon and water injection lines to access the drum's sidewall at an angle other than 90 degrees, using multiple injection pipes, a refractory cover, a distributor crown, and a large removable flange, allowing for uniform heating and cooling and reducing mechanical stress.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the lower flange is disassembled to discharge coke, then the coking cycle can be completed, but operational risks increase and maintenance complexity increases

Engineering Contradiction:

Improvecoking cycle completionVSAvoidoperational safety

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent extracts the charging line disassembly requirement from the coking cycle by redirecting injection lines to access the drum through the sidewall at an angle, allowing the lower flange to remain coupled while still enabling coke discharge through alternative pathways

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces an intermediary injection system with multiple pipes accessing the drum at angled positions on the sidewall, mediating between the charging line and the drum interior to eliminate the need for direct flange disassembly while maintaining process functionality

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the lower flange is disassembled for coke discharge, then the coking process can proceed, but time is lost and efficiency decreases

Engineering Contradiction:

Improvecoking cycle throughputVSAvoidflange disassembly time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent implements preliminary action by pre-positioning multiple injection pipes at angled access points on the drum sidewall, so that the charging line remains permanently connected and ready for immediate operation without requiring time-consuming flange disassembly and reassembly cycles

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent removes the time-consuming flange disassembly step from the coking cycle by extracting the injection function to alternative access points on the drum sidewall, allowing continuous operation without interruption

Inventive Principle:

Principle #2Taking out (Extraction)

3Strength

If injection lines access the drum through the lower portion, then structural strength is maintained, but mechanical stress increases and equipment durability decreases

Engineering Contradiction:

Improvedrum structural strengthVSAvoidmechanical stress on equipment

Core Design Contradiction:

StrengthVSForce

Solution Approach 1:

The patent applies asymmetry by redirecting injection lines to access the drum at angled positions on the sidewall rather than through the lower central portion, distributing mechanical stress more evenly across the drum structure and reducing peak forces on any single point

Inventive Principle:

Principle #4Asymmetry

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

This solution reduces operational risks, simplifies maintenance, and increases efficiency by eliminating the need for constant disassembly and assembly of flanges, allowing for safer and faster coking cycles, and reduces the mechanical forces on equipment, thereby lowering production costs and improving plant design.

Implementation Method 1

redirecting the hydrocarbon and water injection lines to access the drum's sidewall at an angle other than 90 degrees

Methodology Applied

Scientific EffectFluid injection at angle:

Implementation Method 2

using multiple injection pipes, a refractory cover, a distributor crown

Methodology Applied

Scientific EffectThermal protection: Thermal Insulation

Implementation Method 3

a distributor crown with an access flange and a large flange

Methodology Applied

Scientific EffectFluid distribution:

Data Source

PatentUS7393435B2Injection charging system in delayed coking drums

Publication Date: 2008.07.01 PETROLEO BRASILEIRO SA PETROBRAS

AI summary

Described is an injection charging system in delayed coking drums (11), comprised of at least two injection pipes (11a) connected to the sidewall of a coking drum (1) in its tricone portion, and fed by a circular distributor crown, in order to allow coupling or decoupling of the large lower flange (11e) of the coking drum (1) without needing to disconnect the injection system (11) from the pumping and heating system (10).