Fouling mitigation of delayed coker heaters
A method of mitigating fouling in a delayed coking unit heater may include forming a plastic mixture including a plastic material and a carrier. The plastic mixture may be combined with a coker feedstock upstream of a coke drum.
1. A method of mitigating fouling in a delayed coking unit heater comprising:
forming a plastic mixture comprising a plastic material and a carrier, wherein the carrier is a hydrocarbon carrier selected from the group consisting of: light coker gas oil, heavy coker gas oil, vacuum residue, bitumen, atmospheric residue, pitch from a solvent deasphalting unit, pyrolysis fuel oil, diesel, fluid catalytic cracking slurry oil, decant oil, aromatic solvents, and mixtures thereof;
heating the plastic mixture; and
combining the heated plastic mixture with a coker feedstock upstream of a coke drum.
2. The method according to claim 1 , wherein forming the plastic mixture comprises one or more of:
at least partially dispersing the plastic material in the carrier; and
at least partially dissolving the plastic material in the carrier.
3. The method according to claim 1 , wherein forming the plastic mixture comprises:
combining the plastic material and the carrier using a high-shear mixer.
4. The method according to claim 1 , wherein the plastic material is selected from the group consisting of one or more of: polyolefin, polystyrene, polyvinylchloride, waste tire scrap, polyethylene terephthalate, polyester, polyamide, acrylic, and mixtures thereof.
5. The method according to claim 1 , wherein the plastic mixture includes between about 5 wt. % to about 50 wt. % plastic material relative to the total mixture.
6. The method according to claim 1 , wherein the coker feedstock is selected from the group consisting of one or more of: vacuum residue, bitumen, atmospheric residue, pitch from a solvent deasphalting unit, pyrolysis fuel oil, gas oil, fluid catalytic cracking slurry oil, decant oil, and mixtures thereof.
7. The method according to claim 1 , wherein combining the plastic mixture and the coker feedstock includes providing the plastic material at between about 0.5 wt. % to about 30 wt. % of a total of the plastic mixture and the coker feedstock.
8. The method according to claim 1 , wherein combining the plastic mixture and the coker feedstock comprises:
injecting the plastic mixture into the coker feedstock at one or more of:
an inlet of a coker heater pass;
a crossover of coker heater passes; and
a radiant section of a coker heater.
9. The method according to claim 1 , wherein:
heating the plastic mixture comprises one or more of:
injecting the plastic mixture into one or more coker heater passes at least partially separate from the coker feedstock; and
injecting the plastic mixture into a dedicated heater at least partially separate from the coker heater feedstock.
10. The method according to claim 1 , wherein heating the plastic mixture includes heating the plastic mixture to a first temperature, the method further comprising:
heating the coker feedstock to a second temperature, the second temperature being lower than the first temperature;
wherein combining the plastic mixture and the coker feedstock raises the temperature of the coker feedstock above the second temperature prior to introduction of the combined plastic mixture and coker feedstock into the coke drum, thereby allowing an effective increase in overall delayed coking unit liquid yields.
11. The method according to claim 10 , wherein the first temperature is up to about 1000 F.
12. The method according to claim 9 , wherein heating the plastic mixture comprises heating the plastic mixture with one or more ceramic coated heater coils, the one or more ceramic coated heater coils reducing fouling rates of the one or more heater coils.
13. A method of mitigating fouling in a delayed coking unit heater comprising:
combining a plastic material with a hydrocarbon carrier to produce a plastic mixture, combining the plastic material with the hydrocarbon carrier including one or more of at least partially dissolving the plastic material in the hydrocarbon carrier and at least partially dispersing the plastic material in the hydrocarbon carrier, wherein the hydrocarbon carrier is selected from the group consisting of one or more of: light coker gas oil, heavy coker gas oil, vacuum residue, bitumen, atmospheric residue, pitch from a solvent deasphalting unit, pyrolysis fuel oil, diesel, fluid catalytic cracking slurry oil, decant oil, aromatic solvents, and mixtures thereof;
heating the plastic mixture;
heating a coker feedstock;
combining the plastic mixture and the coker feedstock; and
transferring the combined plastic mixture and coker feedstock to a coke drum.
14. The method according to claim 13 , wherein heating the plastic mixture consists of one or more of:
heating the plastic mixture in a dedicated heater; and
heating the plastic mixture in a dedicated coker heater pass; and
wherein combining the plastic mixture and the coker feedstock includes combining the heated plastic mixture and the coker feedstock.
15. The method according to claim 13 , wherein heating the plastic mixture includes heating the plastic mixture to a first temperature, and wherein heating the coker feedstock includes heating the coker feedstock to a second temperature, the second temperature being lower than the first temperature.
16. The method according to claim 13 , wherein heating the plastic mixture and heating the coker feedstock includes combining the plastic mixture and the coker feedstock, and passing the combined plastic material and coker feedstock through at least a portion of one or more coker heater passes.
17. The method according to claim 16 , wherein combining the plastic mixture and the coker feedstock consists of one or more of:
injecting the plastic mixture into an inlet of a coker heater pass;
injecting the plastic mixture into a crossover of coker heater passes; and
injecting the plastic mixture into a radiant section of a coker heater.
18. The method according to claim 17 , wherein injecting the plastic mixture consists of one or more of:
sequentially injecting the plastic mixture into one of a plurality of coker heater passes at a time;
sequentially injecting the plastic mixture into a subset of a plurality of coker heater passes at a time; and
injecting the plastic mixture into a plurality of coker heater passes at one or more of the same time and overlapping times.
19. The method according to claim 13 , wherein the plastic material includes from between about 0.5% wt. % to about 30 wt. % of the combined plastic mixture and coker feedstock.