Course Objectives:

By the end of this training, participants will be able to:

1. Fundamentals of Delayed Coking and Coke Calcination

• Understand the purpose of delayed coking in refining and its role in upgrading heavy residues.
• Explain the chemical transformation of vacuum residuum into coke, light gases, and liquid products.
• Recognize different types of petroleum coke (sponge coke, needle coke, shot coke) and their industrial applications.

2. Delayed Coker Unit (DCU) Process Overview

• Learn the key steps in delayed coking:
• Feed Preheating (Residuum heating and thermal cracking).
• Coke Drums Operation (Coking cycle, switching, and drum cooling).
• Vapor Handling and Fractionation (Gas recovery and liquid product separation).
• Coke Cutting and Removal (Hydraulic cutting and coke handling).
• Identify key equipment in a delayed coker unit, including furnaces, coke drums, fractionators, and quench systems.

3. Basics of Coke Calcination Process

• Understand the purpose of coke calcination in removing volatile matter and improving coke properties.
• Identify key steps in coke calcination:
• Drying and Preheating.
• Calcination in Rotary Kilns or Shaft Kilns.
• Cooling and Coke Handling.
• Recognize key quality parameters for calcined coke, such as density, sulfur content, and volatile matter.

4. Process Safety and Environmental Considerations

• Identify safety hazards in delayed coking and coke calcination, such as hot spots, drum over-pressurization, and combustible dust.
• Understand environmental impacts, including SO₂ and NOx emissions, particulate matter, and water contamination.
• Learn about emission control technologies and regulatory requirements.

5. Basic Troubleshooting and Best Practices

• Identify common operational issues in delayed coking and coke calcination (e.g., drum foaming, coke drum bulging, furnace fouling).
• Learn basic strategies for optimizing yield and minimizing energy consumption.
• Apply best practices for equipment reliability and maintenance.

Target Audience

This course is designed for entry-level professionals and operators involved in refinery coking and calcination processes, including:

1. Engineers & Technical Personnel

• Process Engineers
• Mechanical Engineers
• Chemical Engineers

2. Operations & Maintenance Teams

• Coker Unit Operators
• Coke Handling and Calcination Operators
• Maintenance Technicians