Delayed Coking and Residue Upgrading Training Course

Delayed Coking and Residue Upgrading Training Course

Introduction

Delayed Coking and Residue Upgrading Training Course is designed to equip participants with advanced knowledge and practical skills in heavy oil processing, refinery residue conversion, and bottom-of-the-barrel upgrading technologies. This course provides a comprehensive understanding of delayed coking principles, feedstock characterization, thermal cracking mechanisms, coke drum operation, furnace design, fractionation systems, and the conversion of high-boiling petroleum residues into lighter hydrocarbon products. Participants will explore refinery process optimization, heat integration, operating parameter control, petroleum coke quality, and the relationship between feedstock properties and product distribution. The program also addresses modern refinery challenges, including energy efficiency, operational reliability, process safety, emissions reduction, and the integration of advanced process monitoring technologies.

The course further examines residue upgrading strategies, including delayed coking, visbreaking, solvent deasphalting, residue hydroprocessing, and other complementary conversion technologies. Participants will learn how to evaluate upgrading alternatives, improve liquid yield, reduce undesirable coke formation where technically feasible, manage fouling and corrosion, and optimize the performance of downstream units. Practical case studies will demonstrate how refineries can address coke drum cycle inefficiencies, furnace fouling, unstable operating conditions, product quality deviations, and high energy consumption. Emphasis is placed on data-driven refinery optimization, predictive maintenance, digital process monitoring, sustainable refining, and operational risk management. Through technical exercises, process troubleshooting scenarios, and industrial case studies, participants will develop the capabilities needed to support safe, efficient, and economically competitive refinery operations while maximizing the value recovered from petroleum residues.

Course Duration

5 days

Course Objectives

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

1. Explain the fundamental principles of delayed coking and heavy residue thermal conversion.
2. Evaluate crude oil residues using advanced feedstock characterization and property analysis.
3. Analyze thermal cracking kinetics and their effects on liquid yields, gas production, and petroleum coke formation.
4. Assess delayed coker furnace design, heat transfer efficiency, and operating severity.
5. Optimize coke drum operating cycles, switching procedures, and thermal management.
6. Improve fractionator performance, product separation, and light hydrocarbon recovery.
7. Identify strategies for maximizing middle distillate yield and improving product quality.
8. Compare residue upgrading technologies, including delayed coking, visbreaking, solvent deasphalting, and hydroprocessing.
9. Diagnose furnace fouling, coke drum pressure fluctuations, equipment degradation, and process instability.
10. Apply advanced process control (APC) and real-time monitoring to improve unit performance.
11. Implement predictive maintenance and reliability-centered maintenance strategies for critical equipment.
12. Evaluate energy efficiency, emissions management, and environmental performance in residue conversion operations.
13. Develop integrated refinery optimization strategies that improve profitability, operational safety, and long-term sustainability.

Target Audience

1. Petroleum refinery process engineers.
2. Chemical and petroleum engineers.
3. Refinery operations and production supervisors.
4. Delayed coker unit operators and technical specialists.
5. Process control, instrumentation, and automation engineers.
6. Mechanical maintenance, inspection, and reliability engineers.
7. Refinery planning, economics, and optimization professionals.
8. Technical managers, consultants, and professionals involved in residue upgrading and heavy oil processing.

Course Modules

Module 1: Fundamentals of Delayed Coking and Residue Upgrading

• Principles of thermal cracking and heavy hydrocarbon conversion.
• Characteristics of atmospheric and vacuum distillation residues.
• Role of delayed coking in bottom-of-the-barrel conversion.
• Comparison of delayed coking with other residue upgrading technologies.
• Refinery configuration, product slate, and process integration.
• Case Study: Evaluate the role of a delayed coker in a refinery processing increasingly heavy crude oil, identifying the expected benefits and operational trade-offs.

Module 2: Feedstock Characterization and Thermal Cracking Chemistry

• Physical and chemical properties of vacuum residue and heavy feedstocks.
• Effects of Conradson carbon residue, asphaltenes, sulfur, and metals.
• Thermal cracking reactions, free-radical mechanisms, and coke formation.
• Feedstock variability and its impact on product distribution.
• Laboratory testing, feed compatibility, and characterization data interpretation.
• Case Study: Investigate declining liquid yields following a change in crude oil blend and determine how feed properties may have affected coke formation and product quality.

Module 3: Delayed Coker Furnace Design and Optimization

• Furnace configuration, coil design, and heat transfer fundamentals.
• Operating temperature, pressure, residence time, and feed velocity.
• Coil velocity, steam injection, and suppression of premature coke deposition.
• Furnace fouling, tube skin temperature monitoring, and thermal efficiency.
• Furnace decoking practices, operating limits, and equipment integrity.
• Case Study: Assess a delayed coker furnace experiencing rising tube skin temperatures and increasing pressure drop, then develop a safe troubleshooting and performance improvement plan.

Module 4: Coke Drum Operations and Cycle Management

• Coke drum design, operating principles, and process flow.
• Drum filling, switching, steaming, quenching, and preparation for the next cycle.
• Hydraulic decoking systems and petroleum coke removal.
• Drum pressure and temperature monitoring.
• Prevention of operational upsets, thermal stress, and cycle inefficiencies.
• Case Study: Analyze recurring delays during coke drum switching and identify opportunities to improve cycle coordination, reliability, and operating discipline without compromising safety.

Module 5: Fractionation, Product Recovery, and Quality Control

• Main fractionator operation and internal separation mechanisms.
• Recovery of gas, naphtha, light gas oil, and heavy coker gas oil.
• Fractionator temperature profiles, reflux, and pumparound optimization.
• Product stability, endpoint control, and contamination management.
• Integration with gas recovery, hydrotreating, and downstream conversion units.
• Case Study: Investigate off-specification coker gas oil and identify potential causes involving fractionator operation, feed conditions, and downstream separation requirements.

Module 6: Advanced Residue Upgrading Technologies

• Principles and applications of visbreaking and thermal residue conversion.
• Solvent deasphalting and deasphalted oil recovery.
• Residue hydroprocessing, hydrocracking, and catalytic upgrading.
• Technology selection based on feed properties, product demand, and capital investment.
• Integration of upgrading technologies to improve refinery-wide performance.
• Case Study: Compare delayed coking and residue hydroprocessing for a refinery evaluating alternative strategies to reduce residual fuel production and increase valuable transportation fuel components.

Module 7: Process Control, Troubleshooting, and Digital Optimization

• Advanced process control and multivariable optimization.
• Real-time monitoring of temperatures, pressures, flows, and equipment performance.
• Process data analytics for yield improvement and energy management.
• Predictive maintenance, condition monitoring, and equipment reliability.
• Root cause analysis and structured troubleshooting of coker operating problems.
• Case Study: Use a simulated process dataset to investigate unstable furnace operation and variable product yields, then recommend control improvements and monitoring indicators.

Module 8: Safety, Environmental Performance, and Refinery Economics

• Process safety management and hazard identification in delayed coking.
• Safe handling of hot hydrocarbons, steam, coke, and pressurized systems.
• Sulfur emissions, particulate matter, wastewater, and petroleum coke management.
• Energy efficiency, heat integration, and carbon emissions reduction.
• Refinery profitability, product yield economics, capital expenditure, and performance benchmarking.
• Case Study: Develop an improvement proposal for a delayed coker experiencing high energy consumption, elevated maintenance costs, and inconsistent product yields, balancing profitability with safety and environmental compliance.

Training Methodology

• Interactive lectures and presentations.
• Group discussions and brainstorming sessions.
• Hands-on exercises using real-world datasets.
• Role-playing and scenario-based simulations.
• Analysis of case studies to bridge theory and practice.
• Peer-to-peer learning and networking.
• Expert-led Q&A sessions.
• Continuous feedback and personalized guidance.

Register as a group from 3 participants for a Discount

Send us an email: info@datastatresearch.org or call +254724527104 

Certification

Upon successful completion of this training, participants will be issued with a globally- recognized certificate.

Tailor-Made Course

 We also offer tailor-made courses based on your needs.

Key Notes

a. The participant must be conversant with English.

b. Upon completion of training the participant will be issued with an Authorized Training Certificate

c. Course duration is flexible and the contents can be modified to fit any number of days.

d. The course fee includes facilitation training materials, 2 coffee breaks, buffet lunch and A Certificate upon successful completion of Training.

e. One-year post-training support Consultation and Coaching provided after the course.

f. Payment should be done at least a week before commence of the training, to DATASTAT CONSULTANCY LTD account, as indicated in the invoice so as to enable us prepare better for you.