REFINING INDIA 2025

refining india 2025

to demand more sustainable fuels to help governments around the world meet emis- sion reduction targets, renewable fuel pro- ducers will continue to look for options to optimise their processes and generate lower carbon intensity fuels. Switching from ABE to Grace’s Trisyl silica adsor- bent for the pretreatment of renewable feedstocks can help reduce solid waste up to 85%, as well as reduce feedstock losses, ultimately leading to higher yields of renewable fuels. GRACE ® and TRISYL ® are trademarks, registered in the US and/or other coun- tries, of W. R. Grace & Co.-Conn.

Filter cake (Klbs/yr)

100

1 atm 30 min 0.3 w% T risyl

100˚C 0.6 w% T risyl

Lost feestock Adsorbent solids

100

Temperature (˚C)

Time (min)

Figure 6 Phospholipid removal as a function of temperature and time with Trisyl silica

Clay case

T risyl silica case

ter to remove the particles and trapped impurities from the feedstock. As the transportation sector continues

shrinking the particles’ pores, while trap- ping the phospholipids and metals. The dried mixture is then passed through a fil-

Figure 5 Example of filter cake composition when clay/ABE is used vs Trisyl silica

Contact: chelsea.grimes@grace.com

Fully enclosed, zero-emission coke handling Critical Key Equipment: Designed for Reliability Tmheet eI rn ltion e1 0C0o kme mC ri un sah es irnigs l ea sr ot ebpu. sI tt uf enai tt uernegs i nt we eor iendd feoprerneddeuncti lnygdcroi vk ee nf rhoymd raapupl ircomx i omt oa tr es l y 1 ac rnuds ah es rp’ se csipa el lcyi ac loanlfl iogyu cr eo dn srtor lul ec rt i ao nn de nt osoutrhe sd ea ssi eg rnvti hc ea tl imf ei ne xi mc ei ez edsi nt gh e2 5c ryeeaat iros nwoi ft hf i nmeisn. i Tmhael maintenance effort.

Twheea rS louprer ryaPt iuomn .pI,t tiani cl ol ur ed de st oa tf hr eeqEuCeHn cOy s- cyos nt etmr o, l il se dd ems oi gtno er da ne dx pal ilcairt gl ye fforre el obwa-l sl ppeaes ds a, gl oewt o- gg eunartlaynctoeensvehyigthheducroakbei lsiltuyrirny iwndi tuhsoturitaal dadpiptiloicnaatilofninse. s generation. Its sturdy desi g n

ART-Envi Services

In delayed coking units (DCU), the process- ing and treatment of residual petrol coke is the unloved end of a vital part of the refinery. It requires seemingly endless housekeeping efforts, takes all technical equipment to its limits, and when planning an investment in a new unit, this aspect typically requires the most effort in discussions to obtain approval from the relevant authorities. Conventional petcoke handling systems typically consist of open pits below coke drums, surrounded by retaining walls and equipped with a bridge crane for coke han- dling. These systems generate substantial emissions in the form of coke fine particles and volatile organic compounds (VOCs). Water evaporates over the vast open area and must be replaced continuously. Moreover, heterogeneous drainage within the coke pile necessitates manual agitation using a crane to assist dewatering, which can take several days. Consequently, the coke pad must be dimensioned to accom- modate up to three days of production, resulting in a significant spatial footprint. Drainage water going to the maze still con- tains coke fines, which are retained in drain- age mazes and must be regularly removed via dredging operations. These opera- tional and environmental drawbacks have led to increased regulatory and industrial demand for closed coke handling systems. Advanced Coke Handling Redefined with ECHO To address these challenges, ART-Envi Services has developed the Environmental Coke Handling Operation (ECHO), a com- pletely enclosed, zero-emission solution tailored for installation downstream of a DCU. ECHO is capable of processing vari- ous types of coke, including sponge, shot, and needle coke, and ensures minimised environmental impact alongside high oper- ational efficiency. A flow scheme of ECHO is illustrated in Figure 1 . The process begins at the bottom unheading device (BUD) of the coke drum, where hot coke is discharged into a sealed transition piece. From here, the coke drops into a high-performance inline crusher and is then discharged into a slurry basin, where it is mixed with water to form a slurry. This mixture is pumped via a specialised slurry

Make-up water

Cutting water

Water tank

Dewatering bin

Coke drum

Quench water

Transfer piece

Crusher

Air cooler

Figure 2 Slurry pump

Hydro- cyclone

Drain water tank

ing operational disruption while delivering significant environmental and operational improvements. Its modular construction allows for straightforward adaptation to a variety of site-specific configurations. The system can be interfaced directly below the BUD, replacing conventional discharge areas without requiring complete redesigns. Custom transition components and flexi- ble layout options ensure that installation is feasible even within limited existing space. By retrofitting with ECHO, operators can significantly enhance safety standards, reduce emissions, and minimise water con- sumption. Such upgrades not only help meet current regulatory demands but also future-proof the plant against evolving environmental policies. Moreover, retrofits can often be implemented during sched- uled turnarounds, keeping downtime to a minimum while bringing long-term opera- tional gains. Conclusion ECHO’s fully enclosed, zero-emission design not only meets today’s environmen- tal regulations but positions operators for future compliance. By significantly reduc- ing emissions, water usage, and manual intervention, it delivers measurable bene- fits in safety, sustainability, and operational efficiency. The system’s adaptability for both new installations and retrofits makes it a strategic investment for modern coker operations. With proven performance and minimal disruption during integration, it is a practical solution for refineries aiming to modernise responsibly.

Transport water pump

Drain water pump

Slurry basin Slurry pump

Figure 1 ECHO flow scheme

As ECHO operates within a fully enclosed system, it effectively eliminates emissions of coke particles and VOCs, significantly reduces water usage, and occupies a sub- stantially smaller footprint compared to open pit systems. Additional advantages include a high degree of automation, ele- vated occupational safety standards, and reduced operational and maintenance costs. Retrofitting Potential: Seamless Integration into Existing Units While the benefits of ECHO for newly installed DCUs are apparent, its modular design and flexible integration options also make it an attractive retrofit solution for existing coker facilities. Many legacy units still rely on traditional open pit handling sys- tems, which are increasingly seen as out- dated due to their environmental impact, high operational cost, and high water usage. ECHO addresses these issues by replacing exposed processes with a closed, contained, and fully automated system. ART-Envi has conducted multiple fea- sibility and engineering studies for cli- ents aiming to modernise their DCUs by implementing ECHO. Thanks to its mod- ular design and streamlined installation process, construction and commissioning can be completed in as little as six weeks. This enables seamless integration during a standard turnaround window, minimis-

pump to a dewatering bin, designed to accommodate an entire batch of coke. Internal screens retain the fines within the coke bed, while the water drains off and is directed to a hydrocyclone for second- ary filtration. The resulting filtrate water is collected and routed to a hydrocyclone for secondary clarification and subsequently stored in a clean water tank for reuse within the system. Upon completion of the dewatering pro- cess (residual moisture ~10%), the coke is transferred to downstream transportation systems, such as conveyors or silos, for final storage or shipping. Key Equipment: Designed for Reliability The inline coke crusher is a robust unit engi- neered for reducing coke from approxi- mately 1m to 100mm in a single step. It features two independently driven hydrau- lic motors and a specially configured roller and tooth design that minimises the crea- tion of fines. The crusher’s special alloy con- struction ensures a service life exceeding 25 years with minimal maintenance effort. The slurry pump, tailored to the ECHO system, is designed explicitly for low-speed, low-wear operation ( Figure 2 ). It includes a frequency-controlled motor and a large free ball passage to gently convey the coke slurry without additional fines generation. Its sturdy design guarantees high durability in industrial applications.