Electronic Thesis and Dissertation Repository


Master of Engineering Science


Chemical and Biochemical Engineering


Pjontek, Dominic


Fluid CokingTM is a continuous process that thermally converts heavy hydrocarbons, such as oil-sands bitumen, to lighter and higher-value products by horizontal injection onto a fluidized bed of hot coke particles. The deposition of carbonaceous materials in the cyclone sections of commercial Fluid Cokers has been observed throughout each run. The main objective of this work is to improve unit reliability by proposing cyclone fouling mitigation strategies based on a localized phenomenological model using Aspen Plus®. The heavy ends condensation fouling mechanism was studied by incorporating vapour-liquid thermodynamics, thermal cracking reactions, and overall fluid dynamics in the Fluid Coker. Four case studies were performed to determine the impacts of transfer line temperature, hot coke flow rate, hot coke entrainment and scouring coke flow rate on the predicted temperatures and liquid flow rates. Scouring coke flow rate was identified as the most promising process lever to mitigate Fluid Coker cyclone fouling.