Delayed Coking Unit Operations and Hazards

Overview

Delayed coking units upgrade the heaviest residues in a refinery into valuable gas, naphtha, gas oils and petroleum coke. They play a central role in converting heavy and sour crudes, meeting low-sulphur fuel oil regulations and improving refinery margins. However, delayed cokers are also among the most hazardous units in the industry. Cyclic drum operations, high temperatures, heavy hydrocarbons, steam, hydraulic decoking and the handling of hot coke expose operators to burns, fires, explosions and mechanical injuries. Several serious incidents have occurred during drum switching, unheading and cutting, so strong technical knowledge and disciplined procedures are essential.

This course provides a practical understanding of delayed coking process technology, operation, hazards and safe work practices. Participants learn feedstock properties, coking chemistry and the effect of operating variables on yields and coke quality. The course covers coker heaters and fouling, coke drums and their cycles, fractionator and vapour recovery operation, and the main products. It also explains drum switching, steaming, quenching, venting, unheading, hydraulic cutting and coke handling, together with safety interlocks, process safety risks, mechanical integrity of drums, emissions control and optimisation of cycle times, using incident case studies and real plant experience.

Objectives

• Explain the role of delayed coking in residue upgrading and refinery margins
• Describe coker feed properties, coking chemistry and product yields
• Operate coker heaters and manage fouling, spalling and run length
• Understand coke drum cycles, fractionator and vapour recovery operation
• Apply safe procedures for drum switching, unheading and hydraulic cutting
• Identify major hazards and safety interlocks in delayed coking units
• Optimise cycle times, yields and reliability while protecting drum integrity

Who should attend

Training methodology

The course combines explanation of process technology with step-by-step reviews of drum cycle procedures, interlock logic and real operating data. Participants analyse heater tube temperatures and fouling trends, estimate yields from feed properties, review drum cycle timelines and identify hazards at each stage of the cycle. Videos and photographs of drum unheading, cutting and coke handling support practical understanding. Incident investigations from delayed coking units are analysed in groups to draw lessons on procedures and safeguards. Each day ends with a short quiz and discussion of coker practices at participants' refineries.

Programme outline

Dates and fees

Certificate

Frequently asked questions