Dynamic Modeling and Calibration of an Industrial Delayed Coking Drum Model for Digital Twin Applications

The increasing share of heavy and high-sulfur crude oils in refinery feed slates worldwide highlights the need for models of delayed coking units (DCUs) that are both physically meaningful and computationally efficient. In this study, we develop and calibrate a simplified yet dynamic one-dimensional model of an industrial coke drum intended for integration into digital twin frameworks. The model includes a three-phase representation of the drum contents, a temperature-dependent global kinetic scheme for vacuum residue cracking, and lumped descriptions of heat transfer and phase holdups. Only three physically interpretable parameters—the kinetic scaling factors for distillate and coke formation and an effective wall temperature—were calibrated using routinely measured plant data, namely the overhead vapor and drum head temperatures and the final coke bed height. The calibrated model reproduces the temporal evolution of the top head and overhead temperatures and the final bed height with mean relative errors of a few percent, while capturing the more complex bottom-head temperature dynamics qualitatively. Scenario simulations illustrate how the coking severity (represented here by the effective wall temperature) affects the coke yield, bed growth, and cycle duration. Overall, the results indicate that low-order dynamic models can provide a practical balance between physical fidelity and computational speed, making them suitable as mechanistic cores for digital twins and optimization tools in delayed coking operations.