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NAPHTHA
CRACKER
RECOVERY
SECTION
ETHYLENE BOG
ETHYLENE
PROPYLENE
RAW C4 MIX
NAPHTHA
SRT VI FURNACES
BUTADIENE
EXTRACTION
UNIT
BUTADIENE
(BUTADIENE NOT
OPERATING)
HEAVY CUT
C4
HYDROGENATION
UNIT
C7-C8 CUT
C4 RECYCLE
RAW
PYROLYSIS
GASOLINE
PYGAS
HYDROGENATION
UNIT
STG I AND II
C6-C8 CUT
BENZENE
EXTRACTION
UNIT
BENZENE
C5 RECYCLE
C9+PRODUCT
C6 RECYCLE
Base Case
Case 1
Case 2
Feeds
Naphtha
Hydrogenated C4/C5/C6
recycle
Naphtha
Hydrogenated C4/C5/C6
recycle
LLDPE recycle
PP recycles
Ethylene BOG
Naphtha
Hydrogenated C4/C5/C6
recycle
LLDPE recycle
PP plant recycles
Ethylene BOG
FCC feeds
Ethylene
Capacity, TPA
800,000
830,632
857,408
Propylene
Capacity, TPA
504,834
584,352
666,544
Byproducts
t
t
t
t
t
t
t
Hydrogen
Methane off gas
Butadiene
Benzene
Hydrogenated C7-C8 cut
Partially hydrogenated C9+ cut
Pyrolysis fuel oil (combined PGO + PFO)
Products, kg/h
Case 1
Case 2
Hydrogen
506
584
50,220
51,083
103,829
107,176
73,044
83,318
Butadiene
17,020
17,163
Benzene *
14,491
14,589
C7-C8 cut *
29,422
29,456
C9+ cut
7,627
7,591
10,432
10,629
123
124
Acid Gases
424
428
122
127
Total
307,260
322,268
Products from Benzene Extraction Unit are adjusted based on final feed rate and
composition of treated C6-C8 stream from PGHU
Process Reactions
Steam Cracking
Reaction is endothermic
Requires great amount of heat
Additional Reactions
Hydrogenation of Unsaturated Impurities
C2 Acetylene, C2H2
C3 Acetylene & Diolefin C3H4 ( MAPD )
Highly exothermic ( Releases heat )
Methanation
Catalytic conversion of CO to H2O in H2.
Feed
H2
CH4 Comp
Fuel
ATU
Drier
CGC
Heaters
Cold
Train
C2R
deC1
C2H2
Ethylene
Product
C3R
Quench
C2Frac
deC2
MAPD
GasFrac
Recycle
Propylene
Product
C4 Hydro
DPG2
C3Frac
deC3
deC5
C6-C8
Recycle
DPG
Stab/Tail
C9
DPG1
deC4
Recycle
Cracking Heaters
Six SRT VI and one SRT III type cracking heaters are
provided. Five SRT VI heaters are normally in service
cracking liquid feed stock (naphtha/C4/C5/C6).
Ethylene production capacity set by heater feed rates
Propylene production set by:
Feed slate
Degree of cracking (severity)
Stack
Convection Coils
Feed Preheat & Vaporization
Mixed Preheat (Inc. D/S)
BFW & SHP Coils
Heater Feed
Dil. Stm
BFW
SHP
Convection
Section
Radiation
Section
(Firebox)
Bridgewall or Arch
Heater Outlet
to TLEs
COT
Hearth or Floor
Function
Stop Cracking Reaction
Recover Heat from Heater Effluent
Generate SHP Steam
Design
Considerations
Susceptible to fouling
Gasoline Fractionation
Function
Design
Packed tower in the top
Baffle trays in the bottom
Quench Oil inventory
Quench Tower
Function
Design
Multiple packed bed tower for heat transfer
Direct counter current contact with circulating QW
Design
Large circulation requires large centrifugal pumps
Water circulation through process users for heat
exchange
Cooling water exchangers for final heat rejection
Considerations
Maximizing Heat removed by process users
minimizes cooling water requirements
pH control required to prevent emulsions
Function
Compress cracked gas in order to separate hydrogen and
methane
Design
5 stage centrifugal compressor
Intercoolers and drums to remove heat of compression and
condensed liquids
Wash oil / BFW injection to reduce fouling / cool
Considerations
Controls heater cracking pressure
MP STEAM
S/T
PC
Charge
Gas from
QT
SHP
Steam
0.47
kg/cm2G
TC Tower
QW
FC
Min
Flow
45C
4.25
kg/cm2G
1.72
kg/cm2G
9.41
kg/cm2G
40C
40C
38C
Caustic
PC
Flare
HP Off gas
From PGHU
C4 Hydro
Vent Gas
Acid Gas
Absorber
9.25
kg/cm2G
40C
LC
LC
LC
LC
LC
0.77
kg/cm2G
To
Quench
Tower
Quench Tower
Gasoline
From QT
54C
FC
TC
Gasoline
Stripper
LC
Desuperheated
LP Steam
FC
Debutanizer
Bottoms Cooler
FC
120C
FC
Wash Gasoline
Function
Remove bulk of H2S and CO2 using 5% monoethylene/amine (MEA)
in Acid Gas Absorber.
Design
Acid Gas Absorber
Considerations:
H2S poisons downstream hydrogenation catalyst
CO2 contaminates ethylene product
Amine temperature 10 F hotter than inlet charge gas to
avoid cooling of gas in tower
Rise in temperature of Rich Amine leaving the Tower
(Absorption reactions are is Exothermic)
Expected Leakage from Absorber in Treated Gas:
Case 1: 2.1 ppm mol H2S and 113 ppm mol CO2
Case 2: 2.1 ppm mol H2S and 119 ppm mol CO2
Charge
Gas From
Caustic
Wash
Tower
Flare
5
PC
PC
FC
18.40
kg/cm2G
Min
Flow
CW
43.7C
CW
8.80
kg/cm2G
36.68
kg/cm2G
Bottom
DeC2 Feed
LC
LC
35.5C
C3R
LC
LC
TC 15.5C
37.81
kg/cm2G
CW 31.2C
LC
LC
LC
C3R
LC
(15.6C) (12.0C)
Charge
Gas
Dryer
QT
PC
26.8C
9.46
kg/cm2G
TC
Condensate
Stripper
LC
Desuperheated
LP Steam
FC
To FC on stripper
Bottoms to DeC3
74C
CW
Polymerization AE
C 2H 4
Inhibitor
C 2H 6
Cold
Train
3rd Stage
Suction
NNF Drum
H2O to 3rd Stage Suction
Filter
Coalescer
FC
AE
Dryer
Depropanizer
Product Recovery
Function
Remove all moisture from Charge Gas before chilling
Design
Molecular sieve dryers fixed bed vessel (1+1 spare)
Moisture analyzer monitors water content on-line
Guard bed below 1st moisture probe for additional buffer
time
Regenerate online when saturated
Considerations
Water breakthrough freezes in chilling train and reduces
capacity
TI
AE
H2O
PSHH
Depressurizing line to
1st Stage Suction drum
NC
AE
H2O
Dry Gas to
Chilling Train
Regen Gas
Inlet
Function
Provide liquid feeds for Demethanizer
Cryogenic separation of methane product and crude
hydrogen
Interchange heat with cold process streams &
Ethylene/Propylene refrigerant
Recover refrigeration from cold product streams before
sending to battery limits
Recuperate cold for refrigerant streams
Chilling Train :
Charge Gas Temperature Profile
Charge
Gas
Dryer
-48.8C
15.5 C
-1.8 C
DeC2
Lower
Feed
C2
Frac
S/R
-20 C
-33.4 C
-40C
C3Ref
-38.7C
-65.2 C
TIC
Ethane
Recycle
Charge
Gas
-60C
C2 R
DeC1
BTM
Reb
DeC1 Side
Reboiler
DeC1
Tower
Chilling Train :
Charge Gas Temperature Profile
OFF Gas
LP Methane
HP Methane
H2
TIC
TIC
C1R
PIC
Charge
Gas
E
-98
411
C
-72
C
-65.2 C
C2 R
-131
C
-143
C
TIC
-165
C
C2R
-136
C
FF
C
-113 C
2-Stage Joule
Thompson
Expansion
-100 C
Demethanizer
-76 C
Design
Plate fin (Core) exchangers used for close temperature
approaches of process streams and refrigerant subcooling
C3R and C2R refrigerant exchangers used for trim chilling
when no process streams are available
Separation drums for vapor liquid disengaging
Coldest core exchangers and drums located in Coldbox
Methane compressor for condensing Demethanizer
overheads for reflux.
Joule Thompson expansions used for hydrogen
purification
Permanent strainer on streams to cold box
Demethanizer
Function
Remove methane from process feeds
Provide Deethanizer feed as bottoms product
Design
Considerations
Methane in the bottoms
Ethylene in the vapor from the Reflux Drum
Ethylene in High Pressure Methane
Methane Refrigeration
Function
Temperature required to condense Demethanizer overhead at tower
pressure is well below -101C (coldest Ethylene Refrigeration)
Demethanizer overhead cannot be condensed by conventional Ethylene
Refrigeration alone
Overhead must be compressed to higher pressure to enable condensation
Demthanizer overhead is condensed by Open Loop Methane Refrigeration
System
Design
2 Stage Centrifugal Compressor
Interstage and Discharge Coolers using Cooling Water
Anti-surge recycle loop
Electric Motor Drive
TC
36 C
-132 C
41 C
Fd No. 4
FC
Fd No. 3
PC
Fd No. 2
C2R
Min Flow
Override
Fd No. 1
TC
-107
C2 Frac Vent
Charge
Gas
C
LC
PC
FC
C2R
Charge Gas
CW
CW
LC
- 51 C
500 ppm
Methane
FC
FFC
Deethanizer
Function
Remove CO from H2
Dry H2 used in hydrogenation
Produce H2 for export to OSBL
Design
Methanator used to convert CO to CH4 and H2O
Molecular sieve used for drying
Considerations
Ethylene in methanator feed can cause runaway
CO in H2 poisons hydrogenation catalyst
Deethanizer
Function
Fractionates ethane and ethylene from C3s and heavier
Design
Valve Trayed tower with split feeds
QW reboilers
Spare reboiler using LP steam is provided to ensure
continuity of operation
-27.0C C3R for condenser
Considerations
C2 in bottoms sets propylene purity
Controls C3 in ethane recycle
Deethanizer - Schematic
Flare
Treated FCC Dry
Gas C2s
FC
C3R
22.44
kg/cm2g
PC
PC
LC
C3H 6
C 3H 8
Acetylene
Converters
-19.6C
- 18.5C
LC
Off Spec
Propylene
H2
C 2H 4
CO
C 2H 2
FC
FEED 1
CW
A
Polymerization
Inhibitor
FEED 2
TC
C2- Wash
from C2
Frac
HS
-28.1C
Reset
LC
FC
LP
Stm
FC
FC
Ethylene Drier
Low Level
LC
Override
C2 Green Oil
KO Drum
QW
C 2H 4
C 2H 6
Treated
FCC C3s
65.3C
A
Polymerization
Inhibitor
FC
Depropanizer
Feed
C2s to
C2 Frac
Acetylene Converters
Function
Hydrogenates acetylene to ethylene & ethane
Design
Two Stage, fixed bed, vapor phase reactor ( 1+ 1 Spare )
Selective hydrogenation to ethylene and ethane in a two bed
acetylene converter with intercooling.
Intercooling with cooling water -- Temperature Control
bypass
Feed effluent heat exchanger
Feed preheat exchanger using LP steam
Hydrogen injection to each bed under ratio control
On-line analyzers monitor H2; C2H2; C2H6 ;CO.
Design
Inline mixer mixes cooled converter effluent with liquid
ethylene from Ethylene Fractionator
Knock out drum separates liquid containing green oil
Liquid is pumped to deethanizer to purge green oil
Considerations
Proper operation of acetylene converter minimizes green
oil formation
Recycle to dethanizer acts as reflux
Ethylene Fractionation
Function
Fractionate ethylene from ethane
Strips light gases ( methane & H2 ) from ethylene
Bottoms is ethane recycle feed to cracking heaters
Design
Considerations
Large system slow to react
Heat integration of reboilers requires good fractionation
Methanol injection is done in case of icing problem
Component
Specification
Unit
Test Method
Ethylene
99.95
mol% min.
ASTM D2505
Methane + Ethane
500
ASTM D2505
Ethane
300
ASTM D2505
Acetylene
ASTM D2505
Propylene
10
ASTM D2505
Hydrogen
ASTM D2504
Carbon Monoxide
0.03
ASTM D2504
Oxygen
O2 meter
Carbon Dioxide
5*
ASTM D2505
Water
Ammonia
Colorimetric Method
Phosphine
0.03
O2 meter
Sulfur as H2S
GC
Oxygenated solvents**
GC
Depropanizer
Function
Sharp Separation of C3s and lighter from C4+ feed components from
Deethanizer bottom and Condensate Stripper bottom.
Bottoms feeds Debutanizer
Design
Considerations
Controls C4 content of propane recycle
Controls C3- in Mixed C4 Product
MAPD can concentrate in towers, Never operate on total reflux
Depropanizer Schematic
2.4oC
5.37 kg/cm2G
LC
Deethanizer
Bottoms
Condensate
Stripper
Bottoms
A
FC
Inhibitor
Injection
50
MAPD
C 3H 8
C 4s
PC
LC
FC
FC
11.4oC
-6C
C3R
23
LC
PC
Dry Flare
FC
40.6oC
LC
11
TC
FC
To MAPD
Converters
PC
Desuperheated
LP Steam
FC
71oC
LC
LC
FC
Condensate
Inhibitor
Injection
C 3H 4
C 3H 6
C 3H 8
FC
To Debutanizer
C3 Green Oil
From Recycle KO
MAPD Hydrogenation
Function
Hydrogenate MAPD to form propylene and propane
Decrease MAPD content in Depropanizer overhead stream to
below 200 mol ppm.
Design
Hydrogenation is performed in a single step, liquid phase
reaction in contact with a palladium-based catalyst.
Fixed bed ,Single Stage Reactor (1 +1 Spare )
Partial vaporization of liquid controls reactor temperature
Flash drum disengages effluent and vaporizes net C3s
Considerations
Propylene Fractionator
Function
Design
Considerations
Large system slow to react
Never operate on total reflux.
50.0oC
20.6 kg/cm2g
19.6 kg/cm2g
50.3oC
C3 Recycle
From PP
PC
Flare
PC
18.6 kg/cm2g
46.7oC
15.6C C3R
180
80
CW
171
FFC
FC
170
A
H2
CH4
C2H4
MAPD
C3H8
21
C3H6
A
20
FC
LC
Demethanizer
43oC
LC
FC
58.9oC
C3H6
MAPD
50.3oC
FC
FC
QW
QW
Propylene
38.0C Product to
OSBL
-27.0C C3R
FFC
To C3 Green oil
FCV
Propane to
Propane Recycle Drum
-40.3C C3R
CW
-63.0C C2R
FC
- 45.0C
Low Pressure
Propylene to LP
storage
Specification
Unit
Test Method
Propylene
99.5
wt% min.
100-impurities
Propane
0.4
wt% max.
ASTM D2163
Methyl acetylene
ASTM D2712
Propadiene
ASTM D2712
Methane
200
ASTM D2712
Ethane
300
ASTM D2712
Ethylene
10
ASTM D2712
Acetylene
ASTM D2712
1,3-Butadiene*
ASTM D2712
Total C4s
10
ASMT D2712
C5 s & heavier
10
ASTM D2712
Hydrogen
ASTM D2504
Carbon monoxide
0.03
ASTM D2504
Oxygen
O2
COS
20
GC
Carbon dioxide
ASTM D2505
Water
Ammonia
0.2
Colorimetric Method
0.5
ASTM D3246
Arsine
20
Phosphine
0.03
ASTM D2505
Methanol
GC
Oxygenated solvents**
10
GC
meter
Refrigeration
Propylene Refrigeration
Function
Provide cooling and condensing of process streams
Design
Refrigerant
Pure Propylene
Ethylene Refrigeration
Function
Supplies refrigeration requirements below -40C.
Design
3 stages of compression, Closed System
Condensing medium Propylene refrigerant at 27.8C
Provides three levels of refrigeration :
-101C
0.15 kg/cm2g
-75C
3.24 kg/cm2g
-63C
5.82 kg/cm2g
Refrigerant
Pure Ethylene
Flare System
Flare System
The design basis for the Flare System for the 800,000 TPA
Ethylene Plant includes the NCU, C4 Hydrogenation,
PGHU,BEU & BDEU.
Largest sources of flare relief loads are in the NCU.
To reduce the resulting flare load, highly reliable Safety
Instrumented Systems (SIS) are specified that take action during
a global overpressure event to reduce the number of pressure
relief devices discharging concurrently.
Smokeless Flaring
The final mitigated combined flare load for the two controlling global
failure (Cooling Water and Power Failure) cases are approximately 961
T/h and 951 T/h respectively
For these mitigated loads, heater mitigation was considered as part of
the flare reduction strategy
Without heater mitigation, the loads for the Cooling Water and the
Power Failure cases increase to approximately 1210 T/h and 1151 T/h
respectively
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