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Process Description
The Process of Naphtha Cracking: Steam Pyrolysis Technology
The preheat naphtha is mixed with steam and passes to the convective
section. Its temperature is raised to 300oC temperature and pass to the
radiation section of the furnace for further increasing to 800 oC (This is the
condition where naphtha is cracked into simple compounds)
Steam is added to dilute the feedstock at ratio of 0.6 kg/kg HC to prevent the
coke formation at the cracking zone.
High temperature product gas is cooled by removing the latent heat of water
in steam generators that produce HP steam with 10 to 14Mpa.
Oil quenching mechanism is used to cool the furnace effluent gas and the
recover heat is used to produce low-pressure steam in the plant utility. Gas oil
and fuel oil are obtained when the gas is passed to the primary fractionators.
The volatile components from the primary fractionators are cooled and
compressed to 5 to 6Mpa. Heavy hydrocarbons (above C 3) are liquefied and
separated through separators.
The cracked products are passed through coolers and compressors and
compressed to 30 atm and 30oC and separation of C3, C4, C5and
C6components takes place by partial fractionation and liquefaction.
First stage
Cooling the whole mass of gas to 30C under 35 atm pressure to liquefy C 4and
heavier constituents.
Second stage
Third stage
Dry gas constituting CH4and H2is separated from ethane /ethylene mixture this
mixture is used as a refrigerant. Acidic constituents like CO, CO 2, H2S, and SO2etc are
removed in acid gas removing unit, by caustic wash not shown in process flow sheet.
After the treatment the left out in the gas are methane, hydrogen, ethylene, ethane
and slight amount ofacetylene(1%). Hydrogen is separated initially than the gas is
liquefied. Hydrogen gas is purified and part of it is sent to hydrogenation units, to
convert acetylene and propadiene to ethylene and propane respectively.
Tail gas obtained from demethaniser is abundant in methane and used in fuel
system. The gases are sent to acid gas removal unit, Demethaniser for
methane removal and hydrogen purification unit.
Tail gas is removed and then traces of acetylene are converted into ethylene
by hydrogenation.
Fourth stage
Fifth stage
The heavy bottoms of first stage unit are processed for C 3and heavy ends.
This stage is not shown in the process flowsheet.