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Ethylene Production

Naphtha Steam Cracking Process

Process Description
The Process of Naphtha Cracking: Steam Pyrolysis Technology

A cracking furnace having a separate convection section for preheating and a


radiant section is used.Its interior contains burners placed along the
sidewalls or at the bottom of the furnace. Temperature in the furnace
continuously maintained between 950 to 1000oC by the series of burners
controlling. 5 bar pressure is maintained in the tubes by the naphtha feed
pumps.

By aheat exchanger, fresh feedstock (Naphtha) is preheated with cracked


products stream that comes out from the furnace.

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)

Process Description (cont.)

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.

Transferline heat exchangers operate with high thermal efficiency during


cooling the product gas. Products from C2to C4group are formed during
cracking along with some quantity of BTX and ethyl benzene, Hydrogen and
fuel oil.

Process Description (cont.)


Ethylene Purification And By-products Separation And Recycle

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.

This can be done in four stages:

Process Description (cont.)

This can be done in four stages:

First stage

Cooling the whole mass of gas to 30C under 35 atm pressure to liquefy C 4and
heavier constituents.

Second stage

The uncondensed gas is subjected to severe conditions, i.e.; up to +30c and 20


atmosphere pressure, where by propane condenses leaving ethane and ethylene in
gaseous form.

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.

Process Description (cont.)

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.

Then it is send to ethylene splitter for separation of ethylene.

Fourth stage

Ethane and ethylene are liquefied and fractionated

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.

Process Flow Diagram

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