New Technologies In Ethylene Cracking Furnace Design - AIChE
New Technologies in Ethylene Cracking Furnace Design Jelle Gerard Wijnja Technology Manager Ethylene Furnaces Technip Benelux Presentation for AIChE NL/B Zoetermeer, 31 October 2017 This document and all information herein are confidential, and may not be used, reproduced or distributed without prior authorization of TechnipFMC.
Table of Contents 1. Introduction TechnipFMC 2. Cracking Fundamentals 3. Latest applied Technologies in Furnace Design 2
1. Introduction TechnipFMC 3
TechnipFMC in a Snapshot A unique global leader in oil and gas projects, technologies, systems, and services that will enhance the performance of the world’s energy industry 2 21 Stock Exchange listings – NYSE and Euronext Paris Vessels 48 44,000 Countries in which we operate Employees 4
Three Major Operating Segments A comprehensive and flexible offering from concept to project delivery and beyond Subsea Onshore/Offshore Surface 5
Technip Benelux B.V. Technology center for Ethylene Hydrogen Technologies SPYRO (steam cracking simulation software) Fast pyrolysis oil (biomass to oil) Full EPC capabilities Zoetermeer, The Netherlands Strong front-end engineering capabilities Advisory / Consulting services Procurement, Expediting, QA/QC Construction, Commissioning, Startup Project Management No. 1 in furnace revamp projects (200 ) Alliances with DOW and Air Products 6
Process Technology Centers Around the World London Claremont Zoetermeer Boston/Weymouth Paris Rome Houston 7
Supply of 400 Cracking Furnaces Liquid Furnaces GK6 , USC-U & SU 200 furnaces Gas Furnaces SMKTM, USC-M 200 furnaces 8
2. Cracking Fundamentals Characteristics Cracking Furnace SPYRO simulation software 9
Worldwide Ethylene Capacity Current ethylene capacity 165 000 kta (2016) 271 steam cracking units in operation Plant capacity ranging from 30 to almost 2000 kta 54 countries Average growing ethylene capacity: 3.9% (recorded over the years) Capacity is increased by New grassroots plants Plant expansions Ethylene is the largest chemical produced worldwide 10
Characteristics of Olefins Production Strongly endothermic process Feed Products Heat Ethane Absorbed duty: Q 1.6 MW / ton of feed For 1500 kta cracker: fired heat 890 MW Naphtha Absorbed duty: Q 1.4 MW / ton of feed For 1000 kta cracker: fired heat 790 MW 11
Cracking Reactions - Products Example – ethane cracking C2H6 CH3* C2H5* H* C2H5* H* H* H* CH3* CH3* initiation reaction C2H6 CH4 C2H5* hydrogen abstraction propagation C2H6 C2H4 H* CH4 C2H5* C2H5* C2H5* CH3* H* C2H10 C 2H 6 CH4 H2 termination Mass, dry% ethane Naphtha Hydrogen 4.1 0.8 Methane 5.0 13.4 Acetylene 0.4 0.3 Ethylene 52.8 27.7 Ethane 32.6 3.8 C3H4’s 0.03 0.6 Propylene 1.2 16.4 Propane 0.2 0.5 sum C4’s 1.9 11.2 sum C5s 0.4 5.9 sum C6’s 0.9 8.1 sum C7’s 0.1 4.1 sum C8’s 0.1 2.2 sum C9’s 0.01 1.4 sum C10’s 0.2 3.4 12
Cracking - Coke formation Hydrocarbons Olefins other products coke Coke coats the inside surface of radiant tubes Pressure drop increases Reduce yield TMT increases, limiting furnace runlength (availability) Increase energy consumption Increase carburization (reduce coil lifetime) 15
Cracking - Coke formation Coking mechanism: Catalytic (Ni, Fe) Free radical Condensation Maximum TMT vs Run Length 1100 EOR 1080 TMT at EOR [ C] Longer run length 1060 1040 1020 1000 Run Length [days] 0 10 20 30 40 50 60 70 80 90 100 110 120 130 16
Cracking – Coil failure mechanism Carburisation Internal Carbide formation in carbonaceous atmospheres at high temperatures ( 900 ) Effects tube characteristics by impact on creep properties, ductility, thermal fatique, thermal expansion coefficient Creep ductility exhaustion Each cycle small amount of creep until creep ductility reached radiant coil has a limited lifetime 17
Cracking Furnace layout Flue Gas to stack ID Fan 120 C Steam Drum 119 bara, 324 C Hydrocarbon Feed 60 C FPH Boiler Feed Water 140 C ECO Dilution Steam Cracked Gas to separation section 350 C HTC-1 Convection Section - Heat recovery Desuper heater HPSSH-1 BFW HPSSH-2 HTC-2 Fuel Gas Radiant efficiency: 40-42% Overall efficiency: 93-95% 1250 Radiant CoilC TransferLine Exchanger 620 C 850 C Burner VHP Steam 115 bara, 515 C Radiant Section - Cracking reactions - combustion 18
Cracking Furnace layout Fluegas ID Fan Steam Drum TransferLine exchanger Convection Section Quench Oil Fitting Radiant wall burners Radiant box - radiant coils Bottom burners 19
Furnace before Modernization 20
New Radiant Coil in Transport 21
Lifting New Radiant Coil 22
Facts / Parameter ranges Cracking reaction is non catalytic and not selective Cracking reaction is highly endothermic Inlet temperature: 550-700 C Outlet temperature: 750-900 C Selectivity sensitive for residence time, lower is better Selectivity sensitive for pressure, lower is better Furnace outlet pressure at TLE: 0,5 – 1,5 barg Dilution steam is required; ratio between 0,25 – 1,0 Radiant coil material: 25/35 and 35/45 23
Facts / Limitations Coking rate Coke layer increases TMT Coke layer increases pressure drop over radiant coil Run length determined by: Maximum allowable TMT (Outlet tube) Coil pressure drop (critical flow venturi stays critical) Run length, typically 40-75 days Decoke with steam/air after EOR; 1-3 days duration Operation modes: SOR, MOR, EOR, Hot standby to fractionator, Hot standby to decoke system, Decoke 24
The Magic of Cracking Optimization of: Coil selection Coil sizing against: Yields Runlength Feedstock flexibility Operating cost Investment cost SPYRO steam cracking simulation software is used by most cracking furnace operators 25
Radiant coil - metallurgy GK6 radiant coil - typical Two pass Outlet tube highest temperatures Highest process temperature Coke formation Tube 1 2 25Cr35NiNb Micro-alloy 35Cr45NiNb Micro-alloy DT 1080 C 1115 C DP 100.000 hrs 10.000 hrs 3.9 barg 4.9 barg 3.5 barg 4.6 barg Material 26
Radiant coil - Development Cracking furnaces 165 000 kta, 3.9% yearly Radiant coil Expensive Limited lifetime – consumables Looking for Lower carburization rate – increase coil lifetime Lower coking rate – increase runlength, fewer coils Developments Additives (DMDS) Cr-oxide forming alloys Al-oxide forming alloys Ceramics Finned / riffled tubes Coatings Multi lane SFT – enhanced heat transfer . 27
3. Latest Applied Technologies in Furnace Design Multi lane radiant coils Swirl Flow Tube Large Scale Vortex Burner 28
Dual-lane GK6 top view 80 furnaces & 7,000 KTA ethylene produced with Dual-lane GK6 technology 33
Triple-lane GK6 top view Inlet tubes Outlet tubes Inlet tubes Tube positions optimized: Outlet tubes to the center lane Inlet tubes to the outside lanes 34
Triple-lane Features & Advantages Inlet tubes at outside, facing burners & refractory Heat is shifted to inlet tubes Outlet tubes at inside, away from direct radiant sources Uniform circumferential radiation combined with large tube-tube spacing Reduced Peak to Average Heat-flux on outlet tube Large tube-tube spacing Same amount of tubes in 3 lanes vs in 2 lanes Overall Impact Improved heat flux profile & decreased maximum TMT Improved performance 35
Biasing heat flux towards inlet tubes 2-Lane Heatflux 3-Lane Higher flux to inlet tubes Coil length Lower flux to the outlet tubes Improved thermal utilization of radiant coil 36
Improved Circumferential Temperature Distribution Outlet Tubes Inter-lane side Dual-Lane All tubes peak at refractory side All tubes dip at inter-lane side Inlet Outlet Refractory side Inter-lane side Triple-Lane Inlets peak at refractory side Inlet gradient similar to duallane Outlet tube circumferential heat distribution very uniform Refractory side 37
Maximum Tube Metal Temperature Temperature Profile Comparison Temperature [ C] At Point of Maximum TMT 1150 1100 1050 1000 950 900 850 800 Maximum TMT Average TMT Process Medium Dual-lane Triple-lane Maximum TMT reduced 38
Triple-lane 1-1 “U” Coil: top view perspective view 40
Swirl Flow Tube Round tube Helical geometry Full line of sight No obstructions Improved heat transfer * Veryan Medical Limited: BioMimics 3DTM Helical tubes of different amplitudes and pitches 42
Relative Coking rate Relative Coking Rates Straight SFT Ethane Naphtha Substantially lower coking rates observed due to Lower wall temperature Increased turbulence Footnotes: (1) Data from Pilot Steam Cracker of Universiteit Gent 43
Requirements for Ultra Low NOx burners NOx emission in the range 50 100 mg/Nm3 Safety: Burner shall be stable for all operating conditions Stable flame and no flame impingement Uniform heat flux profile resulting in uniform tube wall temperatures Optimized firebox efficiency Burner shall be suitable for revamp and new furnace design Ability to operate at a high firing intensity Low maintenance costs Sound pressure level 76 dB(A) @ 1 m. The LSV burner meets these requirements 50
LSV burner overview Simple robust design Uses a combination of techniques to prevent NOx formation Proven ultra low NOx performance Designed to have optimized heat release profile for the most optimal furnace design Suitable for furnace revamp and grass root furnace designs 52
Operational Experience LSV design data Excess air % 7 – 15 Flue Gas Temp (box temp) C 1030-1360 Combustion Air Temp C Ambient-470 ppmv 25 – 50 NOx Emission @ 3 % O2 53
Operational Experience Excellent flame patterns and flame stability Very good heat distribution on coils High firebox efficiency Low NOx emission Proven design, trouble free operation Reported low maintenance cost Manufacturing by TechnipFMC More than 1000 LSV burners have been applied 54
This document and all information herein are confidential, and may not be used, reproduced or distributed without prior authorization of TechnipFMC. 55
Technology Manager Ethylene Furnaces Technip Benelux New Technologies in Ethylene Cracking Furnace Design Presentation for AIChE NL/B Zoetermeer, 31 October 2017. 2 Table of Contents 1. Introduction TechnipFMC 2. Cracking Fundamentals . Supply of 400 Cracking Furnaces Liquid Furnaces GK6 .
models of the thermal cracking process of Ethylene Dichloride (EDC) to produce Vinyl Chloride Monomer (VCM) at Abu-Kammash Chemical Complex. The developed design was set against the amount of heat saved. In addition, Both EDC cracking units ( old and new design) were . Exergy Analysis of Ethylene Dichloride Cracking Unit at Abu-Kammash Chemical .
As shown in Figure1, the ethylene cracking furnace is one of the core ethylene production equipment. Ensuring its long-term operational safety and stability is the prerequisite for normal ethylene production. The furnace tube is the main component of the cracking furnace, and it operates in the combustion chamber filled with high-temperature .
3. E/P Feed to the Furnace - for ethylene plants using Ethane/ Propane mix as the feed, this analyzer provides feed-forward data for advanced furnace control in order to maximize cracking furnace efficiency. For ethylene plants using naphtha a the feed to the cracking furnaces, a process FT-NIR is often used instead of a GC. Ethylene Plant 2
tionating the pressurized cracking furnace effluent, wherein the pressure profile within the cracking fur nace is optimized to maximize the yield of ethylene. Modern ethylene plants are normally designed for near maximum cracking severity, a term used to describe the depth of cracking or extent of conversion, because of economic considerations.
The cracking reactions occur via free-radical mechanisms, and for the cracking of naphtha, resulting in yields of ethylene stream is made up of (in between 25 35% and propylene between 14 18% [1]. butadiene as well as 2.1 Steam Cracking process A simplified flowsheet of the steam cracking process that be found in Figure 3.
Jan 27, 2005 · The Ethylene Oxide Product Stewardship Guidance Manual was prepared by the American Chemistry Council’s Ethylene Oxide/Ethylene Glycols Panel (Panel). It is intended to provide general information to persons who may handle or store ethylene oxide. It is not i
quire ethylene in quantities of 100 103 – 200 103 t/a only and ethylene supply from standalone crackers of this size is not feasible in most cases. 2. Physical Properties Ethylene is a colorless flammable gas with a sweet odor. The physical properties of ethylene are as follows: mp
Kesehatan gigi dan mulut yang kebersihannya terjaga merupakan bagian dari faktor yang mendukung terciptanya gigi dan mulut yang sehat, termasuk . 3 jaringan periodontal (Christiany, dkk, 2015). Keberhasilan pemeliharaan kesehatan gigi dan mulut dilakukan dengan tindakan menyikat gigi. Hal yang perlu diperhatikan dalam menyikat gigi adalah teknik menyikat gigi. Teknik menyikat gigi diantaranya .
