Transcript Advances in Ethane Cracking, AIChE, Houston TX, Mar 2014

Advances in
Ethane Cracking
Gabriel Castaneda, P.E.
Gabchem Solutions
Linde
(713) 873 1708
[email protected]
Table of Contents
• Economics
• Process Overview
• Areas of Improvement
•
•
Energy Consumption
Reliability / Operational Issues
• Compression and Fouling
• Refrigeration
• Furnaces
Economical Advantage
Low gas prices thanks to hydraulic fracturing technology
Mark Eramo, IHS
Ethylene Capacity Expansions
Company
Sasol
Project
New cracker
Capacity
1.5m tonnes
Location
Lake Charles, Louisiana
Start-up
2017
Occidental Chemical/Mexichem
New cracker
544,000 tonnes
Ingleside, Texas
Feb-17
ExxonMobil Chemical
New cracker
1.5m tonnes
Baytown, Texas
Late 2016
Chevron Phillips Chemical
New cracker
1.5m tonnes
Cedar Bayou, Texas
mid-late 2017
Dow Chemical
New cracker
1.5m tonnes
Freeport, Texas
2017
Shell
New cracker
1m tonnes
Monaca, Pennsylvania
2019-2020*
Formosa Plastics
New cracker
1.2m tonnes
Point Comfort, Texas
2017
Williams
Expansion
272,158 tonnes
Geismar, Louisiana
Q4 2013**
INEOS
Debottleneck
115,000 tonnes
Chocolate Bayou, Texas
end 2013
Westlake Chemical
Expansion
113,399 tonnes
Lake Charles, Louisiana
2014
Westlake Chemical
Expansion
82,000 tonnes
Calvert City, Kentucky
Q2 2014
LyondellBasell
Expansion
363,000 tonnes
La Porte, Texas
mid-2014
LyondellBasell
Expansion
113,000 tonnes
Channelview, Texas
2015
LyondellBasell
Expansion
363,000 tonnes
Corpus Christi, Texas
Late 2015
BASF Fina Petrochemicals
Expansion
180,000 tonnes
Port Arthur, Texas
2014
* ICIS Estimate **did not consider 2013 explosion
Joseph Chang, ICIS
Considered Expansions
Company
Project
Capacity
Location
Start-up
LyondellBasell
New cracker
World-scale
US
NA
Hanwha Chemical
New cracker
World-scale
US
NA
Axiall
New cracker
World-scale
US
NA
Indorama Ventures
New cracker
1.3m tonnes
US
NA
SABIC
New cracker
World-scale
US
NA
Braskem
New cracker
World-scale
US
NA
PTT Global Chemical
New cracker
World-scale
US
NA
Aither Chemicals
New cracker
272,000 tonnes
US Northeast
2016
NOVA Chemicals
Expansion
NA
Corunna, Ontario, Canada
NA
Joseph Chang, ICIS
Process Overview
Emerson
Areas to Improve
• Energy Consumption
• Reliability / Operational Issues
Energy Consumption,
Ethane Cracking
Operation
Pyrolysis
Compression
Separation
Fraction
65
15
20
Fuel gas provides most of the energy
Tao Ren, Utrecht University
Production Loss due Reliability
Solomon Associates
Equipment Fouling
GE, Dorf Ketal
Polymerization Rate Constant
120oF
160oF
200oF
230oF
ABB/Lummus
Fouling Deposits in Compressors
•
•
•
•
•
Labyrinth Ends
Balance Piston
Inserts
Return channel
Impeller
Mitsubishi
Hans Joachim
Moellering
Siemens
Fouling Control in Cracked Gas Compressors
Hans Joachim
Moellering
Siemens
Water and Wash Oil Injection
Oil composition >
80% aromatics
Hans Joachim
Moellering
Siemens
Water Injection in Compressors
Hans Joachim
Moellering
Siemens
Refrigeration
Ethane Cracker Process Flow Diagram
Chevron
Phillips
Single Refrigerant
Ethylene : 3 levels
Propylene : 2 levels
Chevron Phillips
Frank Del Nogal
Cascade Process
Environment
Propylene
Ethylene
Process
Ethylene and propylene used
Mixed Refrigerant
Cooling Curve of Gas
Natural gas MR: 8% N2 45% C1,45%C2, 2% C3
Cracked Gas MR: Methane/Ethylene, Methane/Ethylene/Propylene
7-20% Methane, 7-20% ethylene, 50-86 %propylene
Lee
Natural Gas Cooling Curves
Single Refrigerant
Mixed Refrigerant
Double
Mixed Refrigerant
Mixed and
Single Refrigerant
Il Moon et al
Efficient Heat Exchanger Arrangement
used with Mixed Refrigerants
Kettle vs BAHE
Frank Del Nogal
Olefin Plant Refrigeration System
In 2010 there were 13
mixed refrigeration
systems in operation and
9 more in engineering
Lummus
US 6,637,237
Coalescers
Pall
Furnace
Linde
Tubes
1-2.5 in DI tubes
Length reduced to about 30-40 feet
Operate between 1900-2100oF
Residence time : 0.2 seconds
Element
C
Ni
Cr
Mn
Al
Ta
Ti
Si
% min
.35
38
28
.5
-
-
Add
0.5
% max
.6
42
32
1.5
3
add
Add
2
Carburization resistance, longer run lengths
Sandvik
G Verdier, Manoir Industries
Gas Chromatography
Mass Chromatograph vs GC
Emerson
Coke Resistant Coating
• CAMOL Coating, BASF, Quantiam
[email protected]
Camol Coating Benefits
Quantiam / BASF
Effect of Fins on Furnace Efficiency
Nova Chemicals, US 2012/0251407 A1
Thanks!
Gabriel Castaneda, P.E.
713 873 1708
[email protected]
Water Injection In Compressors
Hans Joachim
Moellering
Siemens
Steam Cracking Furnace
A Chauvel
Heat Exchanger for Cracked Gas
US 2008/0121383
Linde Furnace
US 20030070963
KM Van Geem
Steam Cracking Furnace
Nova Chemicals, US 2012/0251407 A1
Mixed Refrigerant Loop for Ethylene Process
M Amidpour
Composite Curve of System
Selection of Mixed Refrigerant Composition
C1 to C4 and Nitrogen
Cracked Gas Compressor
Failures/ Problems Overview
Bill Broussard
Emerson
Steam Cracking Furnace
A Chauvel
Linde Furnace
US 20030070963
Cold Separation of Products
A Chauvel
Hydraulic Fracturing
Propublica.org
North America New Polyethylene Projects
Sarpol
Global Polyethylene Capacity Additions
Sorpol
Furnace Main Components
Linde
Hydrocarbon Pyrolisis Furnace
US 7718052
Heat Exchanger for Cracked Gas
US 2008/0121383
Announced Capacity, 1000 MT
BASF/Total (Port Arthur)
Chevron Phillips (Cedar Bayou)
Dow (Taft/ Freeport)
Eastman
Equistar (all locations)
Exxon (Baytown)
Formosa (Point Comfort)
Ineos (Chocolate Bayou)
Oxy (Ingleside)
Sasol (Lake Charles)
Shell (Northeast)
Westlake (Lake Charles / Calvert City)
Williams (Geismar)
Nova (Sarnia)
Braskem / Idesa (Mexico)
Total
Cummulative Total
2012-2014 2016-2020
180
1500
396
1500*
90
521
1500
800
107
550*
1400
1000*%
310
300
250*
1000
1894
9500
11394
IHS
Coalescers/ Filters in Ethane Cracking Process
Pall
Ethylene Production Costs, Naphtha, 2010
item
naphtha
catalyt and chemicals
raw materials cost
dollars/ton
1651.1
3.6
1655
fuel
high pressure steam, (40 bar)
cooling water
electricity
other utilities
total utilities
195.1
24.1
14
5.9
0.3
239.4
total variable costs
1894.4
direct fixed cost
allocated fixed cost
38.8
31.8
total costs
1965
utilities costs
0.10
0.06
0.02
0.00
fuel
high pressure steam, (40 bar)
cooling water
electricity
0.81
other utilities