Gabriel Castaneda PE Gabchem Solutions Linde 713 873 1708 Gabrielgabcheminccom Table of Contents Economics Process Overview Areas of Improvement Energy Consumption Reliability Operational Issues ID: 671703
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Slide1
Advances in Ethane Cracking
Gabriel Castaneda, P.E.Gabchem Solutions
Linde
(713) 873 1708
Gabriel@gabcheminc.comSlide2
Table of Contents
EconomicsProcess OverviewAreas of Improvement
Energy ConsumptionReliability / Operational Issues
Compression and Fouling
Refrigeration
FurnacesSlide3
Economical A
dvantageMark Eramo, IHS
Low gas prices thanks to hydraulic fracturing technologySlide4
Ethylene Capacity Expansions
Company
Project
Capacity
Location
Start-up
Sasol
New cracker
1.5m tonnes
Lake Charles, Louisiana
2017
Occidental Chemical/Mexichem
New cracker544,000 tonnesIngleside, TexasFeb-17ExxonMobil ChemicalNew cracker1.5m tonnesBaytown, TexasLate 2016Chevron Phillips ChemicalNew cracker1.5m tonnesCedar Bayou, Texasmid-late 2017Dow ChemicalNew cracker1.5m tonnesFreeport, Texas2017ShellNew cracker1m tonnesMonaca, Pennsylvania2019-2020*Formosa PlasticsNew cracker1.2m tonnesPoint Comfort, Texas2017WilliamsExpansion272,158 tonnesGeismar, LouisianaQ4 2013**INEOSDebottleneck115,000 tonnesChocolate Bayou, Texasend 2013Westlake ChemicalExpansion113,399 tonnesLake Charles, Louisiana2014Westlake ChemicalExpansion82,000 tonnesCalvert City, KentuckyQ2 2014LyondellBasellExpansion363,000 tonnesLa Porte, Texasmid-2014LyondellBasellExpansion113,000 tonnesChannelview, Texas2015LyondellBasellExpansion363,000 tonnesCorpus Christi, TexasLate 2015BASF Fina PetrochemicalsExpansion180,000 tonnesPort Arthur, Texas2014
Joseph Chang, ICIS
* ICIS Estimate **did not consider 2013 explosionSlide5
Considered Expansions
Company
Project
Capacity
Location
Start-up
LyondellBasell
New cracker
World-scale
US
NA
Hanwha Chemical
New crackerWorld-scaleUSNAAxiallNew crackerWorld-scaleUSNAIndorama VenturesNew cracker1.3m tonnesUSNASABICNew crackerWorld-scaleUSNABraskemNew crackerWorld-scaleUSNAPTT Global ChemicalNew crackerWorld-scaleUSNAAither ChemicalsNew cracker272,000 tonnesUS Northeast2016NOVA ChemicalsExpansionNACorunna, Ontario, CanadaNAJoseph Chang, ICISSlide6
Process Overview
EmersonSlide7
Areas to Improve
Energy ConsumptionReliability / Operational IssuesSlide8
Energy Consumption,
Ethane CrackingTao Ren, Utrecht University
Operation
Fraction
Pyrolysis
65
Compression
15
Separation
20
Fuel gas provides most of the energySlide9
Production Loss due Reliability
Solomon AssociatesSlide10
Equipment Fouling
GE,
Dorf
Ketal
Slide11
Polymerization Rate Constant
ABB/Lummus
120
o
F 160
o
F 200
o
F 230
o
F Slide12
Fouling Deposits in Compressors
Hans Joachim
MoelleringSiemens
Labyrinth Ends
Balance Piston
Inserts
Return channel
Impeller
MitsubishiSlide13
Fouling Control in Cracked Gas Compressors
Hans Joachim
MoelleringSiemensSlide14
Water and Wash Oil Injection
Hans JoachimMoelleringSiemens
Oil composition > 80% aromaticsSlide15
Water Injection in Compressors
Hans Joachim
MoelleringSiemensSlide16
RefrigerationSlide17
Ethane Cracker Process Flow Diagram
Chevron PhillipsSlide18
Single Refrigerant
Chevron Phillips
Frank Del
Nogal
Ethylene : 3 levels
Propylene : 2 levelsSlide19
Cascade Process
Ethylene and propylene used
Propylene
Ethylene
Environment
ProcessSlide20
Mixed RefrigerantSlide21
Cooling Curve of Gas
Natural gas MR: 8% N2 45% C1,45%C2, 2% C3
Cracked Gas MR: Methane/Ethylene, Methane/Ethylene/Propylene
Lee
7-20% Methane, 7-20% ethylene, 50-86 %propyleneSlide22
Natural Gas Cooling Curves
Single Refrigerant
Mixed Refrigerant
Double
Mixed Refrigerant
Mixed and
Single Refrigerant
Il Moon et alSlide23
Efficient Heat Exchanger Arrangement used with Mixed Refrigerants
Frank Del
Nogal
Kettle vs BAHESlide24
Olefin Plant Refrigeration System
LummusUS 6,637,237
In 2010 there were 13 mixed refrigeration systems in operation and 9 more in engineeringSlide25
Coalescers
PallSlide26
Furnace
LindeSlide27
Tubes
Element
C
NiCr
Mn
Al
Ta
Ti
Si
% min
.35
38
28.5--Add0.5% max.642321.53addAdd21-2.5 in DI tubesLength reduced to about 30-40 feetOperate between 1900-2100oFResidence time : 0.2 secondsCarburization resistance, longer run lengthsG Verdier, Manoir IndustriesSandvikSlide28
Gas Chromatography
Emerson
Mass Chromatograph vs GCSlide29
Coke Resistant Coating
CAMOL Coating, BASF, Quantiam
majid.keyvani@lyondellbasell.comSlide30
Camol Coating Benefits
Quantiam / BASFSlide31
Effect of Fins on Furnace Efficiency
Nova Chemicals, US 2012/0251407 A1Slide32
Thanks!
Gabriel Castaneda, P.E.713 873 1708Gabriel@gabcheminc.comSlide33
Water Injection In Compressors
Hans Joachim MoelleringSiemensSlide34
Steam Cracking Furnace
A
ChauvelSlide35
Heat Exchanger for Cracked Gas
US 2008/0121383Slide36
Linde Furnace
US 20030070963Slide37
KM Van
GeemSlide38
Nova Chemicals, US 2012/0251407 A1
Steam Cracking FurnaceSlide39
Mixed Refrigerant Loop for Ethylene Process
M
AmidpourSlide40
Composite Curve of SystemSlide41
Selection of Mixed Refrigerant Composition
C1 to C4 and NitrogenSlide42
Cracked Gas CompressorFailures/ Problems Overview
Bill BroussardEmersonSlide43
Steam Cracking Furnace
A
ChauvelSlide44
Linde Furnace
US 20030070963Slide45
Cold Separation of Products
A
ChauvelSlide46
Hydraulic Fracturing
Propublica.orgSlide47
North America New Polyethylene Projects
SarpolSlide48
Global Polyethylene Capacity Additions
SorpolSlide49
Furnace Main Components
LindeSlide50
Hydrocarbon Pyrolisis Furnace
US 7718052Slide51
Heat Exchanger for Cracked Gas
US 2008/0121383Slide52
Announced Capacity, 1000 MT
2012-2014
2016-2020
BASF/Total (Port Arthur)
180
Chevron Phillips (Cedar Bayou)
1500
Dow (Taft/ Freeport)
396
1500*Eastman90 Equistar (all locations)521 Exxon (Baytown) 1500Formosa (Point Comfort) 800Ineos (Chocolate Bayou)107 Oxy (Ingleside) 550*Sasol (Lake Charles) 1400Shell (Northeast) 1000*%Westlake (Lake Charles / Calvert City)310 Williams (Geismar)300 Nova (Sarnia) 250*Braskem / Idesa (Mexico) 1000Total18949500Cummulative Total 11394IHSSlide53
Coalescers/ Filters in Ethane Cracking Process
PallSlide54
Ethylene Production Costs, Naphtha, 2010
item
dollars/ton
naphtha
1651.1
catalyt and chemicals
3.6
raw materials cost
1655
fuel
195.1
high pressure steam, (40 bar)
24.1cooling water14electricity5.9other utilities0.3total utilities239.4total variable costs1894.4direct fixed cost38.8allocated fixed cost31.8total costs1965