A FULL FULL-- SERVI SERVICE CE ETHY ETHYLENE LENE PROD PRODUCT UCT LINE
TECHNIP-COFLEXIP ETHYLENE TECHNOLOGY TECHNIP-COFLEXIP offers the ethylene manufacturing industry SINGLESOURCE PROJECT RESPONSIBILITY RESPONSIBILITY throughout all phases of a new grassroots ethylene plant or revamp project, from basic design phase up to project implementation, start-up and operational services.
THE TECHNOLOGY CORNERSTONES TECHNIP-COFLEXIP applies unique technology features: • SPYRO ® FURNACE DESIGN AND OPTIMIZATION SOFTWARE • TECHNIP-COFLEXIP CRACKING FURNACE TECHNOLOGY • PROGRESSIVE SEPARATION TECHNOLOGY • TH THE E T-P -PAR AR ® PROCESS • OPERA OPERATIONS TIONS SUPPORT SERVICES: e -OSS ® - CLX ® anti-coking services developed jointly with ATOFINA ATOFINA of France, - Unattended operations concepts. And for capaci capacity ty expansi expansion on of o f existing exi sting plants : • THE SYSTEMATIC APPROACH TO MODERNIZATION • THE CAPACITY AND PERFORMANCE IMPROVEMENTS OF EXISTING FURNACES. The application of these proven proprietary technologies in the design of modern large-scale large- scale grassroots ethylene plants and in the revamp of existing ethylene crackers offers the plant operator a SAFE, RELIABLE ethylene plant, easy to operate and maintain, resulting in a very efficient cost saving olefin production unit for the Owner. SPYRO ®, e-OSS ® and T-PAR ® are registered trademarks of TECHNIPCOFLEXIP.
Simulation of a large capacity furnace
THE SPYRO ® FURNACE DESIGN AND OPTIMIZATION SOFTWARE Hydrocarbons are thermally cracked in a tubular fired reactor, the cracking furnace. The thermal cracking process requires high temperatures and to be selective to the desired light olefins, optimal residence times and pressure profile have to be selected. Due to the complex nature of the cracking process, accurate predictive design and simulation tools are needed to arrive at the best reactor coil and firebox design. TECHNIP-COFLEXIP ETHYLENE TECHNOLOGY makes use of TECHNIP’s proprietary SPYRO ® yield prediction program. The heart of SPYRO ® is a rigorous kinetic model describing in detail the thousands of elementary reactions occurring during pyrolysis of hydrocarbons, ranging from light gases such as ethane to heavy oils such as hydrocracked VGO (Hydrowax). SPYRO ® is the result of more than 30 years of joint development and continuing improvements improvement s in close cooperation with the original authors of the program, the team of Professor Dente in Milan.
SPYRO ® is now used by the vast majority of ethylene producers and is applied for feedstock selection, process scheduling and production optimization. A large number of plants run on-line control and optimization systems having a dedicated SPYRO ® program embedded in the system software. The application of the proven SPYRO ® program provides detailed information on yields and furnace availability which can also be used to set up reva mp scenarios for the furnace and downstream sections of the plant. For optimum design of largelarge- capacity ®, ®, GK and SMK cracking furnaces, TECHNIP-COFLEXIP applies SPYRO ® linked with CFD ( computa computational tional fluid dynamics dynamics), ), enabling the best design of burner arrangement, cracking coil layout and flue gas ducting.
THE TECHNIP-COFLEXIP CRACKING FURNACE TECHNIP-COFLEXIP CRACKING FURNACES use the proven high selective, short residence time coils of the GK ® and SMK SM K® types (originally developed by KTI ® ). The Cracking Coils of GK ® and SMK ® furnace na ces s are tailored to the specific needs needs of the ethylene plant. Normally these are geared towards the maximum production of the light olefins, ethylene and propylene. Additionally Addition ally,, for liquid crackers crackers integrated integrated with downstream production units, requirements such as maximum BTX co-production and feed/products flexibility are also important parameters for an optimal coil design. TECHNIP-COFLEXIP CRACKING FURNACES are equipped with a combination of low NOx bottom and up- shot side wall burners. The specific GK ® or SMK ® coil arrangement, burner lay-out and the box dimensions allow for a very large capacity per furnace cell, while maintaining high radiant fuel efficiency. In most cases the application of low NOx burners will meet emission specifications imposed by country or state legislation. For stringent NOx specifications, the application of flue gas NOx removal using low temperature SCR (selective catalytic NOx removal) can also be applied.
TECHNIP-COFLEXIP CRACKING FURNACES feature shell-and-tube TLE’s (transfer line exchangers) as well as double pipe direct quench coolers. High onstream time is achieved by minimizing mechanical decoke cycles of the TLE’s. In 1999 TECHNIP introduced the GK6 furnace. The GK6 furnace features an 8-8 cracking coil configuration. The GK6 furnace can be equipped with all available types of quench coolers. The GK6 cracking furnace is a large capacity furnace with high selectivity and large on-stream time characteristics at the lowest possible capital costs. The applied design tools and expertise contained in TECHNIP-COFLEXIP ETHYLENE TECHNOLOGY enables TECHNIP-COFLEXIP to offer its customers an optimized, tailor-made cracking furnace design at the LOWE LOWEST ST COS COST T OF OWNERSHIP for their specif spe cific ic nee need. d. GK ® and SMK ® are registered trademarks of TECHNIP-COFLEXIP.
PROGRESSIVE SEPARATION PROGRESSIVE SEPARATION technology is a stepwise separation of the lightest and the heaviest components in a multicomponent hydrocarbon mixture. It uses a series of condensate strippers that have only bottom product purity specifications. Hence, easy controllability and operability make multivariable optimizers redundant. The tailgas from the strippers is processed for recovery of valuable ethylene by self- contained cryogenic technology. technology. This concept lends itself well to revamp pro jects where where the standard package package can be implemented without extensively modifying the existing equipment. PROGRESSIVE SEPARA SEPARATION TION can be applied appl ied for the t he revamping of existing existing back- end and frontend hydrogenation schemes in relation to either high pressure or low pressure demethanizers. Due to the intrinsic autostability of new and revamped ethylene plants equipped with PROGRESSIVE SEPARATION, startup is extremely smooth and easy. New and revamped ethylene plants based on PROGRESSIVE SEPARATION have a track record of short start-up times, typically 24 hours from first feed intake to full operations. As one oper operator ator put it: “You start start it up up and and you experience a new feeling of comfort and ease”.
THE T- PAR PROC PROCESS ESS The ethylene recovery and purification process is energy and investment cost intensive. For large capacity gas or liquid feed crackers TECHNIP-COFLEXIP has developed a unique processing sequence centered on the efficient acetylene removal by either hydrogenation or liquid absorption. The main features of this process are: • Controlled acetylene hydrogenation avoiding runaway reaction and poisoning • Reduced equipment dimensions and piece count • Reduced compression machine size and power • Excellent control stability by process-to-process heat integration • Very competiti com petitive ve investment cost.
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Main steps involved in the Systematic Approach to Modernization
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ETHYLENE PLANT MODERNIZATION, CAPACITY CAP ACITY EXP EXPANSION ANSION AND REVAMP PROJECTS Ethylene plant modernization projects vary in scope and size. Existing cracking furnaces, even if they originate from a recent generation, may be redesigned to increase their ethylene capacity by some 20% to 100 % of original capacity. At the same time, specific feed consumption is drastically reduced, thereby contributing to an attractive low cost of production per ton of incremental ethylene. For complete modernization of existing ethylene plants, including revamp of the cracking section, compression and separation sections, TECHNIP-COFLEXIP offers a unique proven approach, applied successfully in several recent revamp projects.
THE SYSTEMATIC APPROACH APPROA CH TO MODERNIZATION The SYSTEMATIC APPROACH TO MODERNIZATION DERNIZA TION developed and applied by TECHNIP-COFLEXIP is a project oriented methodology which enables an indepth evaluation of the technology options and project implementation scenarios, leading to the most economical capacity expansion of the existing ethylene plant. With the application of the Systematic Approach to Modernization, bottlenecks in an existing plant are identified and prioritized such that a maximum return on a given investment is obtained.
The SYSTEMATIC APPROACH TO MODERNIZATION concept considers the ethylene plant to consist of a series of interrelated functional blocks. To determine the best capacity increase option versus energy demand and investment cost, to yield lowest cost of production per ton of incremental ethylene, each functional block can be evaluated separately on those three targets that are related to particular technical and economic aspects. The final result of the evaluation is an insight into the relationship
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Interrelated functional blocks of an ethylene plant
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between required investment cost and target capacity increase. This enables the choice of the best revamp scenario leading to incremental ethylene production at lowest cost.
IMPROVEMENT OF EXISTING CRACKING FURNACES When extra capacity is needed in an existing ethylene plant, to consider one or more additional furnaces seems to be the obvious choice. The recoiling or even complete modernization of existing furnaces however can be a more attractive option. Capital cost per ton of incremen incremental tal ethylene can be significantly reduced, and
furnace fuel consumption, as well as emissions (noise, NOx), can be brought into line with today’s standards. Many existing furnace designs of different origins have a large potential for extra ethylene output when a redesign is applied. This extra ethylene can be more than double, as is proven by recent real life revamp references. TECHNIP-COFLEXIP has the the tools and expertise to quantify this potential and to study the available revamp options in comparison with newly built furnace capacity. capacity. TECHNIP-COFLEXIP has executed TECHNIP-COFLEXIP executed many furnace conversion projects, resulting in minimum downtime requirements and minimum impact on existing plant operations.
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Insight into the relation between required investment cost and target capacity increase
OPERATIONS SUPPORT SERVIC SER VICES ES : e- OSS ® e-OSS ® : advanced technology for optimal operations of ethylene plants. Under e-OSS ® , TECHNIP-COFLEXIP is offering services based on recent advances in automation, control and information technologies that are dramatically impacting the economics of ethylene plants: Process observability • Use of Near Infrared Spectroscopy with the TOPNIR ® technology to measure at high frequency the naphtha feed properties, inclu including ding the PIONA distribution distribution per number of carbon atoms which is used by SPYRO ® .
• Real time data reconciliation using the DATREC technology to close mass and heat balances and detect abnormal behaviour of instrument instruments. s. Unattended operations • Use of field- bus, wireless equipment, equipment, smart sensors to automate most sequential operations.
• Abno rma l sit situat uation ion man manage agemen mentt to detect potentially hazardous situations before they escalate into incidents. • Equipment health management to remotely perform diagnosis of critical hardware. Optimal operations • Optimized scheduling of operations using the FORWARD technology: technology: Feeds sequencing, de-coking schedule, modes of operations.
• Overall plant accounting and losses monitoring using the GERA technology.
CLX Anti- coking Services Services ® CLX : On-line On- line pretreatment of radiant coil to improve cracking furnace performance. TECHNIP-COFLEXIP and ATOFINA, a subsidiary of TotalFinaElf, have developed a system to pretreat radiant coils of gascracking crac king furnaces. When applied, the furnace run-length run- length is dramatically improved and doubling of the run-length is proven to be achievable.
The CLX ® system is based upon a proprietary sulphur-silica organic component mixture and is well tested both on lab and pilot scales and on an industrial scale in ATOFINA's commercial installations. The CLX ® system is easy to apply apply.. The CLX ® ingredients are injected during a very short period in the dilution steam directly after the decoke cycle of a running furnace before next feed is taken in. The sys tem works optimally when followed by continuous DMDS dosing with the feed. The CLX ® system contains chemicals, which fall in the category of normal paraffins on the aspects of toxicity, safety and environment. The CLX ® system is exclusively available through TECHNIP-COFLEXIP for new furnace installations and through ATOFINA for existing installation installations. s. The service which is provided by ATOFINA consists of a dosing kit lease, CLX ® inhibitor, maintenance, training and hot line support.
ETHYLENE PLANT PROJECT EXECUTION TECHNIP-COFLEXIP is active in many areas of the petrochemi petrochemical cal industry. industry. For the ethylene production units, which form the heart of the petrochemical industry, TECHNIP-COFLEXIP executes grassroots and modernization projects worldwide. TECHNIP-COFLEXIP TECHNIP- COFLEXIP offers offers the full scope of engineering, procurement and construction services ranging from the execution of feasibility studies, FEED ( front end engineering and design) design ) packages, EPC (engineering, ( engineering, procurement procurement and construction) projects up to full LSTK (lump sum turn key) project responsibility. This also includes the supply of proprietary technology, the start-up capabilities for the olefins plant, its ancillary units and the associated off-sites and utility sections. TECHNIP-COFLEXIP has the process capabilities and resources to serve the industry through TECHNIP’s multiple offices in all parts of the world.
Project services offered by TECHNIP to satisfy the need of the customer are: • TECHNIP-COFLEXIP applies high standard safety related procedures in a constant dialog with the client to arrive at an intrinsically safe plant throughout all phases of the project, from basic design stage to start-up and plant hand-over. • TECHNIP-COFLEXIP’s recognized expertise in quality assurance and quality control procedures ensures the future plant operator is able to run a trouble free plant which is safe and reliable and which meets its production objectives from day one. TECHNIP-COFLEXIP is a world leader in executing projects under the LSTK ( lump sum turn key) contract type with or without financing constraints. TECHNIPCOFLEXIP’s global presence and access to international resources enable TECHNIP to include local knowledge and domestic capabilities in its projects teams, thus ensuring a smooth interface with the client.
• Financing support
• Procurement including purchasing, expediting and inspection
• Project management
• Construction
• Feasibility study
• Start-up services
• Conceptual design
• Environmental permitting
• Cost estimating
• HAZOP & HAZAN
• Project planning and scheduling
• Safety studies
• Front end engineering and design (FEED)
• Support in authority approval and permit procedures
• Detailed engineering of equipment, piping, civil, instrumentation, electrical and automation
Photographs: Photog raphs: Technip- Coflexip photo library, Synchro Copyright ®, X.
Coverr photo : Cove GK6 furnace.
Did you know that apples produce ethylene?
0 2 3 1 6 9 2 0 4 B e r r e t n a N S C R M U M I T L U
So does TECHNIP-COFLEXIP with its in-house technology
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