25
Appendix C Process Flow Diagrams
Appendix C Process Flow Diagrams
Acid Gas Removal
Once Furnace Hot Stand-by/Decoking
Five Furnaces Normal
Operations
Que
nch
Tow
er
Natural Gas Feeds
Recycle Feeds
Oxidizer Feeds
Product Feeds
Fuel Burning Equipment
Thermal Oxidizer
Figure C-1: Ethane Cracker Process Flow Diagram
C2 Cut C2 Splitter
Ethylene Storage
Deet
hani
zer De
met
hani
zer
C3 Splitter
Depr
opan
izer
Gasoline Storage De
buta
nize
r
Raw C4 Storage
C4 Cut
C5+
Acetylene Reactor
Ethane Recycle to Furnace
C3 Cut
Fresh Ethane CGC
5th Stage Dryers &
Chilling Train
Spent Caustic System
Pressure Swing Adsorption
Recycled H2
Recycled Tail Gas
CGC Stages 1-4
Propylene Storage
Propane Recycle to Furnace
Ethane Cracker Flares
Figure C-2: Ethane Cracker Emission Sources
Notes: 1. The Ethane Crackers ‘ fuel consists of a mixture of recycled tail gas (hydrogen rich) and natural gas
(methane), with a heating value of 523 Btu/scf. 2. Normal operation assumes five furnaces continuous operation and one furnace on hot stand-by or
decoking operations.
Emission Unit: Pyrolysis Furnace #1 - EC-PF-101
Cracked Gases
Ethane
Fuel: Tail Gas + Natural Gas
Emission Control: Ultra Low NOx Burners
To Atmosphere
Emission Unit: Pyrolysis Furnace #2 - EC-PF-102
Cracked Gases
Ethane
Fuel: Tail Gas + Natural Gas
Emission Control: Ultra Low NOx Burners
To Atmosphere
Emission Unit: Pyrolysis Furnace #3 - EC-PF-103
Cracked Gases
Ethane
Fuel: Tail Gas + Natural Gas
Emission Control: Ultra Low NOx Burners
To Atmosphere
Emission Unit: Pyrolysis Furnace #4 - EC-PF-104
Cracked Gases
Ethane
Fuel: Tail Gas + Natural Gas
Emission Control: Ultra Low NOx Burners
To Atmosphere
Emission Unit: Pyrolysis Furnace #5 - EC-PF-105
Cracked Gases
Ethane
Fuel: Tail Gas + Natural Gas
Emission Control: Ultra Low NOx Burners
To Atmosphere
Emission Unit: Pyrolysis Furnace #6 - EC-PF-106
Cracked Gases
Ethane
Fuel: Tail Gas + Natural Gas
Emission Control: Ultra Low NOx Burners
To Atmosphere
Figure C-3: Decoking Operations
Decoking Effluent
Fuel: Tail Gas + Natural Gas Furnace Fried at 30% Full Load
To Atmosphere
Steam/Air Mixture
Effluent sent to combustion chamber (i.e. Firebox)
Notes: 1. Max decoking firing time for all six furnaces is 864 hours per year @ 30% normal load (119 MMBtu/hr) 2. Decoking operations will occur a maximum of 12 events per year per furnace.
PURIFICATIONPA-PE-201
MAIN FLARE
EC-FL-101
Figure C-4A: Polyethylene Plant A Process Flow Diagram
Product Feeds
Vent Streams
Recycle Feeds
Flare Feeds
Fuel BurningEquipment
PM Pollution ControlDevices
POLYMERIZATIONPA-PE-202
PURGING AND VENTRECOVERY
PA-PE-203
EXTRUSION & PELLETIZING
PA-PE-204ETHYLENE
INERTHYDROCARBON
NITROGEN
Polyethylene
HYDROGEN
NITROGEN
PA-PE-301 PA-PE-302
PA-PE-304PA-PE-303
CATALYSTACTIVATOR
PA-CA-101
COMONOMER
PURIFICATIONPB-PE-201
POLYMERIZATIONPB-PE-202
PURGING AND VENTRECOVERY
PB-PE-203
EXTRUSION & PELLETIZING
PB-PE-204
ETHYLENE
INERTHYDROCARBON
COMONOMER
NITROGEN
POLYETHYLENE
HYDROGEN
NITROGEN
LOW PRESSURE
FLAREPB-FL-105
Figure C-4B: Polyethylene Plant B Process Flow Diagram
Product Feeds
Vent Streams
Recycle Feeds
Flare Feeds
Fuel BurningEquipment
PM PollutionControl Devices
PB-PE-301 PB-PE-302
PB-PE-303 PB-PE-304
COMPRESSIONPC-PE-201
POLYMERIZATIONPC-PE-202
EXTRUSION & PELLETIZING
PC-PE-204
ETHYLENE
COMONOMER
REGENERATIVE THERMAL OXIZIZER
PC-TO-102
Figure C-4C: Polyethylene Plant C Process Flow Diagram
Product Feeds
Vent Streams
Recycle Feeds
Waste Feeds
Oxidizer Feeds
Fuel BurningEquipment
PM PollutionControl Devices
COMONOMER
LIQUIDWASTE
WASTEWAXES
PELLETHANDLING
PC-PE-205
RECYCLED GAS TRANSPORTED TO CRACKER
DEGASSING & TRANSPORTATION
PC-PE-206
POLYETHYLENE
SEPARATIONPC-PE-203
PC-PE-301
PC-PE-302 PC-PE-303
Figure C-5: Cracker Thermal Oxidizer and RTO Emission Sources
Note: Each oxidizer has two emission sources associated with normal operation; (1) burner fuel combustion and (2) oxidization waste combustion
Emission Unit: Cracker Thermal Oxidizer EC-TO-101 Emission Controls: Low NOx Burners
Fuel and Waste Combustion Emissions
Waste Streams Natural gas
Emission Unit: Cracker Process Oxidizer Emissions EC-CP-101
Emission Unit: Regenerative Thermal Oxidizer PC-TO-102 Emission Controls: Low NOx Burners
Natural gas
Waste Streams
Emission Unit: PE Process - Oxidizer Emissions PC-TO-103
Fuel and Waste Combustion Emissions
Figure C-6: Flare Emission Sources Notes: Potential emissions from flares include natural gas pilot combustion and non-emergency pressure relief events.
To Atmosphere
Natural gas
Main Flare Emission Unit: EC-FL-101
Pressure Relief Stream
To Atmosphere
Natural gas
Low Pressure Flare Emission Unit: PB-FL-105
Pressure Relief Stream
To Atmosphere
Natural gas
Cracker Storage Flare Emission Unit: EC-FL-103
Pressure Relief Stream
To Atmosphere
Natural gas
Oxygen Flare Emission Unit: EC-FL-104
Pressure Relief Stream
To Atmosphere
Natural gas
Ethylene Storage Flare Emission Unit: EC-FL-102
Pressure Relief Stream
Figure C-7: Cogeneration Combustion Turbine and HRSG Emission Sources
Notes: Combustion Turbine model number : GE 7EA
Emission Unit: HRSG Duct Burner SU-GT-102 Emission Controls: SCR and Oxidation Catalyst
To Atmosphere
NG Fuel
Emission Unit: Gas Combustion Turbine SU-GT-101 Emission Controls: SCR and Oxidation Catalyst
Steam Turbine
HRSG Duct Burner
Compressor Combustion Turbine
Combustion
NG Fuel
Figure C-8: Auxiliary Boilers and Cooing Tower Emission Sources
Notes: ULNB – Ultra Low NOx Burners FGR – Flue Gas Recirculation PM – Particulate Matter
Emission Unit Auxiliary Boiler #1 SU-AB-101 Emission Controls: ULNB & FGR
To Atmosphere
Natural gas
Emission Unit Auxiliary Boiler #2 SU-AB-102 Emission Controls: ULNB & FGR
To Atmosphere
Natural gas
PM/PM10/PM2.5 and VOC fugitive emissions to atmosphere
Emission Unit: Cooling Tower SU-CT-101 Emission Controls: High-efficiency Drift Eliminator
Make-up Cooling Water
Figure C-9: Wastewater Treatment Plant Process Flow Diagram
Oily Water Storage Tank
CPI
DAF
Sludge Dewatering
EQ Tank Aeration Basin MBBR
Sanitary Lift Station
Pretreated Spent Caustic Flare Hydraulic Seal
PE/Logistics Effluents ISBL Effluents
Sanitary Waste
Oily Process Wastewater
Effluent to River
Emission Points
Other Process Wastewater Influent
Sludge
Notes: CPI – Chemical-Physical Treatment Unit DAF – Dissolved Air Flotation Unit MBBR - Membrane Biological Reactor EQ Tank - Equalization Tank
Mix Tank
Oily Water Lift Station
ULSD Fuel
Emission Point to atmosphere
Emission Unit
Figure C-10: Internal Combustion Engine Emission Sources
Notes: EG – Emergency Generator FP – Firewater Pump PE - Polyethylene WWTP – Wastewater Treatment Plant
SU-EG-101
Cracker Plant EG - 2800 kW
SU-EG-102
PE Plant A EG - 2800 kW
SU-EG-103
PE Plant C EG - 2800 kW
SU-EG-104
PE Plant B EG - 2800 kW
SU-EG-105
Utility #1 EG - 2800 kW
SU-EG-106
Utility #2 EG - 2800 kW
SU-EG-107
WWTP EG - 2800 kW
Cooling Water Area - 350 kW
SU-EG-108
Product Storage- 350 kW
SU-EG-109
Firewater Pump #1- 485 kW
Firewater Pump #2- 485 kW
Firewater Pump #3- 485 kW
SU-FP-101
SU-FP-102
SU-FP-103
