Technip Ethylene

8/20/2019 Technip Ethylene

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A FULL-SERVICE ETHYLENE PRODUCT LINE


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TECHNIP-COFLEXIP

ETHYLENE TECHNOLOGY

TECHNIP-COFLEXIP offers the ethylene manufacturing industry SINGLE-

SOURCE PROJECT 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

• THE T-PAR® PROCESS

• OPERATIONS SUPPORT SERVICES: e -OSS ®

- CLX ® anti-coking services developed jointly with ATOFINA of France,

- Unattended operations concepts.

And for capacity expansion of existing 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 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 TECHNIP-

COFLEXIP.


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Simulation of a largecapacity furnace

THE SPYRO ® FURNACE DESIGN AND

OPTIMIZATION SOFTWARE

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 sys-

tem software. The application of the proven

SPYRO® program provides detailed infor-

mation on yields and furnace availability

which can also be used to set up revamp

scenarios for the furnace and downstreamsections of the plant.

For optimum design of largecapacity

GK®, and SMK®, cracking furnaces, TECH-

NIP-COFLEXIP applies SPYRO ® linked

with CFD (computational fluid dynamics),

enabling the best design of burner arran-

gement, cracking coil layout and flue gas

ducting.

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 se-

lected. 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 fire-

box design.

TECHNIP-COFLEXIP ETHYLENE TECH-

NOLOGY makes use of TECHNIP’s pro-prietary 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 in close cooperation with

the original authors of the program, theteam of Professor Dente in Milan.


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THE TECHNIP-COFLEXIP

CRACKING FURNACE

TECHNIP-COFLEXIP CRACKING FUR-

NACES use the proven high selective,

short residence time coils of the GK ® and

SMK® types (originally developed by KTI ® ).

The Cracking Coils of GK®

and SMK®

fur-naces are tailored to the specific needs

of the ethylene plant. Normally these are

geared towards the maximum production

of the light olefins, ethylene and propylene.

Additionally, for liquid crackers integrated

with downstream production units,

requirements such as maximum BTX

co-production and feed/products flexi-

bility are also important parameters for

an optimal coil design.

TECHNIP-COFLEXIP CRACKING FUR-NACES 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 coun-

try 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 FUR-

NACES feature shell-and-tube TLE’s

(transfer line exchangers) as well as dou-

ble pipe direct quench coolers. High on-

stream time is achieved by minimizingmechanical decoke cycles of the TLE’s.

In 1999 TECHNIP introduced the GK6 fur-

nace. The GK6 furnace features an 8-8

cracking coil configuration. The GK6 fur-

nace can be equipped with all available

types of quench coolers.

The GK6 cracking furnace is a large capa-

city furnace with high selectivity and large

on-stream time characteristics at the

lowest possible capital costs. The applieddesign tools and expertise contained in

TECHNIP-COFLEXIP ETHYLENE TECH-

NOLOGY enables TECHNIP-COFLEXIP

to offer its customers an optimized,

tailor-made cracking furnace design

at the LOWEST COST OF

OWNERSHIP for their

specific need.

GK ® and SMK ® are

registered trademarks

of TECHNIP-COFLEXIP.


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THE T-PAR PROCESS

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 absorp-

tion. The main features of this process are:

• Controlled acetylene hydrogenation

avoiding runaway reaction and poisoning

• Reduced equipment dimensions andpiece count

• Reduced compression machine size

and power

• Excellent control stability by

process-to-process

heat integration

• Very competitive

investment cost.

PROGRESSIVE

SEPARATION

PROGRESSIVE SEPARATION technology

is a stepwise separation of the lightest

and the heaviest components in a multi-

component hydrocarbon mixture. It uses

a series of condensate strippers that haveonly bottom product purity specifications.

Hence, easy controllability and operability

make multivariable optimizers redundant.

The tailgas from the strippers is proces-

sed for recovery of valuable ethylene by

self-contained cryogenic technology. This

concept lends itself well to revamp pro-

jects where the standard package can be

implemented without extensively modi-

fying the existing equipment. PROGRES-

SIVE SEPARATION can be applied for the

revamping of existing back-end and front-

end hydrogenation schemes in relation to

either high pressure or low pressure deme-

thanizers.

Due to the intrinsic autostability of new

and revamped ethylene plants equipped

with PROGRESSIVE SEPARATION, start-

up 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 opera-

tions.

As one operator put it: “You start it up and

you experience a new feeling of comfort

and ease”.


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ETHYLENE PLANT

MODERNIZATION,

CAPACITY EXPANSION

AND REVAMP PROJECTS

Ethylene plant modernization projects vary

in scope and size. Existing cracking fur-

naces, 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 dras-

tically 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 pro-

ven approach, applied successfully inseveral recent revamp projects.

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Main steps involvedin the Systematic Approachto Modernization

THE SYSTEMATIC

APPROACH

TO MODERNIZATION

The SYSTEMATIC APPROACH TO MO-

DERNIZATION 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 expan-

sion 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 invest-ment is obtained.

The SYSTEMATIC APPROACH TO MO-

DERNIZATION 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 invest-

ment cost, to yield lowest cost of pro-

duction per ton of incremental ethylene,

each functional block can be evaluatedseparately on those three targets that are

related to particular technical and econo-

mic aspects. The final result of the eva-

luation is an insight into the relationship


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Interrelated functionalblocks of an ethylene plant

between required investment cost and

target capacity increase. This enables the

choice of the best revamp scenario lea-

ding 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 fur-

naces however can be a more attractive

option.

Capital cost per ton of incremental ethy-

lene 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 ethy-

lene 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 tools and

expertise to quantify this potential and to

study the available revamp options in com-

parison with newly built furnace capacity.

TECHNIP-COFLEXIP has executed many

furnace conversion projects, resulting in

minimum downtime requirements and

minimum impact on existing plant opera-

tions.

Insight into the relation betweenrequired investment costand target capacity increase


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OPERATIONS SUPPORT

SERVICES: e- OSS ®

e-OSS ®: advanced technology for optimal

operations of ethylene plants.

Under e-OSS ®, TECHNIP-COFLEXIP is

offering services based on recent advan-

ces in automation, control and information

technologies that are dramatically impac-

ting the economics of ethylene plants:

Process observability• Use of Near Infrared Spectroscopy with

the TOPNIR ® technology to measure at

high frequency the naphtha feed proper-

ties, including the PIONA 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 beha-

viour of instruments.

Unattended operations

• Use of field-bus, wireless equipment,

smart sensors to automate most sequen-

tial operations.

• Abnormal situation management to

detect potentially hazardous situations

before they escalate into incidents.

• Equipment health management to remo-

tely perform diagnosis of critical hardware.

Optimal operations

• Optimized scheduling of operationsusing the FORWARD technology: Feeds

sequencing, de-coking schedule, modes

of operations.

• Overall plant accounting and losses

monitoring using the GERA technology.

CLX Anti-coking Services

CLX®: On-line pretreatment of radiant coil

to improve cracking furnace performance.

TECHNIP-COFLEXIP and ATOFINA, a sub-

sidiary of TotalFinaElf, have developed a

system to pretreat radiant coils of gas-

cracking furnaces. When applied, the fur-

nace run-length is dramatically improvedand doubling of the run-length is proven

to be achievable.

The CLX ® system is based upon a pro-

prietary 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. 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 system

works optimally when followed by conti-

nuous DMDS dosing with the feed.

The CLX ® system contains chemicals,

which fall in the category of normal pa-

raffins on the aspects of toxicity, safety

and environment.

The CLX® system is exclusively available

through TECHNIP-COFLEXIP for new fur-

nace installations and through ATOFINA for existing installations.

The service which is provided by ATO-

FINA consists of a dosing kit lease, CLX ®

inhibitor, maintenance, training and hot

line support.


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ETHYLENE PLANT

PROJECT EXECUTION

TECHNIP-COFLEXIP is active in many

areas of the petrochemical industry. For

the ethylene production units, which form

the heart of the petrochemical industry,

TECHNIP-COFLEXIP executes grass-

roots and modernization projects world-

wide. TECHNIP-COFLEXIP offers the full

scope of engineering, procurement andconstruction services ranging from the

execution of feasibility studies, FEED

( front end engineering and design) pack-

ages, EPC (engineering, procurement and

construction) projects up to full LSTK

(lump sum turn key) project responsibility.

This also includes the supply of proprie-

tary technology, the start-up capabilities

for the olefins plant, its ancillary units and

the associated off-sites and utility sec-

tions. TECHNIP-COFLEXIP has the pro-

cess 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 stan-

dard safety related procedures in a cons-

tant dialog with the client to arrive at an

intrinsically safe plant throughout all pha-

ses of the project, from basic design stage

to start-up and plant hand-over.

• TECHNIP-COFLEXIP’s recognized ex-

pertise 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 with-

out financing constraints. TECHNIP-

COFLEXIP’s global presence and access

to international resources enable TECHNIP

to include local knowledge and domestic

capabilities in its projects teams, thus en-

suring a smooth interface with the client.

• Financing support

• Project management

• Feasibility study

• Conceptual design

• Cost estimating

• Project planning and scheduling• Front end engineering and design

(FEED)

• Detailed engineering of equipment,

piping, civil, instrumentation, electrical

and automation

• Procurement including purchasing,

expediting and inspection

• Construction

• Start-up services

• Environmental permitting

• HAZOP & HAZAN

• Safety studies• Support in authority approval and

permit procedures


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Photographs:Technip-Coflexip photo library, Synchro Copyright ®, X.

Cover photo:GK6 furnace.


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Did you know

that apples

produce

ethylene?

So does TECHNIP-COFLEXIP with its in-house technology

U L T I M U M -

R C S N a n t e r r e B 4 0 2 9 6 1 3 2 0


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TECHNIP-COFLEXIP

Tour Technip - La Défense 692973 Paris La Défense cedexPhone: + 33 1 47 78 21 21

Fax: + 33 1 47 78 33 40

TECHNIP FRANCE

Phone: + 33 1 47 78 21 21Fax: + 33 1 47 78 33 40

TECHNIP ITALY

Phone: + 39 06 65981Fax: + 39 06 655 1402

TECHNIP BENELUX BV

Phone: + 31 79 329 36 00Fax: + 31 79 351 35 61

TECHNIP GERMANY

Phone: + 49 211 659-1

Fax: + 49 211 659-3264

TECHNIP MALAYSIA

Phone: + 60 3 21 16 78 88Fax: + 60 3 21 16 79 99

TECHNIP USA CORP.

Phone: + 1 713 548 4000Fax: + 1 713 548 4013

Phone: + 1 909 592 4455Fax: + 1 909 592 3399

www.technip-coflexip.com

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Technip Ethylene

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