Process Software Platform Steam Cracking Furnaces
Tailored workspaces—optimized facility Symmetry
Intelligent Simulation and Optimization of Steam Cracking FurnacesSymmetry*, a process software platform, is a comprehensive simulator that empowers all aspects of your models from reservoir to product distribution.
The Symmetry platform’s steam cracking furnaces are thermal cracking models that include rigorous kinetic reactions where a wide range of feeds—from light hydrocarbons, such as ethane, all the way to vacuum residues—are heated. The resulting changes in composition due to cracking and other reactions are tracked at every point of the coil(s), all while calculating coke growth rate simultaneously. Furnace simulation enables the optimization of ethylene production in the case of lighter feeds and rigorously predicts the effect of feed compositions and process conditions on coke formation and therefore service time runs.
Tailored workspaces—optimized facility Symmetry
FeedstocksSelection
YieldPrediction
TotalOptimization
Coke GrowthPrediction
FriendlyInterface
■ Paraffins, isoparaffins, olefins, naphthenes, and aromatics (PIONA) molecular structure environment
■ Feedstock selection and blending optimization ■ Easy matching of plant operating data ■ Seamless integration of cracking furnaces and product separation ■ Geometry input for radiant box and convection sections ■ User-friendly Excel interface ■ Rigorous coke growth and service time prediction ■ Multiple cracking furnace scheduling
User-Friendly InterfaceUsers can easily link the Symmetry platform to Excel using our built-in Excel Unit Operation which eliminates the need to write code.
Additionally, the Symmetry platform includes a Component Object Model (COM) link layer which provides a customizable interface that enables you to interact directly with the process simulator without the GUI. This can be used to link the Symmetry platform with any COM-compliant application such as Excel, Visual Basic, C++, Python, and many others.
PIONA Molecular Structure TechnologyHydrocarbon fluids are complex mixtures of many chemical species. This poses a challenge for characterization using conventional methods, where hypothetical components need to be created for each sample, blends, and product.
The Symmetry platform’s PIONA molecular-structure-characterization approach represents hydrocarbon fluids in terms of chemical families and carbon number. We can rigorously capture the essential chemistry of the fluids and blends to calculate chemical and physical properties. This approach can also mechanistically predict kinetic rates using only a limited number of components. This enables you to perform highly accurate feed blending studies, including reaction kinetics prediction.
8 Cur Row = 170 Tube Coil Inlet = 0.02 mm Case Name = SteamCrackingFurnace-C2-C3.vsymRow = 171 Tube Pass 2 = 7.64 mm
LastRow = 500 Tube Pass 4 = 7.98 mm Number of service runs = 8Tube Coil Outlet = 13.61 mm Service Run Profit = 37561
Max Coil DP = 150.0 kPa *Unit conversion:Max Tube T = 1093.3 C y = BIAS + x*MULT (from data to model) Time Step = 6
Run Length 39COKE COKE COKE COKE COKE COKE COKE COKE MAX MAX
Description "Fixed" "Fixed" "Fixed" "Fixed" "Fixed" "Fixed" "Fixed" "Fixed" "Constraint""Constraint"Tag Name Coil Inlet Pass 6 Pass 7 Coil Outlet Coil Inlet Pass 6 Pass 7 Coil OutletCoil DP Tube TUnit BiasUnit Mult
Units (Y/N) mm mm mm mm mm/day mm/day mm/day mm/day kPa C01-Jan-19 00:00:00 No 0.0 0.0 0.0 0.0 0.00 1.80 1.90 3.50 102.0 965.001-Jan-19 06:00:00 No 0.0 0.5 0.5 0.9 0.00 0.19 0.19 0.36 103.6 975.301-Jan-19 12:00:00 No 0.0 0.5 0.5 1.0 0.00 0.19 0.19 0.36 103.9 976.301-Jan-19 18:00:00 No 0.0 0.6 0.6 1.1 0.00 0.19 0.19 0.36 104.1 977.302-Jan-19 00:00:00 No 0.0 0.6 0.6 1.2 0.00 0.19 0.20 0.36 104.4 978.402-Jan-19 06:00:00 No 0.0 0.7 0.7 1.3 0.00 0.19 0.19 0.36 104.6 979.302-Jan-19 12:00:00 No 0.0 0.7 0.7 1.3 0.00 0.19 0.20 0.36 104.9 980.402-Jan-19 18:00:00 No 0.0 0.7 0.8 1.4 0.00 0.19 0.19 0.35 105.1 981.303-Jan-19 00:00:00 No 0.0 0.8 0.8 1.5 0.00 0.19 0.20 0.36 105.4 982.403-Jan-19 06:00:00 No 0.0 0.8 0.9 1.6 0.00 0.19 0.20 0.36 104.9 983.303-Jan-19 12:00:00 No 0.0 0.9 0.9 1.7 0.00 0.19 0.20 0.36 105.1 984.303-Jan-19 18:00:00 No 0.0 0.9 1.0 1.8 0.00 0.19 0.20 0.36 105.4 985.304-Jan-19 00:00:00 No 0.0 1.0 1.0 1.9 0.00 0.19 0.20 0.36 105.6 986.304-Jan-19 06:00:00 No 0.0 1.0 1.1 2.0 0.00 0.19 0.20 0.35 105.8 987.204-Jan-19 12:00:00 No 0.0 1.1 1.1 2.1 0.00 0.19 0.20 0.35 106.1 988.104-Jan-19 18:00:00 No 0.0 1.1 1.2 2.1 0.00 0.19 0.20 0.35 106.3 989.105-Jan-19 00:00:00 No 0.0 1.2 1.2 2.2 0.00 0.19 0.20 0.35 106.6 990.105-Jan-19 06:00:00 No 0.0 1.2 1.3 2.3 0.00 0.19 0.20 0.35 106.8 990.9
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8 Cur Row = 170 Tube Coil Inlet = 0.02 mm Case Name = SteamCrackingFurnace-C2-C3.vsymRow = 171 Tube Pass 2 = 7.64 mm
LastRow = 500 Tube Pass 4 = 7.98 mm Number of service runs = 8Tube Coil Outlet = 13.61 mm Service Run Profit = 37561
Max Coil DP = 150.0 kPa *Unit conversion:Max Tube T = 1093.3 C y = BIAS + x*MULT (from data to model) Time Step = 6
Run Length 39COKE COKE COKE COKE COKE COKE COKE COKE MAX MAX
Description "Fixed" "Fixed" "Fixed" "Fixed" "Fixed" "Fixed" "Fixed" "Fixed" "Constraint""Constraint"Tag Name Coil Inlet Pass 6 Pass 7 Coil Outlet Coil Inlet Pass 6 Pass 7 Coil OutletCoil DP Tube TUnit BiasUnit Mult
Units (Y/N) mm mm mm mm mm/day mm/day mm/day mm/day kPa C01-Jan-19 00:00:00 No 0.0 0.0 0.0 0.0 0.00 1.80 1.90 3.50 102.0 965.001-Jan-19 06:00:00 No 0.0 0.5 0.5 0.9 0.00 0.19 0.19 0.36 103.6 975.301-Jan-19 12:00:00 No 0.0 0.5 0.5 1.0 0.00 0.19 0.19 0.36 103.9 976.301-Jan-19 18:00:00 No 0.0 0.6 0.6 1.1 0.00 0.19 0.19 0.36 104.1 977.302-Jan-19 00:00:00 No 0.0 0.6 0.6 1.2 0.00 0.19 0.20 0.36 104.4 978.402-Jan-19 06:00:00 No 0.0 0.7 0.7 1.3 0.00 0.19 0.19 0.36 104.6 979.302-Jan-19 12:00:00 No 0.0 0.7 0.7 1.3 0.00 0.19 0.20 0.36 104.9 980.402-Jan-19 18:00:00 No 0.0 0.7 0.8 1.4 0.00 0.19 0.19 0.35 105.1 981.303-Jan-19 00:00:00 No 0.0 0.8 0.8 1.5 0.00 0.19 0.20 0.36 105.4 982.403-Jan-19 06:00:00 No 0.0 0.8 0.9 1.6 0.00 0.19 0.20 0.36 104.9 983.303-Jan-19 12:00:00 No 0.0 0.9 0.9 1.7 0.00 0.19 0.20 0.36 105.1 984.303-Jan-19 18:00:00 No 0.0 0.9 1.0 1.8 0.00 0.19 0.20 0.36 105.4 985.304-Jan-19 00:00:00 No 0.0 1.0 1.0 1.9 0.00 0.19 0.20 0.36 105.6 986.304-Jan-19 06:00:00 No 0.0 1.0 1.1 2.0 0.00 0.19 0.20 0.35 105.8 987.204-Jan-19 12:00:00 No 0.0 1.1 1.1 2.1 0.00 0.19 0.20 0.35 106.1 988.104-Jan-19 18:00:00 No 0.0 1.1 1.2 2.1 0.00 0.19 0.20 0.35 106.3 989.105-Jan-19 00:00:00 No 0.0 1.2 1.2 2.2 0.00 0.19 0.20 0.35 106.6 990.105-Jan-19 06:00:00 No 0.0 1.2 1.3 2.3 0.00 0.19 0.20 0.35 106.8 990.9
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8 Cur Row = 170 Tube Coil Inlet = 0.02 mm Case Name = SteamCrackingFurnace-C2-C3.vsymRow = 171 Tube Pass 2 = 7.64 mm
LastRow = 500 Tube Pass 4 = 7.98 mm Number of service runs = 8Tube Coil Outlet = 13.61 mm Service Run Profit = 37561
Max Coil DP = 150.0 kPa *Unit conversion:Max Tube T = 1093.3 C y = BIAS + x*MULT (from data to model) Time Step = 6
Run Length 39COKE COKE COKE COKE COKE COKE COKE COKE MAX MAX
Description "Fixed" "Fixed" "Fixed" "Fixed" "Fixed" "Fixed" "Fixed" "Fixed" "Constraint""Constraint"Tag Name Coil Inlet Pass 6 Pass 7 Coil Outlet Coil Inlet Pass 6 Pass 7 Coil OutletCoil DP Tube TUnit BiasUnit Mult
Units (Y/N) mm mm mm mm mm/day mm/day mm/day mm/day kPa C01-Jan-19 00:00:00 No 0.0 0.0 0.0 0.0 0.00 1.80 1.90 3.50 102.0 965.001-Jan-19 06:00:00 No 0.0 0.5 0.5 0.9 0.00 0.19 0.19 0.36 103.6 975.301-Jan-19 12:00:00 No 0.0 0.5 0.5 1.0 0.00 0.19 0.19 0.36 103.9 976.301-Jan-19 18:00:00 No 0.0 0.6 0.6 1.1 0.00 0.19 0.19 0.36 104.1 977.302-Jan-19 00:00:00 No 0.0 0.6 0.6 1.2 0.00 0.19 0.20 0.36 104.4 978.402-Jan-19 06:00:00 No 0.0 0.7 0.7 1.3 0.00 0.19 0.19 0.36 104.6 979.302-Jan-19 12:00:00 No 0.0 0.7 0.7 1.3 0.00 0.19 0.20 0.36 104.9 980.402-Jan-19 18:00:00 No 0.0 0.7 0.8 1.4 0.00 0.19 0.19 0.35 105.1 981.303-Jan-19 00:00:00 No 0.0 0.8 0.8 1.5 0.00 0.19 0.20 0.36 105.4 982.403-Jan-19 06:00:00 No 0.0 0.8 0.9 1.6 0.00 0.19 0.20 0.36 104.9 983.303-Jan-19 12:00:00 No 0.0 0.9 0.9 1.7 0.00 0.19 0.20 0.36 105.1 984.303-Jan-19 18:00:00 No 0.0 0.9 1.0 1.8 0.00 0.19 0.20 0.36 105.4 985.304-Jan-19 00:00:00 No 0.0 1.0 1.0 1.9 0.00 0.19 0.20 0.36 105.6 986.304-Jan-19 06:00:00 No 0.0 1.0 1.1 2.0 0.00 0.19 0.20 0.35 105.8 987.204-Jan-19 12:00:00 No 0.0 1.1 1.1 2.1 0.00 0.19 0.20 0.35 106.1 988.104-Jan-19 18:00:00 No 0.0 1.1 1.2 2.1 0.00 0.19 0.20 0.35 106.3 989.105-Jan-19 00:00:00 No 0.0 1.2 1.2 2.2 0.00 0.19 0.20 0.35 106.6 990.105-Jan-19 06:00:00 No 0.0 1.2 1.3 2.3 0.00 0.19 0.20 0.35 106.8 990.9
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Hydrocarbon fluids are complex mixtures of many chemical species. This poses a challenge for characteriza�on using conven�onal methods,
where hypothe�cal components need to be created for each sample, blends and products.
Symmetry’ s PIONA molecular structure characteriza�on approach represents hydrocarbon fluids in terms of chemical families and carbon
number. The structures used are the PIONA group: Paraffins, iso-Paraffins, Olefins, Naphthenes and different forms of Aroma�cs. We can
capture the essen�al chemistry of the fluids and blends rigorously to calculate chemical and physical proper�es. This approach can also
mechanis�cally predict kine�c rates using only a limited number of components. This allows the user to perform highly accurate feed blending
studies, including reac�on kine�cs predic�on.
P I O N A A-Dehyd
A-S,N,V
C1C2
C[3-4]C[5-6]
C[7-8]C[9-11]C[12-14]
C[15-17]C[18-20]
C[21-24]C[25-28]
C29+P I O N A A-
Dehyd
A-S,N,V
C1C2
C[3-4]C[5-6]
C[7-8]C[9-11]C[12-14]
C[15-17]C[18-20]
C[21-24]C[25-28]
C29+ P I O N A A-Dehyd
A-S,N,V
C1C2
C[3-4]C[5-6]
C[7-8]C[9-11]C[12-14]
C[15-17]C[18-20]
C[21-24]C[25-28]
C29+
P I O N A A-Dehyd
A-S,N,V
C1C2
C[3-4]C[5-6]
C[7-8]C[9-11]C[12-14]
C[15-17]C[18-20]
C[21-24]C[25-28]
C29+P I O N A A-
Dehyd
A-S,N,V
C1C2
C[3-4]C[5-6]
C[7-8]C[9-11]C[12-14]
C[15-17]C[18-20]
C[21-24]C[25-28]
C29+
P I O N A A-Dehyd
A-S,N,V
C1C2
C[3-4]C[5-6]
C[7-8]C[9-11]C[12-14]
C[15-17]C[18-20]
C[21-24]C[25-28]
C29+
Ethane
Naphtha Gas Oil
Propane C4LPGBlending Feed
Service time study.
Cracking furnace feed blending.
Custom Furnace Geometry InputThe PIONA molecular-structure-characterization approach opens the door for rigorous reaction kinetics prediction. The cracking furnace’s rigorous kinetic engine can describe any reaction pathway, including PIONA-based coke growth. Based on the detailed geometry input for both the radiant box and convection sections, the Symmetry platform will calculate the product yields, radiant/convection heat transfer, and pressure drop. This enables you to study and optimize the operation of cracking furnaces accounting for continuous coke formation across all furnace sections.
Rigorous Coke Growth PredictionThe Symmetry platform’s coke growth prediction accounts for the different factors that could cause reduced service run times over the lifespan of a coil. The cracking furnace unit considers reduced tube cross section, heat flux, and yield changes as coke is formed. Coke also causes an increase in pressure drop and metal tube temperatures, reducing service time.
Naphtha_I
Naphtha_II
Naphtha_III
M_Feed
NaphthaFeed_Preheat
BFW_Preheat
MPreheatBFW
Exhaust
M1
Set_Steam
Super_Heater
Preheat
SHP
Blowdown
HP_Stm
Steam_Drum
ETH1
Fuel_burner
~Feed
Bridge_Wall
TLE
Effluent_to_TLE
Product
Hot_BFWSteam
Simplified convec�on
sec�on
Rigorous convec�on
sec�on
Feed blending
Cracking furnace
H2P C1
P C2O C2
O C3O C4
O C5N C3
N C4N C5
N C6A C6
A C7A C8
A C9A(dh) C9A(dh) C10+
0
5
10
15
20
25
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61
Tube Inlet
Tube Outlet
EthylenePropylene
Naphtha_I
Naphtha_II
Naphtha_III
M_Feed
NaphthaFeed_Preheat
BFW_Preheat
MPreheatBFW
Exhaust
M1
Set_Steam
Super_Heater
Preheat
SHP
Blowdown
HP_Stm
Steam_Drum
ETH1
Fuel_burner
~Feed
Bridge_Wall
TLE
Effluent_to_TLE
Product
Hot_BFWSteam
Simplified convec�on
sec�on
Rigorous convec�on
sec�on
Feed blending
Cracking furnace
H2P C1
P C2O C2
O C3O C4
O C5N C3
N C4N C5
N C6A C6
A C7A C8
A C9A(dh) C9A(dh) C10+
0
5
10
15
20
25
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61
Tube Inlet
Tube Outlet
EthylenePropylene
Aluminum coa�ng effect
800830
860890
920950
0.0
0.2
0.4
0.6
0.8
1.0
Uni
t Of C
oke
Form
ed
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0 5 10 15 20 25 30 35 40 45
Service Time [%]
Coke
Thi
ckne
ss [%
]
no coa�ng
Al coa�ng
Cracking furnace in a full simulation environment.
Coke growth kinetic model.
Naphtha feed molecular profiles.
Coke forma�on surface temperature -18 C
Heat transfer model.
Furnace SchedulingThe Symmetry platform’s rigorous yield prediction and simultaneous heat transfer and coke growth solution enables optimization studies on cracking furnace operation scheduling.
Total Ethylene Plant ModelThe Symmetry platform’s comprehensive and user-friendly process simulator enables seamless integration between different processes; it can model a complete ethylene plant in only one flowsheet. The use of rigorous thermodynamics enables proper hydrocarbon-water solubility trending in the quench section and also enables hydrate formation prediction in the cold-box section.
Symmetry’ s rigorous yield predic�on and simultaneous solu�on of heat transfer and coke growth allows for op�miza�on studies on cracking
furnace opera�on scheduling.
1-Ja
n-19
3-Ja
n-19
5-Ja
n-19
7-Ja
n-19
9-Ja
n-19
11-J
an-1
913
-Jan
-19
15-J
an-1
917
-Jan
-19
19-J
an-1
921
-Jan
-19
23-J
an-1
925
-Jan
-19
27-J
an-1
929
-Jan
-19
31-J
an-1
92-
Feb-
194-
Feb-
196-
Feb-
198-
Feb-
1910
-Feb
-19
12-F
eb-1
914
-Feb
-19
16-F
eb-1
918
-Feb
-19
20-F
eb-1
922
-Feb
-19
Furnace DecockingTime [d]
COTOffset [°C]
Start Date Total RunLength [d]
Profits[units]
13 0 1-Jan-19 39 37929 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 10 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
13 -3 14-Jan-19 39 37561 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 10 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
13 -6 27-Jan-19 39 14494 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 10 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
13 -5 10-Feb-19 40 -961 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1
No. Unit Running 1 1 1 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3
C2
C2-C3
Naphtha
Heavy-Naphtha
Run All
Run C2 Furnace
Run C2-C3 Furnace
Run Naphtha Furnace
Run Heavy Naphtha Furnace
DC
DC
DC
E-g3E-g2E-g1
E-q4
E-Q3
C-Q2
T-deC2
T-C3_Splitter
T-DC3
T-C2Splitter
Sep-c4
M2
SepLLV2
T4
Sep-g2
CP1
T1
SQ-6
S-Q3
SQ-4
SQ-5
T2
S-Q8S-Q9
~S-Q7
T3
S-Q18
S-Q12
SepLLV1
S-Q13
S-Q19
S-Q20
S-Q16
S-Q13Mass Flow 18143.64 [ton(metric)/d]
S-Q14
SP2
~S-Q10
S-Q17
S-Q15
S-g3
S-g4
S-g5
Sg-8
Sep-g3
SC-9CP2
S-g6 S-g12
Sep-g4
S-g13CP3
S-g10 S-g16
CP4
S-g14
M1S-g7
S-g11
S-g18S-g19
S-g20
S-g21
SP3
S-g23
~S-g2
S-C22
SQ-21
S-g24
Sg-25
Sep-g1
S-g15
S-g1
Ethane
Exhaust
Steam
BFW
Hot_BFW
Blowdown Product
Fuel
~Hot_Feed
SHP
HP_Stm
Flame
Feed
M1_1
Brn1
Feed_Preheat
BFW_Preheat
MPreheat
Super_Heater
Preheat
SRT4211
V1
Air
Set_Steam
TLE
EffluentBridge_Wall
Steam_Drum
1_C2-FurnaceMixed_Feed
C2_Furnaces
Ethane_Furnace_Count
NaphthaNap_Feed
Feed_Preheat_1
BFW_Preheat_1
MPreheat_1BFW_1
Exhaust_1
M1_2
Set_Steam_1
Super_Heater_1
Preheat_1
SHP_1
Blowdown_1
HP_Stm_1
Steam_Drum_1
SW8
Fuel_burner
~Feed_1
Bridge_Wall_1
TLE_1
Effluent_to_TLE
Product_1
Hot_BFW_1Steam_1
Ethane_Furnace_CountFurnace Count *22.00 [Fraction]
M3
Naphtha_Furnace_Count
1_Nap-Furnace
Nap_Furnaces
Naphtha_Furnace_CountFurnace Count *22.00 [Fraction]
E-Q1
RXN
CRx1
E2E1_2E1_1E1E-g4
Sep-g5
Sep-c1
E-c2E-c1
T-deC1
S-c1 S-c8
S-g17 S-c16
S-c17
S-c18
S-c12
S-c2
S-c27
L-Drier
S-c3
V-Drier
S-c23
Sep-c2
S-c10
S-c9
S-c24
S-c4
S-c20
S2-c32
S-C21
S-c33_C1
S-c22_H2
S-c19
S-c5
S-c6
S-c7M1_3
S-c11
E-c3
S-c13
Sep-c3
S-c15
S-c14
M3_1S-d5S-d4
T-deC2Acet_TOP_Recov 100 [%]
S-d3
S-d3C2== 6.9 [ppm]
S-d6
S-c30S-c31
E-d5
S-d7
S-d8
S-d9_ETHYLENE
S-d10
S-d1
Set1
S-d9_ETHYLENEC2= 99.95 [%]ACETYLENE 0 [ppm]
S-d11
S-d12
S-d13
M4S-d14
RXN
CRx2
S-d15
E-d6
S-d16
Set2
S-d19C3= 5.00 [%]
S-d17
S-d18_CGP
S-d19
S-d18_CGPC3= 95.50 [%]
T-DeC5
E-d7S-d20
Sd12_C4s
S-d25_C5s
M5
S-c25
S-c26
V3
S-c29
S-c28
S-d2
Env1
~SQ-1
Ethylene plant example.
Scheduling of cracking furnace operations.
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