Naphtha Cracking Unit : Ethylene Production
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The document summarizes ethylene production via naphtha cracking. It provides an overview of the history and development of naphtha cracking and steam cracking processes. It also discusses global ethylene consumption trends, production processes like steam cracking, MTO, and green routes. The key drivers of increasing ethylene demand are highlighted as polyethylene production. Major existing naphtha crackers in India and their capacities are listed. Process design considerations for ethylene plants emphasize safety, energy efficiency, and reliability.
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Naphtha Cracking Unit : Ethylene Production
- 1. Naphtha Cracking Unit: Ethylene Production Literature Survey Mayank Mehta Rakesh Choudhary Nikita Mittal Akshara Goyal CH#2 MALAVIYA NATIONAL INSTITUTE OF TECHNOLOGY DEPARTMENT OF CHEMICAL ENGINEERING 2014-15
- 2. Content Overview History Production and Consumption scenario Manufacturers Process design considerations Flow sheets Various Manufacturing processes of ethylene Refinery processes MTO Methanol to Ethylene Green Ethylene References Saturday, 04 July 2015 2Department of Chemical Engineering
- 3. An overview: Cracking Cracking Less valuable products: Naphtha (C1 – C9) From refinery More useful & valuable products: Ethylene (24%) Propylene (20%) Butadiene (3%) Petroleum Ether (25%) Saturday, 04 July 2015 3Department of Chemical Engineering
- 4. conti... *source- origbouk.ru/products.html Naptha Cracking- •Petroleum Industry: Hydro cracking •Petrochemical Industry: Steam cracking Saturday, 04 July 2015 4Department of Chemical Engineering
- 5. Recovery after cracking: Saturday, 04 July 2015 5Department of Chemical Engineering
- 6. Use of products of steam cracking of naphtha Saturday, 04 July 2015 6Department of Chemical Engineering
- 7. • 1941: Standard Jersey developed the world’s first steam cracker at Baton Rouge. • In 1891 The thermal cracking method was invented. • modified in 1908 • In 1934 factory of Shukhov cracking process established at Baku, USSR. William Burton Vladmir Shukov History: NCU Saturday, 04 July 2015 7Department of Chemical Engineering
- 8. History: Ethylene 1913: Standard Oil’s scientist patented thermal cracking process 1930ties: Ethylene was first separated from coke oven gas and the first commercial plant for the production of ethylene was built by Linde at that time 1941: Standard Jersey (ExxonMobil’s predecessor) developed the world’s first steam cracker at Baton Rouge 1950ties: Ethylene emerged as a large-volume intermediate, replacing acetylene as prime material for synthesis Today ethylene is primarily produced by thermal cracking of hydrocarbons in the presence of steam. Plant capacities are up to 1-1,5 million t/yr ethylene.Saturday, 04 July 2015 8Department of Chemical Engineering
- 9. Importance of ethylene and propylene in the chemical industry The largest volume petrochemicals produced. Annual global production of ethylene is about120 million tons with a continuous annual increase of some 4 - 5 % Ethylene and propylene have no end use, they are building blocks for a large variety of chemicals and petrochemical products. Polymers are the dominating end-users. Saturday, 04 July 2015 9Department of Chemical Engineering
- 10. Building Block Of Petrochemicals- ethylene consumption (sector wise): *source-2011-november_Olefinek eloallitasa.pdf Saturday, 04 July 2015 10Department of Chemical Engineering Form of Use Percentage LDPE 28 HDPE 33 Ethlene Oxide 14 EDC (PVC) 12 Styrene 6 VAM 1 Others 6 28% 33% 14% 12% 6% 1% 6% Ethylene Consumption LDPE HDPE Ethlene Oxide EDC (PVC) Styrene VAM Others
- 11. Global consumption of ethylene *source-2011-november_Olefinek eloallitasa.pdf Saturday, 04 July 2015 11Department of Chemical Engineering 1990 1994 1998 2002 2006 2010 2014 million t/yr 57 61 80 90 110 117 146 0 20 40 60 80 100 120 140 160 1990 1994 1998 2002 2006 2010 2014 million t/yr million t/yr
- 12. Main drivers for ethylene demand: PE *source-2011-november_Olefinek eloallitasa.pdf Saturday, 04 July 2015 12Department of Chemical Engineering 7 12 14 17 18.5 19.52 4 3 12 18.5 19.5 12 22 29 37 0 10 20 30 40 50 60 70 80 1970 1980 1990 2000 2005 2010 milliont/yr HDPE LLDPE LDPE 1970 1980 1990 2000 2005 2010 LDPE 7 12 14 17 18.5 19.5 LLDPE 2 4 3 12 18.5 19.5 HDPE 12 22 29 37
- 13. World consumption (country wise) https://www.ihs.com/products/ethylene- chemical-economics-handbook.html Saturday, 04 July 2015 13Department of Chemical Engineering
- 14. Top 10 Ethylene Complexes COMPANY LOCATION CAPACITY (TPY) Formosa Petrochemical Corp. Mailiao, Taiwan, China 2935000 Nova Chemicals Corp. Joffre, Alta 2811792 Arabian Petrochemical Co. Jubai, Saudi Arabia 2250000 Exxon Mobi Chemical Co. Baytown, Tex. 2197000 Chevron Philips Chemical Co. Sweeny, Tex. 1865000 Dow Chemical Co. Terneuzen, Netherlands 1800000 Ineos Olifins& Polymers Chocolate Bayou, Tex. 1752000 Equistar Chemicals LP Channelview, Tex. 1750000 Yanbu Petrochemical Co. Yanbu, Saudi Arabia 1705000 Source: Oil and Gas Journal, 4 Jul 2011 Saturday, 04 July 2015 14Department of Chemical Engineering
- 15. Existing Naphtha / Gas Cracker (2011) NAME OF UNIT STATE FEEDSTOCK Ethylene Capacity (TPA) Sourcing Of Feedstock Reliance, Vadodara Gujarat Naphtha Cracker 130000 Jamnagar Refinery RIL, Hazira Gujarat Naphtha/ NGL Dual Feed 750000 Jamnagar Refinery/ Imported Reliance, Gandhar Gujarat Gas 300000 Natural Gas produced by ONGC Reliance, Nagothane Maharashtra Gas 400000 Natural Gas produced by ONGC (Bombay High) GAIL, Auriya Uttar Pradesh Gas 400000 Natural Gas producedSaturday, 04 July 2015 15Department of Chemical Engineering
- 16. cont... NAME OF UNIT STATE FEEDSTOCK Ethylene Capacity (TPA) Sourcing Of Feedstock Haldia Petrochemical s Ltd., Haldia West Bengal Naphtha 520000 IOCL, Haldia Refinery/Impo rted IOC, Panipat Haryana Naphtha 857000 IOC Refinery (Panipat /Mathura) SOURCE - http://chemicals.nic.in/petro1.htm (as of 2011) Saturday, 04 July 2015 16Department of Chemical Engineering
- 17. Process design considerations Ethylene process is one of most complex systems in petrochemical industry. The following challenges have to be faced: ◦ Safety first ◦ High energy efficiency and minimum environmental emissions ◦ Low production costs and low investment costs ◦ High plant reliability ◦ Simple operation ◦ Good maintainability ◦ Minimum losses Saturday, 04 July 2015 17Department of Chemical Engineering
- 18. Types of Cracking Thermo Cracking Catalytic Cracking Saturday, 04 July 2015 Department of Chemical Engineering 18
- 19. Saturday, 04 July 2015 Department of Chemical Engineering 19
- 20. Saturday, 04 July 2015 Department of Chemical Engineering 20 Ethylene Block Diagram (CB&I)
- 21. Process Flow Sheet Saturday, 04 July 2015 Department of Chemical Engineering 21
- 22. Various Manufacturing processes of ethylene Saturday, 04 July 2015 Department of Chemical Engineering 22 3. MTO Methanol to Ethylene
- 23. Wide range of feedstock for steam cracking Saturday, 04 July 2015 Department of Chemical Engineering 23 In middle east and North America, ethane is favoured due to price advantage Gaseous feeds • Ethane • Propane • N-butane/i-butane Liquid feeds • Condensates from natural gas • Naphtha • Atmospheric gas oil (AGO) • Hydrocracker residue (HCR), hydrogenated vacuum gas oil (HVGO)
- 24. Considerations for feedstock Saturday, 04 July 2015 Department of Chemical Engineering 24 • Lower carbon number gives higher ethylene yield • Cracking severity influences product yield • The highly paraffinic nature of the naphtha makes it an excellent feedstock that provides a high ethylene yield
- 25. Refinery processes Saturday, 04 July 2015 Department of Chemical Engineering 25 Refinery gas is a mixture of hydrocarbons, nitrogen, carbon oxides, and sulfur oxides. For ethylene production, the most important components in the refinery gas are ethane, propane, and propylene. This new process enables refinery and petrochemical plant integration that maximizes the benefits to both facilities. The process enables: • 30% ethylene yield increase from existing naphtha cracker • 5-6% octane increase of reformate from reforming unit to gasoline pool • 2-3% aromatics yield increase for reformate from reforming unit to aromatics complex
- 26. MTO Methanol to Ethylene Saturday, 04 July 2015 Department of Chemical Engineering 26 Olefins (e.g., ethylene and propylene) can also be produced from natural gas (i.e., methane) via: - Methanol i) Production of methane and oxygen - Methane is separated from natural gas and is purified - Oxygen is separated from air cryogenically ii) Oxidative coupling 4 CH4 + O2 -> <catalyst> → 4 •CH3 + 2 H2O 2 •CH3 -> H3C-CH3 -> H2C=CH2 + H2 • Low yields • Relatively high energy use in separation and recycling • Additional oxygen and hydrogen are required for reducing coking on catalysts • CO and CO2 emissions
- 27. Syngas via Fisher Tropsch Saturday, 04 July 2015 Department of Chemical Engineering 27 Synthesis gas (syngas = carbon monoxide and hydrogen), is converted into liquid hydrocarbons. (2n+1)H2 + nCO -> CnH(2n+2) + nH2O Process conditions 150-300oC, in the presence of a metal catalyst Higher temperatures lead to faster reactions and higher conversion rates Advantages: • environmental friendly by recycling wood and agricultural wastes • reduced emissions of greenhouse gases (CO, CO2 , SO2 , NOx , unburned hydrocarbons and particulate matters) • absence of sulphur and nitrogen • higher combustion efficiency
- 28. Green Ethylene Saturday, 04 July 2015 Department of Chemical Engineering 28 - Scaling miniature reactors to industrial proportions poses a problem, as even the slightest increase of size of the reactors will produce less favourable results - increasing the quantity of microreactors to meet commercial demands is potentially more costly Biomass •Fermentation of glucose, starch Ethanol •Dehydration Ethylene
- 29. • Olefins from conventional and heavy feedstock's: Energy use in steam cracking and alternative processes. Energy 31 (2006) 425-251, By Tao Ren, Martin Patel, Kornelis Blok • http://chemicals.nic.in/petro1.htm (as of 2011) • http://cpcb.nic.in/upload/NewItems/NewItem_130_emmstdpe trochemplants.pdf • https://www.ihs.com/products/ethylene-chemical-economics- handbook.html • 2011-november_Olefinek eloallitasa • James. G. Speight (2006). The Chemistry and Technology of Petroleum (4th ed.). CRC Press. • Dr. Ram Prasad (2010). Petroleum refining Technology (1st edition). Khanna publishers Saturday, 04 July 2015 29Department of Chemical Engineering References
- 30. Naphtha Cracking Unit: Ethylene Production Literature Survey Mayank Mehta Nikita Mittal Rakesh Choudhary Akshara Goyal CH#2 21-02-2015 Saturday, 04 July 2015 30Department of Chemical Engineering
Editor's Notes
- Under 600 oC, the rate of reaction is slow, but above 600 oC undesired oxidations dominate the reactions.
- FT synthesis combines carbon and hydrogen molecules into chains by reacting carbon monoxide with hydrogen in the presence of a metal catalyst, heat and pressure.
- Ethylene can alternatively be produced by the dehydration of ethanol, which can be produced from fermentation processes using renewable substrates such as glucose, starch and others.