Naphtha cracking is the most energy intensive process in the chemical industry. It involves thermally cracking naphtha at high temperatures to produce more useful and valuable products like ethylene, propylene and gasoline. The presentation discusses the history of naphtha cracking, the steam cracking process, products obtained and latest developments to reduce energy usage like advanced furnace materials and distillation columns. Catalytic cracking technologies can lead to energy savings of up to 20% compared to steam cracking by reducing activation energy requirements and selectively removing coke. Overall, plenty of opportunities exist to improve the energy efficiency of naphtha cracking through technological advancements.

1. Naphtha Cracking
A presentation by :
Niteesh Kumar Vats
ME, Chemical Engg.
IISc Bangalore

2. Cracking

3. Need for cracking
Less valuable More useful &
products valuable products
Cracking
most of the gasoline/petrol is produced by
cracking!

4. Naphtha?
Historical Present

5. Sources of naphtha
*source- origbouk.ru/products.html

6. • In 1891 The thermal cracking
method was invented.
Vladmir Shukov
• modified in 1908
William Burton
• In 1934 factory of Shukhov cracking
process established at Baku, USSR.
• 1941: Standard Jersey developed the world’s first steam
cracker at Baton Rouge.

7. Naphtha cracking
Petroleum industry
Hydrocracking
Petrochemical industry
Steam cracking

8. Motivation for steam cracking
*source-2011-november_Olefinek eloallitasa.pdf
The worldwide
demand and
production of
olefins…
1. 94% of the world propylene.
2. In Western Europe, 95% of
Currently, production
`````ethylene and 70–75% of
through steam cracking
111propylene.
3. In Asia, 61% of ethylene.

9. Use of products of steam cracking
of naphtha

10. Chemistry of steam cracking
Initiation
Propagation
Termination

11. Process of steam cracking of naphtha
Naphtha Pyrolysis section
Fractionation and
Compression Section
Product recovery and
Separation Section

12. Energy analysis in steam cracking
sections
Section Energy Energy loss
required
pyrolysis 65% 75%
fractionation 15% 25%
and
compression
recovery 20% 15%
section

13. Pyrolysis section
Naphtha Pyrolysis furnace
Transfer line exchange
(producing steam)
Cracked gas

14. Products from separation
section
Ethylene (24%)
Propylene(20%)
Separation Butadiene(3%)
section
BTX(1%)
Petroleum
ether(25%)

15. “ Steam cracking is the most energy-
consuming process in the chemical industry
and globally uses approximately 8% of the
sector’s total primary energy use.”

16. Latest Development in steam cracking
of naphtha
Advanced furnace materials
Advanced distillation columns
Membranes

17. “These latest developments in
naphtha cracking can lead to
approximately 10% savings on the
process energy used.”

18. Alternative technologies
Hydro-pyrolysis
of naphtha
Catalytic cracking
of naphtha
zeolite

19. How Catalytic cracking Technologies Save
Energy?
1st way:
Energy saving!
Energy required in a pyrolysis furnace
In the case of conventional steam cracking
Activation Energy
Energy
without catalysts
Energy required in a reactor In the case of
catalytic cracking technologies
Activation Energy
with catalysts
Thermodynamic Olefins and byproducts
Energy requirement
Naphtha
Progress of Cracking Process

20. 2nd way:
selectivity of
catalyst
3rd way:
Removal of coke

21. Conclusion
Plenty of room for energy savings is possible in
steam cracking. And Catalytic cracking technologies
can lead to energy saving up to 20%.
90% chemical processes
already benefits from catalysis,
so can steam cracking!

22. References
• 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
• 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