Engineering and technologies
Ethylene plant modernization Unmatched technologies and optimized solutions
ETHYLENE LEADERSHIP Grassroots and modernization Technip is a world leader in ethylene technology for grassroots plants (including mega-crackers) and plant modernizations / expansions
Ethylene in our daily life Ethylene, the simplest of olefins, is used as a base product for many syntheses in the petrochemical industry: plastics, solvents, cosmetics, pneumatics, paints, packaging, etc. Today, the demand for ethylene is over 150 million tons per year with a growth rate of 3.5% per year. To meet the average yearly growth rate, new capacity is being provided through grassroots plants and plant expansions.
Ethylene plant modernization The increased availability of ethane from shale-derived natural gas is driving numerous chemical producers to expand their ethylene capacity, particularly on the US Gulf Coast. Many of these producers, who are looking for reliable, efficient, low-cost gas-cracking facilities, are turning to Technip for their solutions. For complete modernization of existing plants, including modification of the cracking section, compression and separation sections, Technip offers a unique proven approach, applied successfully in several recent projects using decades of experience. Since 2000, more than 150 cracking furnaces have been modernized for increased production, energy efficiency and overall performance, using Technip's technology.
Centers of excellence Thanks to our highly qualified process engineers and experts, Technip can provide its clients with sound technological expertise and the ability to design and develop proprietary technologies. Our centers of ethylene expertise based in the U.S. (California and Texas), the Netherlands, Italy, England and France, supported by a global procurement network, contribute to Technip’s leadership, experience and resources, making it the partner of choice for any ethylene project.
Our approach to ethylene plant modernization
Terneuzen - The Netherlands
Ethylene plant optimization, modernization and capacity expansion projects Ethylene plant modernization projects vary in scope and size. Existing cracking furnaces, even if they originate from a recent generation, may be redesigned to increase the original ethylene capacity by 20% to more than double. At the same time, specific feed consumption is drastically reduced, thereby contributing to an attractive low cost of production per ton of incremental ethylene while improving energy and environmental performance.
The systematic approach to modernization Technip’s systematic approach to modernization enables an in-depth evaluation of technology options and project implementation scenarios, leading to the most cost effective, energy efficient and high performance of an existing ethylene plant. This approach ensures that bottlenecks are identified and prioritized to ensure a maximum return on investment, reduction of operating costs and application of the highest standards of HSE, quality and sustainability.
Main steps involved in the systematic approach to modernization
Client's objective
CAPACITY TARGET
Equipment technology
Energy: Process technology, key Energy users
ENERGY TARGET
Furnace technology Process technology Heat exchange network Rotating machinery Performance data
Investment: Key equipment cost & schedule
ECONOMIC & HSE TARGETS
Capacity: Equipment technology
Equipment cost Plot plan arrangement Scheduling Erection cost Iterations
FINAL REPORT
Technip proprietary equipment Thanks to a variety of associated proprietary technologies and equipment, Technip offers ethylene producers the ability to meet the toughest production related challenges, reduce capital costs and improve operational efficiency of existing furnaces.
Proprietary furnace technology
USC-M
Ripple Trays™ Ripple Trays are designed to avoid the solids collection and polymer formation problems that reduce capacity levels in towers that use conventional trays in fouling service. Ripple Trays provide outstanding anti-fouling service in a number of applications: more than 150 in quench towers and more than 90 in caustic towers. The use of Ripple Trays improves column capacity by more than 40%.
Liquid
SMK
GK6 USC-U
The furnace technologies contain a wide range of design options for reliable, flexible and highly selective solutions best suited to the operational needs of our clients. Standard design features include radiant coils, combustion systems, quench exchangers and multi-level shutdown features. Today, the largest gas cracking furnace is more than 250 KTA, and the largest liquids cracking furnace is 260 KTA.
Vapor
SFT® (Swirl Flow Tube) technology SFT® technology is designed to boost olefins production through the highest heat transfer increase at the lowest cost with respect to increased pressure drop. SFT® can be implemented in all furnaces to further improve performance (selectivity, capacity and run-length). Typical capacity increases of 10 to 30% have been recorded at similar or same ethylene yield.
Enhanced heat transfer solutions Technip and Wieland jointly market innovative heat exchangers and offer two main products: GEWA-PB enhanced boiling tubes GEWA-KS enhanced condensing tubes In ethylene mega-crackers, the Technip-Wieland enhanced heat exchangers allow further reduction in energy consumption and CO2 emissions. They have been successfully implemented in ethylene plants across the world. Applications using GEWA-PB tubes
Ethylene plant modernization
Key plant modernization references Kazanorgsintez In 2007, Technip completed the modernization and capacity expansion of three existing ethylene plants in Kazan in the Russian Federation. The capacity was increased from 400,000 (three plants) to 605,000 tons per year in a single facility, ensuring 20% of the national Russian ethylene production.
Westlake Calvert City In early 2013, Technip was awarded the expansion and modernization of the ethylene cracking furnaces and recovery section of the Westlake ethylene plant in Calvert City, Kentucky, USA. The ethylene production capacity will be increased by 40% and will use low-cost ethane feedstock instead of propane, due to shale gas development.
Eastman Chemical Company In 2012, Technip was selected to provide its technology and engineering services for a new Ultra Selective Conversion® furnace for Eastman’s ethylene plant in Longview, Texas, USA. The technology contained a range of design options which provided flexible solutions for the plant’s operating needs.
Williams – Single-pass furnace revamp Between 2010 and 2013, Technip proceeded with the phased modernization of the three existing single-pass furnaces at the Williams ethylene plant in its Geismar complex, Louisiana, USA. The initial goal of improving run length and furnace availability was achieved with higher results than planned.
Multi-lane GK6 application In 2011 Technip was awarded an EPC contract to revamp a furnace section consisting of single pass furnaces. The project required the upgrading of the Radiant Section with Technip’s proprietary Three-Lane Coil design. A significant run length increase together with a capacity increase over 15% was achieved while meeting all the latest safety and environmental requirements. The Three-Lane Coil technology has provided a yearly ethylene capacity increase of approximately 25%.
Client advantages Our state-of-the-art steam cracking furnaces are equipped with the latest coil designs featuring high selectivity and excellent on-stream time characteristics. These furnaces are combined with separation technologies that offer lowest energy consumption, environmental emissions and commercially attractive conditions.
Our clients benefit from furnace modernization through: Increased ethylene capacity or reduced feed consumption Increased selectivity for better yields Red ucing the specific energy consumption per ton of ethylene Increased flexibility: for wider range of feed qualities in operating severity / conversion Increased plant capacity Reduced maintenance cost with new state-of-the-art technology Reduced emissions
Our capabilities and extensive experience in separation technologies allow modernization of: Front-end hydrogenation Back-end hydrogenation at lower investment costs and reduced energy consumption.
Follow us on This document is the property of Technip and is not intended to be a binding contractual document. Any information contained herein shall not result in any binding obligation on the part of Technip, or any of its affiliates, and is provided for information purposes only. Technip - Group Communications - July 2015 - Photo credits: Technip
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