FACULTY OF ENGINEERING
DEPARTMENT OF CHEMICAL
ENGINEERING
COMMUNICATION ASSIGNMENT
(ENPC03)
Investigating the profitability of expanding an ethylene
plant into the petrochemical sector.
By
SURNAME AND INITIALS PERU ME
PERU. ME 21946431
DUBE AN 22119681
Due date: 07 Assignment 2022 Lecture: Makhathini TP
Examiner: Nkosi N
1
Moses Emmanuel E. Peru 21946431
2022-03-27
2
3
ABSTRACT
The petrochemical industry is a byproduct that produces organic items including refinery
products, natural gas, plastics, and fibre raw materials. The separation of light hydrocarbon
binaries such as ethylene-ethane and propylene-propane mixtures is performed solely through
the distillation separation technique.
This method, however, uses a lot of energy because it uses huge distillation columns and has
many trays because of the close relative volatilities. The reflux ratio and the number of stages
rise because of this. To reduce high-energy usage, energy efficiency methods and energy-
efficient technology were implemented.
The Hybrid Distillation Membrane is introduced to improve both energy and recovery. It was
demonstrated that by utilizing this new technology, the procedure would be more efficient.
We see that by using the new technology the process will separate more efficiently, and it
separates materials based on their quantity, electrical nature and physical properties.
i
ACKNOWLEDGEMENT
Without the help of many people, this investigation report would not have been possible.
Many thanks to Makhathini TP, our lecturer, for allowing us to put this technique into action.
Also, for her invaluable guidance and support throughout the course and execution of this
investigation project.
She also deserves credit for providing intermediate feedback via Microsoft Teams and
WhatsApp due to the lockdown restriction (level 4) as well as technical insights, which were
critical in ensuring that the project's performance and reporting met expectations.
Mr Nkosi N, the computer lab instructor, for his dedication to us by elucidating the methods
and inquiries required to do this inquiry.
Finally, all thanks are due to God, the Omnipotent, the Most Charitable, the one, the
Architect, and the Most Forgiving.
ii
Contents
ABSTRACT....................................................................................................................................... i
ACKNOWLEDGEMENT ............................................................................................................. ii
LIST OF FIGURES ...................................................................................................................... iii
CHAPTER ONE ............................................................................................................................... 1
1. INTRODUCTION ..................................................................................................................... 1
1.1 Background ......................................................................................................................... 1
1.3 Objective ................................................................................................................................. 3
CHAPTER TWO .............................................................................................................................. 4
2 LITERATURE REVIEW ............................................................................................................... 4
2.1 The Ethylene Process In Terms Of Energy And Refrigeration .................................................. 4
2.1.1 The Energy ........................................................................................................................... 4
2.1.2 The Refrigeration .................................................................................................................. 4
2.2 Economic Possibilities If The Separation Process Is Changed................................................... 5
2.3 Economically The Feasibility Of Using Conventional Based-Case Ethylene Plant And Ethylene
Plant Utilizing New Improved Technology In The Separation Section............................................ 5
2.4 The Hybrid Distillation Membrane Separation System Can Be Configured In Four Different
Ways (Drawn Using CHEMCHAD) .............................................................................................. 5
2.5 Introduction Of Membrane Technology Into The Process ......................................................... 7
CHAPTER 3 ................................................................................................................................. 8
A CONVENTIONAL PROCESS FLOW DIAGRAM FOR ETHYLENE (Drawn using
CHEMCHAD)............................................................................................................................... 8
CONCLUSION ............................................................................................................................. 9
REFERENCE.................................................................................................................................... 9
LIST OF FIGURES
Figure 1.1: This process diagram depicts the breakdown of an ethane-propane mixture to yield
ethylene. ............................................................................................................................................ 1
Figure 1.2: Role of conventional distillation column (Hot & Cold Composite Curves)
[Link] .................................................................................................................... 2
Figure 2.1: A series configuration for membrane/distillation is employed in the
ethane/ethylene process.…………………………………………………………….................6
Figure 2.2: Absorption-Distillation hybrid system configuration for the propane/propylene
process………………………………………………………………………………………....6
Figure 2.3: Propylene/propane separation using a hybrid technique………………………….6
Figure 2.4: Separation of propane and propylene in hybrid membrane distillation systems….7
Figure 3: Shows a Process Flow Diagram for a Conventional Ethylene Process…………….8
iii
CHAPTER ONE
1. INTRODUCTION
1.1 Background
Ethylene is a widely used organic molecule in industry. It is made by heating the natural
gases, ethane and propane components to 800–900 °C (1,470–1,650 °F), resulting in a
mixture of gases from which the ethylene is extracted. (Britannica studies by Francis A. Carey)
In terms of output volume, the petrochemicals industry makes up around 10% of the total
petroleum industry. Technology improvements in established industrialized economies
spawned the industry. Until the last quarter of the twentieth century, petrochemical
production was concentrated in Western Europe, the United States, and Japan. (R.J. Clews,
in Project Finance for the International Petroleum Industry, 2016)
Figure 1.1: This process diagram depicts the breakdown of an ethane-propane mixture to yield ethylene.
1.2 Motivation
A natural gas business is thinking about expanding into the petrochemical industry. The
company produces ethane and propane. Furthermore, having their customers use massive
amounts of ethane and propane gas supplied by the company in the manufacture of costly
ethylene and propylene yields has pushed the company to produce these higher-priced
chemicals itself. However, according to the process engineers employed to evaluate the
feasibility of this action, they discovered that entering the market without considerable
upgrades in the process would be challenging.
According to the process engineers, our investigation evaluation of the process will be on the
separation phase of the ethylene process, which is the most promising area for attaining an
increase because it is particularly energy heavy, consuming about 70% of the total energy
required for the entire process.
1
Ethylene is a common organic molecule utilized in the petrochemical industry. It is produced
in steam-cracking plants from a range of petroleum-based feedstocks, such as ethane, and is
used to make several important derivatives.
Nevertheless, the conventional distillation process is not suitable for the proposed schematics
for this separation investigation due to the high consumption, and also how the system heat
utility system is built in comparison to the cold utility system of the process.
Figure 1.2: Role of conventional distillation column (Hot & Cold Composite Curves) [Link]
Because of rising energy or environmental constraints, various process modifications have
been implemented over the history of ethylene manufacturing. Within the conventional
ethylene production method, there have been some developments and advancements
throughout the last forty-five years. Researchers in the field of thermal cracking worked on
improving product yield, feedstock flexibility, and thermal efficiency. Different unit
activities, such as distillation, refrigeration, and separation, have made improvements in
purification and recovery.
Natural gas has sparked attention as a potential alternative feedstock for ethylene synthesis
due to its clean-burning features, domestic resource base, and commercial availability. As the
price of crude oil rises and an oil crisis looms in the future, scientists attempting to use
natural gas as an alternative source of energy and as a feedstock in chemical industries will be
concerned. Countries with abundant natural gas have begun to invest in research in this field.
2
If positive changes can be made to mitigate the high consumption of energy then, energy
consumption and CO2 emissions will be reduced and the opportunities available will be
further increased as a result.
1.3 Objective
Examine the ethylene process' separation portion to see if any new separation
technology could give enough incentives to justify a significant investment in a 500
000 ton per year ethylene plant
In the separation section, compare the economic feasibility of using a standard based-
case ethylene plant to an ethylene plant using new upgraded technology.
3
CHAPTER TWO
2 LITERATURE REVIEW
The majority of ethylene-related studies in the literature have been undertaken to improve
present process technology.
In this section, I go through the fundamental chemistry of ethylene synthesis as well as the
many techniques and units used to produce it. Then, depending on the most common
feedstocks, I go over the various ethylene production techniques. In terms of energy and
refrigeration requirements, will discuss the separation process and its efficiency. Talk about
the energy and economic possibilities if the separation process is changed. Examine the
economic viability of using a standard based-case ethylene plant and upgraded enhanced
technology, as well as possible configurations for the membrane separation system with
hybrid distillation that may be used in such a plant, in this section. Compare the costs and
advantages of employing different methods to create different grades of hydrocarbons in the
separation section. Finally, I go over the most recent method for directly manufacturing
ethylene from natural gas and explain how membrane technology may be a good solution in
this situation, and back it up with relevant material.
2.1 The Ethylene Process In Terms Of Energy And Refrigeration
2.1.1 The Energy
Ethylene is a highly reactive molecule with a double bond that may be converted to several
intermediates and end products on a large industrial scale.
Ethylene is an olefin, which indicates that the bonds between its atoms are unsaturated (like
unsaturated fats). Separating ethylene from ethane currently necessitates cooling the mixture
to extremely low temperatures, liquefying it, and putting it into a massive distillation column,
which is a time-consuming and costly process.
2.1.2 The Refrigeration
Ethylene Cost & Energy Distribution
According to research done at Ghent University, 35% of the total energy consumption is in
the cold section, therefore, optimization of the cold section can significantly reduce energy
consumption.
The separation of ethylene and propylene gas via condensation and fractionation at cryogenic
temperatures necessitates external refrigeration and is a key component of the ethylene
system. Because it is acceptable and easily accessible in the plant, propylene-ethylene
cascade refrigeration is now the most regularly utilized in ethylene facilities. The complete
cooling cascade in an ethylene refrigerator contains two or three steps, for a total of between
4
five and seven stages. To minimize excessive refrigeration consumption, the reflux ratios in
the columns are carefully chosen.
For the complex petrochemical industries, energy efficiency improvement and energy
management may deliver many economic benefits. The impact of production size and
materials has a direct impact on production prediction and energy efficiency optimization.
The distribution of investment and energy usage is presented in the table above. We can see
that in refrigeration that if we increase the refrigeration system (cooling units in the system)
this will result in energy efficiency for the ethylene production process concerning the
material product.
2.2 Economic Possibilities If The Separation Process Is Changed
To manufacture ethylene/propylene, petrochemical companies have a variety of options.
Several things influence the process of decision. The cost of the process, the availability of
raw materials, and environmental concerns are all essential aspects to consider when
selecting a method. The most important issue in commercializing any chemical product is its
cost. The key parts of chemical process economics are the costs of raw materials, utilities,
and operations.
2.3 Economically The Feasibility Of Using Conventional Based-Case Ethylene Plant And
Ethylene Plant Utilizing New Improved Technology In The Separation Section.
Traditional ethylene and propylene separation procedures are energy-intensive until they
reach petrochemical grade. As a result, alternative separation methods, such as chemical
affinity-based technologies, provide a feasible option for designing environmentally friendly
processes. One of these technologies is silver ion (Ag+) complexation. In this study, -
complexation is compared to standard technologies in terms of process and economics to see
if they are feasible to employ at an industrial scale in both new and existing units.
In addition, hybrid processes, which blend traditional and chemical affinity technologies, give
greater cost benefits when utilized to remodel existing units to reduce required energy or
increase processing capacity. (Source from ResearchGate by Hernando [Link])
2.4 The Hybrid Distillation Membrane Separation System Can Be Configured In Four
Different Ways (Drawn Using CHEMCHAD)
5
Figure 2.1: A series configuration for membrane/distillation is employed in the ethane/ethylene process.
Figure 2.2: Absorption-Distillation hybrid system configuration for the propane/propylene process
Figure 2.3: Propylene/propane separation using a hybrid technique.
6
Figure 2.4: Separation of propane and propylene in hybrid membrane distillation systems
From Figure 2.1 to Figure 2.4, we can see that to achieve the highest product purity (ethylene
or propylene), various configurations are suggested. These technologies are compared to
traditional C2- and C3-splitters in terms of capital, operational, and utility expenses. The
membrane cascade system produced the best ethylene purity in ethane/ethylene separation.
2.5 Introduction Of Membrane Technology Into The Process
Membrane technology is a broad phrase that encompasses a variety of distinct separation
methods. Membranes can be of great support because they can help separate the process
efficiently, they can also be helpful in the separation of different applications in the
process. If membrane technology is integrated into process operation it can help separate
materials based on their quantity, electrical nature, physical properties, and as well as
potential alternatives to standard processes. The existence of semipermeable membranes
is used in the membrane separation process.
The premise is straightforward: The membrane acts as a highly selective filter, allowing
water to flow while trapping suspended particles and other pollutants. ([Link])
A hybrid separation system combining membrane and distillation processes is offered as an
alternative design to replace current distillation technology. This innovative approach, on the
other hand, allows us to simulate the viability of a variety of hybrid membrane distillation
systems.
7
CHAPTER 3
A CONVENTIONAL PROCESS FLOW DIAGRAM FOR ETHYLENE (Drawn using CHEMCHAD)
Figure 3: Shows a Process Flow Diagram for a Conventional Ethylene Process
8
CONCLUSION
Because the process requires a large number of stages and a large extremely energy-intensive,
consuming almost 70% of the total energy of the process. It then must be carried out under strict
operating conditions, which include theoretical trays greater than 180, a high reflux ratio of 12 -20,
ultra-low operating temperatures of -30 degrees Celsius, and high operating pressure of 30 bars. All of
these factors contribute to a decrease in energy consumption.
In addition, high selectivity, low energy consumption, moderate cost-to-performance ratio, and small
modular construction, will further be suitable when there is an introduction of a Hybrid Distillation
Membrane rather suitable.
REFERENCE
Francis A. Carey, (2003). Ethylene. Contributor. Available from:
[Link]
Clews R.J, (2016). Project Finance for the International Petroleum Industry. Available from:
[Link]
Chemical Engineering (2015). Ethylene Production via Cracking of Ethane-Propane.
Available from: [Link]
propane/
K. Van Geem, J. Grootjans,G. B. Marin, (2017). Laboratory for Chemical Technology, Ghent
University. Total Petrochemicals, Antwerp, Belgium. Available from:
[Link]
Hernando [Link] (2011).A technical and economic evaluation of the separation of
light olefins (ethylene and propylene) by using p-complexation with silver salts, by
ResearchGate. Available from:
[Link]
f_the_separation_of_light_olefins_ethylene_and_propylene_by_using_p-
complexation_with_silver_salts
Marzouk B, Bora A (2010). Separation and Purification Technology. Ethane/ethylene and
propane/propylene separation in hybrid membrane distillation systems: Optimization and
economic analysis. Volume 73 (Issue 3), Pages 377-390. Available from:
[Link]