GUJARAT TECHNOLOGICAL UNIVERSITY, AHMEDABAD

July, 2025

“Plant Process Flow and Equipment Analysis of the Gas

Cracker Unit, Reliance Industries Limited, Dahej”

A PROJECT REPORT

Submitted by

Parmar Abhishek Chimanbhai

230283105010

In the partial fulfilment for the award of the ° of

BACHELOR OF ENGINEERING
in

Chemical Engineering
[Link] of Engineering, Ahmedabad

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 [Link] of engineering, Ahmedabad

CERTIFICATE

This is to certify that the project report submitted along with the project entitled
Internship on Plant Process Flow and Equipment Analysis of the Gas Cracker
Unit at RELIANCE INDUTRIES LIMITED, has been carried out-by Parmar
Abhishek Chimanbhai (230283105010) under my guidance in partial fulfilment
for the ° of Bachelor of Engineering in Chemical Engineering, 7th semester of
GujaratTechnological University, Ahmedabad during the academic year 2024.

________________ _____________
Head of department Guide

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 Under supervision of Industrial Mentor Mr. Vasant Patel

Reliance Industries Limited, Dahej Manufacturing Division, Bharuch.

_____________ _____________ _
Plant Head Industrial mentor
(Anjaney Shukla) (Mr. Vasant Patel)

_________________
(L&D) HEAD OF HR RIL-DMD
([Link])

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 L.D College Of Engineering, Ahmedabad

DECLARATION

I hereby declare that the Internship report submitted along with the Internship
entitled in Plant Training submitted in partial fulfilment for the ° of Bachelor of
Engineering in Chemical engineering to Gujarat Technological University,
Ahmedabad, is a bonafide record of original project work carried out by me at
Reliance Industries Limited. under the supervision of Mr. Vasant Sir and that no
part of this report has been directly copied from any students report or taken from
any other source, without providing due reference.

Name of student
Parmar Abhishek Chimanbhai Sign of student

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 ABSTRACT

➢ The Gas Cracker Unit (GCU) at Reliance Industries Limited’s Dahej Manufacturing
Division in Gujarat represents a cornerstone of India’s petrochemical infrastructure.
Utilizing a dual-feed cracker configuration, the unit processes both imported ethane
and domestic propane/off-gases to produce high volumes of key olefins—primarily
ethylene and propylene. These basic building blocks are further utilized for
manufacturing polymers like polyethylene (PE), polypropylene (PP), polyvinyl
chloride (PVC), and other downstream petrochemicals.
➢ Reliance pioneered the large-scale import of ethane from North America,
establishing a cryogenic logistics chain using Very Large Ethane Carriers (VLECs)
and specialized storage systems. This strategy significantly reduces feedstock costs
and enhances the global competitiveness of the Indian petrochemical sector. The
GCU has undergone strategic expansions, including a ₹13,250 crore debottlenecking
project in 2017 and a recent 2024 upgrade involving the installation of new cracking
furnaces. These upgrades aim to increase production capacity, improve energy
efficiency, and reduce operational bottlenecks.
➢ The Dahej GCU stands as a benchmark in modern petrochemical engineering
integrating advanced process technology, logistical innovation, and sustainability-
focused operations to support India’s growing industrial demands.

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 ACKNOWLEDGEMENT

Every project big or small is successful largely due to the effort of a number of
wonderful people who have always given their valuable advice or lent a helping
hand. I sincerely appreciate the inspiration, support and guidance of all those people
who have been instrumental in making this project a success

I am extremely grateful to "Reliance Industries Limited (DMD)" for granting me

the permission to work on my industrial training and encouraging me by providing
the needful support in all possible ways. Working in such an esteemed organization
has not only honed my skills in the Engineering context, but has also contributed
in making more complete individual out of me

In this journey, a group of people we might call industry experts has helped me. I
will be embedded with their kind gesture and support. I am very much thankful to
HR Department and Learning Centre. I express my gratitude to [Link] Patel
and all members Gas Cracker Unit plant for giving their support during my training
period. Without their support this project couldn’t be successful.

We sincerely thank to Dr. Paresh Rana sir (Head, Department of Chemical

Engineering, L.D.C.E.) for giving us this great opportunity for industrial training.
We would like to thank who guided us during this industrial training and also help
for prepare industrial training report. We also thank to all officers, shift in-charge,
who co-operate with us and help us in all our need.

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 Contents

[Link]. Particulars Page

No.
1. Overview of Reliance Industries Limited, Dahej 9

2. Overview of Gas Cracker Unit Plant 10

3. About Ethane Feed Tank 11-12

5. GCU flow diagram 13

Details
4. Area 1 consists of: 14-19
• Furnace Section
• Quench Water System
• Dilution Steam Generation System
• Condensate Polishing Unit
• Steam Distribution System
• Chemical Injection System
• Steam Letdown System
• Boiler Feed Water System
5. Area 2 consists of: 20-24
• Cracked Gas Compressor
• Caustic Scrubbing System
• Primary Dehydrators
• Cooling Towers
• Fuel Gas System
6. Area 3 consists of: 25-30
• Ethylene Refrigeration System
• Propylene Refrigeration System
• Chilling Train
• Demethanizer Section
• Deethanizer Section
• Pressure Swing Adsorber
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 • Expander Compressor Unit
• Ethylene Tower
7. Area 4 consists of: 31-34
• Depropanizer Section
• Propylene Stripper and Rectifier
• Debutanizer Section
• Gasoline Fractionator
• Depentanizer Section
• Acetylene Converter Unit
• MAPD reactor Unit

8. Safety and Precautions 35

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Overview of Reliance Industries Limited, Dahej
• Reliance’s Dahej Manufacturing Division is a keystone in India’s petrochemicals
infrastructure—offering a high ° of integration, scale, and strategic growth. With
its cracker-to-polymer chain, flexible feedstock access, and continued expansions,
DMD strengthens RIL’s position as a global petrochemical powerhouse—all while
maintaining commendable environmental sensitivity.

Key Plants at Dahej petrochemical complex

• The campus houses a Purified Terephthalic Acid (PTA) plant built with
INVISTA technology, recognized for its efficiency and environmental
performance, and a 650 KTA bottle-grade Polyethylene Terephthalate (PET)
resin plant that uses INVISTA continuous polymerization and Bühler solid-state
polymerization technologies, making it one of the largest such facilities globally.
Supporting units include a caustic chlorine plant, ethylene–propylene recovery
units, and downstream polymer and fibre intermediate facilities producing ethylene
oxide (EO), mono-ethylene glycol (MEG), di-ethylene glycol (DEG), and tri-
ethylene glycol (TEG)—chemicals vital for textiles, adhesives, and solvents. The
complex also has a 270 MW captive co-generation power plant and extensive utility
infrastructure, including water treatment, steam, nitrogen, and cooling systems.

Key Products at Dahej Petrochemical Complex

• The product spectrum from Dahej covers petrochemicals (ethylene,
propylene, caustic chlorine), polymers (PET resin, proposed PET-G,
PVC from existing and planned VCM capacity, and ethylene dichloride),
and polyester intermediates (PTA, MEG, CHDM for PET-G). Planned
expansions—worth thousands of crores—aim to add new facilities for
ethylene dichloride (EDC), cyclohexanedimethanol (CHDM), PET-G,
hydrogen separation, and CO₂ recovery, alongside a significant increase
in VCM/PVC capacity from the current 360,000 tonnes per year to over
1.2 million tonnes per year. This integration from feedstock to specialty
polymers allows DMD to operate as a self-sufficient petrochemical hub,
contributing significantly to RIL’s position as a global leader in polyester
and polymer markets, while maintaining operational flexibility and
environmental stewardship.

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 Overview of Gas Cracker Unit
• The Gas Cracker Unit at Reliance Industries Limited’s Dahej Manufacturing Division
is a high-capacity petrochemical processing facility designed to convert light
hydrocarbons—primarily ethane and propane—into key building block chemicals.
Using high-temperature cracking technology, the unit breaks down these feedstocks to
produce ethylene and propylene, which are critical raw materials for a wide range of
downstream products, including polymers, fibres, and industrial chemicals.
• The cracker is integrated with advanced ethylene–propylene recovery systems to
maximize yield and efficiency, and it operates with a flexible feedstock capability that
allows switching between ethane, propane, or a mix, depending on market and supply
conditions. Supported by extensive utility systems such as high-capacity cooling water,
demineralized water, nitrogen generation, etc.
• Plant Details:
1. Commissioning Date: 12 february 2000,
2. Production Capacity: 500,000 TPA (Ethylene + Propylene)
3. Capacity Utilization: 118.379%
4. Plant Area: 64,000 m2
5. Initial Investment: 750 Crores
6. Plant Inputs: Shale Ethane, Imported ethane, Jamnagar Propane
7. Main Products: Ethylene (Polymer Grade), Propylene (Polymer Grade)
• Applications: Used for polyethylene and polypropylene production
• By-products: Hydrogen, Methane, C4 Mix, RARFS, Mix oil, Light
Fuel Oil, Tar
8. Highest Daily Production:
Ethylene: 1474 MT (04-sept-2017)
Propylene: 449 MT (13-Feb-2016)
Combined (E+P): 1773 MT (11-Jan-2018)

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 Ethane Feed Tank

The ethane feed tank at Reliance Industries Limited's (RIL) Dahej Manufacturing
Division (DMD) in Gujarat is a critical component of its petrochemical infrastructure.
This facility enables the import, storage, and distribution of ethane, primarily sourced
from North America, to serve as feedstock for RIL's gas cracker units at Dahej, Hazira,
and Nagothane.

The tank is designed for cryogenic storage, with a capacity of 90,000 metric tonnes
(MT), allowing it to store ethane at extremely low temperatures necessary for
maintaining its liquid state.

Ethane is received at the Gujarat Chemical Port Terminal Company Limited

(GCPTCL) jetty and transported via a dedicated cryogenic pipeline approximately 2
km in length to the storage tank within the DMD complex.

The ethane storage tank at DMD is a double-walled, vacuum-insulated cryogenic

tank, designed to safely store ethane at cryogenic temperatures (approximately -
89°C). This configuration minimizes heat ingress and maintains the ethane in its liquid
state. The diameter of the tank is 84m and the height is 34m.

Materials Used

Inner tank: Constructed from austenitic stainless steel (e.g., 304L or 316L), which is
chosen for its excellent strength, durability, and resistance to low temperatures and
corrosion.

Outer Tank: Made of carbon steel, providing structural support and protection.

Insulation: The annular space between the inner and outer tanks is filled with perlite
or aerogel, combined with a high vacuum, to reduce heat transfer significantly.

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 Components of the Ethane feed tank are:

❖ Recondensers are integral to managing boil-off gas (BOG), which is vaporized

ethane resulting from heat ingress. These units condense the BOG back into
liquid ethane, maintaining tank pressure and minimizing product loss. This
process enhances operational efficiency and safety.

❖ Booster pumps are employed to increase the pressure of the liquid ethane for
transfer to downstream processes or pipelines. They ensure a consistent and
adequate flow rate, compensating for pressure drops and facilitating efficient
distribution

❖ Heaters serve multiple purposes in cryogenic ethane storage systems:

• Foundation Frost Protection: To prevent soil freezing beneath the tank,

which can cause structural instability, electric heating systems are installed
within the foundation slab. This measure mitigates frost heave and maintains
foundation integrity

• Pressure Regulation: Heaters may also be used to vaporize a portion of the

liquid ethane, generating pressure within the tank to facilitate the withdrawal
of liquid or gas as needed.

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 GCU Flow Diagram Area 2
Hydrogen
PSA
Fuel
Gas
Ethane
Ethane chill Quench
recovery Furnace CG
tower
Compressor De
Dryer
methanizer
Area 1

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Ethylene
Area 4 De-ethanizer Ethylene converter
Propylene
Propylene MAPD De
tower RXR propanizer
RARFS
Mix C4 Area 3
C2/C3 refrigeration
Fuel oil Gasoline units
Fuel Oil Stripper Reactor Debutanizer
 Area 1 ( First Part of the Process)

It consists of:
1. Furnace
2. Quench Water System
3. Dilution steam generation system
4. Condensate Polishing system
5. Steam Distribution system
6. Chemical Injection System
7. Steam Letdown System
8. Boiler Feed Water System

[Link]

Purpose: Cracks ethane, propane, and LPG into ethylene and propylene at 830-850°C.
Each furnace has 24 W-coils of swaged design (increasing diameter for better heat
transfer and flow). Divided into 2 sections.

Convection Section:

The convection section is the upper part of a pyrolysis (cracking) furnace in a gas
cracker unit. It plays a critical role in preheating and energy recovery, thereby
improving furnace efficiency. It has 6 convection banks and each bank consists of
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tubes arranged in a particular row.

Bank 1: Hydrocarbon feed preheat 1

Bank 2: Boiler feed Water preheat bank
Bank 3: Hydrocarbon feed preheat 3
Bank 4: Very high-pressure steam
Bank 5: Hydrocarbon + Dilution Steam preheat bank
Bank 6: Dilution steam preheat tank.

The above banks are installed to perform the following function:

Feed Preheating
Hydrocarbon feed (ethane, propane, etc.) enters the convection section first. It is
heated using hot flue gases before entering the radiant coils. It helps reduce thermal
shock and lowers the fuel required for final cracking.

Dilution Steam Superheating

Dilution steam (added to reduce coke formation and hydrocarbon partial pressure) is
superheated here. Superheated steam improves cracking efficiency and minimizes
coke.

Boiler Feed Water (BFW) Preheating

BFW is preheated before going to the steam drum or boiler. It recovers waste heat,
increasing steam generation efficiency.

Radiation Section:

The radiation section is the heart of a cracking furnace in a Gas Cracker Unit (GCU),
where the actual thermal cracking of hydrocarbons like ethane or propane takes
place.

Located below the convection section, it consists of high-temperature radiant coils

enclosed within a firebox, where burners provide intense heat (typically 800-850°C).

The hydrocarbon feed, already preheated in the convection section, enters these coils
and undergoes endothermic cracking reactions, breaking down into smaller molecules
like ethylene and propylene.

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The design ensures minimal residence time to prevent over-cracking or coke
formation. Efficient heat transfer by radiation and careful coil design are critical to
maximize olefin yield while minimizing energy consumption and coke buildup.

A total of 144 wall burners, 24 floor burners, and 24 pilot burners are present in a
single furnace. Hydrocarbons are cooled down using a heat exchanger. The product
coming out of 2 coils is sent to one Ultra Selective Heat Exchanger (USX), so a total
of 12 USX are present.

Furthermore, the cracked gas is sent to the Primary and Secondary Transfer Line
Heat Exchangers (PTLX, STLX) for quenching and cooling upto 230°C.

2. Quench Water System

The Quench Water System is a vital part of the hot section of a gas cracker unit
(GCU). Its main job is to rapidly cool the cracked gas exiting the radiant section
(furnace coils) to stop further cracking reactions and stabilize the product mixture.
After cracking in the radiant coils (at ~800-850°C), the cracked gases still carry
residual heat.

If not cooled rapidly, secondary cracking or polymerization of olefins can occur.

Rapid cooling also prevents coke formation, which could clog downstream
equipment. The process flow is given below:

Radiant Coil Outlet → Transfer Line Exchanger (TLE) → Quench Oil Tower →
Quench Water Tower
Quench Oil Tower: First level of cooling using hot circulating oil

Quench Water Tower/System: Further cools cracked gas using water spray and
direct contact. Rapid gas cooling from 200-250°C to 40°C before further processing.

Components of Quench Water System

1. Quench Water Tower (Column):

➢ A vertical column where cracked gas flows upward and quench water is sprayed
downward
➢ Gas and water come into direct contact, leading to effective heat exchange
➢ Has trays or packing to increase surface area and contact time

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2. Quench Water Circulation Pumps:
➢ Circulate water from the bottom of the tower to the top spray nozzles
➢ Ensure continuous and uniform spray

3. Quench Water Cooler / Heat Exchanger:

➢ Cools the hot water collected from the tower bottom before recirculation
➢ Typically air-cooled or water-cooled exchanger

4. Blowdown System:
➢ Removes a portion of the used water to control impurities and fouling
➢ Fresh makeup water is added as required

5. Makeup Water System:

➢ Supplies clean water to compensate for losses via evaporation, blowdown, or drift
➢ Water quality is often treated to avoid scale or corrosion

3. Dilution Steam Generation System

Dilution steam is superheated steam mixed with hydrocarbon feed (like ethane or
propane) before it enters the radiant coils of the cracking furnace. The steam-to-
hydrocarbon ratio is 3:1; that is, 3 tons of steam are added per ton of hydrocarbon
cracked.

Improves selectivity towards light olefins (like ethylene, propylene). Reduces

pressure drop by lowering hydrocarbon viscosity. Protects coil metallurgy by
lowering peak temperature.

Prevents coke deposition in radiant coils by reducing hydrocarbon partial pressure

and acting as a thermal ballast.

4. Condensate Polishing Unit

The Condensate Polishing Unit (CPU) is a water treatment system that cleans and
purifies steam condensate (return water) before it is reused as Boiler Feed Water
(BFW). It removes dissolved and suspended impurities like salt, minerals to prevent
scaling, corrosion, and fouling in boilers, steam drums, and process equipment.

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Components of CPU are:

Heat exchanger, Activated Carbon filter (primary and secondary), Strong Acid
Caution Exchanger, Mixed Bed Exchanger.

6. COS Hydrolysis Reactor

Propane contains COS(Carbonyl Sulphide).In the reactor, hydrolysis occurs to

convert: COS+H2O ->CO2 +H2S in the presence of platinum sulphide to make fuel
free of secondary items.

7. Steam Distribution System

Abbreviation Full Form Meaning/Usage

SVH Superheated High pressure superheated steam,

Vapor High usually used in cracking furnaces or
turbines
SH Superheated General superheated steam, can be
medium or high pressure, used in
heating or cracking
SLM Steam Low A utility steam grade, typically at
medium intermediate pressure, used in
process heating
SL Steam Low Low pressure steam is used for
stripping, minor heating or
deaeration
8. Condensate System

The condensate system collects, stores, and recycles condensed steam (i.e., steam that
has released its heat and turned back into water) from various parts of the plant. This
system is critical for maintaining energy efficiency, water reuse, and boiler
performance in a petrochemical facility.

9. Boiler Feed Water System

The Boiler Feed Water (BFW) system prepares and supplies high-purity water to
boilers, where it is converted to steam (used for heating, cracking, stripping, etc.). This
system ensures the feedwater meets the required chemical and physical standards to
18
avoid corrosion, scaling, and boiler tube failure.

Supplies high-quality water to generate: Dilution steam, Utility steam (HP, MP, LP),
Steam tracing and stripping steam. Main components are:

Deaerator (DA Tank)

• Removes dissolved oxygen (O₂) and carbon dioxide (CO₂)
• Prevents corrosion in boilers and steam systems
• Usually operated at 105-120°C under pressure
• Mechanical + steam stripping action

Boiler Feed Pumps

• Pump deaerated water from DA tank to high-pressure boilers
• Must withstand high temperatures and have NPSH control
• Often multi-stage centrifugal pumps

General Safety & Precautions - Area 1 (GCU)

Feed Handling Section

• Use pressure relief valves (PRVs) to prevent overpressure in feed lines.
• Ensure hydrocarbon leak detection systems are functional (gas detectors, alarms).

Convection Section
• Avoid sudden temperature changes to prevent coil rupture (thermal shock).
• Regularly inspect for fouling or scaling in coils to maintain heat transfer.

Radiation Section
• Maintain burner flame stability to avoid flashbacks or furnace explosions.
• Do not enter furnace area during operation; ensure permit-to-work is followed.

Quench System
• Ensure proper quench water flow to avoid downstream thermal damage.
• Monitor for any steam-water imbalance that could cause pipe vibration or erosion.

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 Area 2 (Second Part of process)

It consists of :
1. Cracked gas Comnpressor
2. Caustic Scrubbing system
3. Primary Dehydrators
4. Cooling Towers
5. Fuel Gas System

1. Cracked gas compressor

The Cracked Gas Compressor (K-45) is a steam turbine-driven, 4-stage centrifugal

compressor manufactured by Mitsubishi. It is crucial in the gas cracker plant,
serving as a key step between the quench tower overhead and downstream
separation and refrigeration units.

It compresses cracked gas (from 0.4 kg/cm² to 25 kg/cm²), which comes from the
quench tower overhead.

Compression is required to enable downstream acid gas removal (CO2, H2S),

facilitate cryogenic separation (via chilling and fractionation), and ensure
efficient condensation in refrigeration cycles.

4-Stage Compression Process

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Stage 1-Initial Compression
• Inlet Pressure: ~0.4-0.5 kg/cm² (from quench tower overhead).
• Cracked gas enters the 1st stage impeller, where centrifugal force accelerates
the gas.
• Kinetic energy is converted to pressure energy in the diffuser section.
• Outlet pressure increases, but the temperature also rises due to compression.

After Stage 1
• Gas is passed through intercooler 1 to reduce the temperature and condense out
any heavy hydrocarbons or water.
• Then passed to a knockout drum to remove condensates.

Stage 2-Intermediate Compression

• Cooled and partially dried gas enters the 2nd stage.
• Pressure is further increased to the intermediate range.
• Temperature again rises due to compression.

After Stage 2
• Intercooler 2 is used to reduce gas temperature.
• Another knockout drum removes condensed water or hydrocarbons.
• Helps protect the compressor from fouling or erosion.

Stage 3 - High Compression Zone

• Gas enters the 3rd stage at moderate pressure and temperature.
• Gets further compressed; typically around 15-25 kg/cm² pressure range is
achieved.

After stage 3
• Gas is routed to intercooler 3.
• V-49 is a knockout drum where condensed liquids are separated.
• This stage ensures the gas is conditioned before the final stage.

Stage 4-Final Compression

• From V-49, gas goes to the 4th stage (C-56).
• Final compression boosts pressure up to - 45kg / c * m ^ 2
• Temperature rises significantly, typically requiring strong after-cooling.

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After Stage 4
• Gas flows through aftercooler (E-185) to bring down temperature to - 15 deg C
• Sent to Dehydrator (Molecular Sieve Dryer) to reduce water content to <1 ppm
before refrigeration and separation.

2. Caustic Scrubbing System

Used to remove acidic gases like CO2 and H2S from cracked gas using a liquid-
phase absorption process. These impurities must be removed to:
• Prevent corrosion of downstream equipment.
• Avoid catalyst poisoning in cryogenic units.
• Comply with product purity specifications.

Source of Acidic Gases:

• CO2: Formed due to the steam cracking of hydrocarbons.
• H2S Added by design via DMDS injection (dimethyl disulfide) to protect
furnace tubes by forming a protective sulfide layer, but must be removed later.

Removal Process:
• CO2 reacts with NaOH (Sodium Hydroxide) in aqueous solution
• H2S is a weak acid and reacts readily with NaOH

End Products: Sodium carbonate (Na2CO3), Sodium sulphide (Na2S), Water.

These reactions convert toxic acidic gases into non-volatile, water-soluble salts.

Safety & Maintenance:

• Corrosion monitoring: NaOH is corrosive-lined vessels/pipes are used.
• pH alarms: Ensure the reaction zone does not go acidic.
• Spent caustic handling: Toxic; should be neutralized/treated.
• Vent scrubber system: Captures any off-gas with residual H₂S or CO2.

3. Primary Dehydrators

The Primary Dehydrators are used to remove moisture (H₂O) from cracked gas
before it enters the cryogenic separation section. Even traces of water can freeze
at low temperatures and block or damage the cryogenic equipment. Hence, gas
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must be dried to <1 ppmv water content.

The system uses molecular sieves (adsorbents) in fixed-bed vessels to adsorb

water molecules from the gas phase.

Operates on a cyclic adsorption-desorption (regeneration) principle using two

parallel vessels: One vessel is in service (adsorbing moisture) and the other is in
regeneration mode (desorbing and drying for the next cycle).

4. Cooling Tower

A cooling tower is a heat rejection device that removes excess heat from process
water (usually coming from exchangers, compressors, or reactors) by evaporative
cooling. The cooled water is recirculated back into the plant to absorb more heat,
forming a closed-loop cooling water system.

Working:
• Hot water (40-45°C) from process equipment is pumped to the top of the
cooling tower.
• It flows downward over fill material (increases surface area).
• Air is drawn in (natural draft or forced draft), moving upward.
• A small portion of water evaporates (~1-2%), taking away latent heat.
• The remaining water cools down (~30-32°C) and is collected at the bottom
basin (cold well).
• This cooled water is recirculated to process units.

5. Fuel Gas System

The Fuel Gas System provides clean, consistent combustible gas to fire:
Furnaces (like cracking furnaces), Boilers, Reboilers, or flare pilots.

Sources of Fuel Gas: Cracked gas offcuts (light hydrocarbons like methane,
ethane), Natural gas (as backup or supplement), Recycled gas from purification
systems or Fuel gas headers collecting fuel from various units.

General Safety & Precautions - Area 2 (GCU)

• Monitor CGC vibration, pressure & temperature trips to prevent failure.
• Ensure no hydrocarbon leaks; the area must have gas detectors.

23
• Handle NaOH with full PPE (face shield, gloves, apron).
• Regularly check pH and concentration to avoid chemical hazards in the
caustic scrubbing system.
• Ensure proper regeneration sequence to avoid bed fouling or pressure spikes
in dehydrators.
• Never allow liquid entry into beds; it may damage molecular sieves.
• Use flame arrestors & auto shut-off valves to prevent backflash.
• Keep the system within design pressure limits; monitor for leaks.

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 Area 3 (Third Part of process)

It consists of :
[Link] Refrigeration Unit (C2R)
[Link] Refrigeration Unit (C3R)
[Link] Train
25
[Link]
[Link] compressor
[Link]-ethaniser
[Link] Swing Adsorption
8. Ethylene Tower

1. Ethylene Refrigeration Unit (C2R)

The Ethylene Refrigeration System plays a critical role in low-temperature chilling

in the Gas Cracker Unit (GCU) to condense and separate hydrocarbons. It operates
using a four-stage compressor system, cooling streams down to temperatures as
low as -100°C, required in processes like demethanizer and chilling train.

Process Flow Summary:

1. Suction & First Stage Compression:

• Low-pressure ethylene vapor from process exchangers is compressed
in the 1st stage.
• Intercooling is done before moving to the next stage using inter-stage coolers.

2. Second & Third Stage Compression:

• After each stage, intermediate coolers remove the heat of compression.
• Suction scrubbers remove any entrained liquid or impurities.

3. Fourth Stage Compression:

• Final high-pressure vapor is compressed and cooled.
• Sent to condensers, where it's liquefied.

4. Condensation and Expansion:

• Liquid ethylene is expanded through control valves.
• This sudden pressure drop causes cooling (Joule-Thomson effect).
• The cold liquid/vapor mixture is then circulated through process exchangers to
provide chilling.

This ethylene is used as a refrigerant to cool ethane which comes out of the
26
 ethylene tower.

2. Propylene Refrigeration Unit (C3R)

The Propylene Refrigeration System provides intermediate cooling (~-40°C) for

the early stages of chilling in the Gas Cracker Unit (GCU). It complements the
Ethylene Refrigeration System, handling temperatures that are too warm for
ethylene and too cold for water-based systems. It follows the same cooling stages
process as C2R.

3. Chilling Train

The chilling train is a critical section of the ethylene/propylene-based cracking

unit. It is responsible for progressive cooling of cracked gas to condense and
recover heavier hydrocarbons like C2, C3, and C₂+ components, while allowing
lighter gases (like H2, CH4) to remain in vapor phase.

To cool the cracked gas stream from the radiant section/quench tower in a
stepwise manner using:
Propylene refrigeration system (K-160): For initial chilling (-40 deg C)
Ethylene refrigeration system (K-150): For deeper chilling (-100 deg C)

Stage Refrigerant used Target Temp Purpose

1st stage Propylene (K-160) -20 deg C Initial C4+
condensation
2nd stage Propylene (K-160) -40 deg C C3
hydrocarbons
start condensing
3rd stage Ethylene (K-150) -90 deg C C2 and residual
C3 recovery

After each exchanger, condensed hydrocarbons are separated. Separated liquids are
sent to Deethanizer, Depropanizer, and Deisobutanizer, respectively, for
fractionation.

Light gases (H2, CH4, some C2) exit for further separation in the Demethanizer.

4. Demethanizer

27
The Demethanizer Column is one of the most critical components in the Gas
Separation Section of an ethylene plant. Its main purpose is to separate methane
and lighter gases (H2, CO) from the heavier hydrocarbons (C2 and above),
particularly ethylene and ethane.

The main purpose is to recover C2 hydrocarbons (ethane, ethylene) from the bottom
and to remove CH4 (methane), H2 and CO from the cracked gas stream and send
them to the fuel gas system or hydrogen recovery.
Feed Composition: Comes from the Chilling Train as cold vapor (-90°C).
Contains: Hydrogen (H2), Carbon Monoxide (CO), Methane (CH4), Ethylene
(C2H4), Ethane (C2H6) Minor traces of C3S

Equipment used:
Demethanizer Column:
• A cryogenic distillation column operating at 16kg / cm2g.
• Has trays or structured packing.
• Reflux is supplied by Demethanizer Reboiler (bottom) and Demethanizer
Condenser (top).

Demethanizer Condenser (Top):

• Uses expander-recompressed gas or ethylene refrigerant ( -100 ° C ) to fully
condense the overhead vapor.
• Cooled gases are collected in the Demethanizer Reflux Drum.
• Part is returned as reflux, rest sent as fuel gas or to hydrogen recovery (PSA).

Demethanizer Reboiler (Bottom):

• Provides heat input to vaporize methane from heavier hydrocarbons.
• Uses steam or hot oil (depending on design).
• Ensures heavier C2+ stays at the bottom.

5. Expander Compressor

The Expander Compressor plays a crucial role in achieving ultra-low temperatures

(-150°C) required for the top condenser of the Demethanizer. It is a key part of the
cryogenic refrigeration system and is often used in conjunction with ethylene or
methane-rich gas streams.

Main Components: Heat Exchangers, Expansion Turbine, Compressor Section.

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The Demethanizer Condenser (top section) requires cooling to -120 ° C to - 150
° C to condense methane and hydrogen-rich vapors. Regular ethylene refrigeration
may not suffice at this low temperature. The Expander helps produce this deep
refrigeration using internal process streams without needing external refrigerants
like nitrogen.

The Expander Compressor utilizes the principle of gas expansion to produce

refrigeration. It expands a high-pressure gas (typically methane-rich overhead from
the Demethanizer or C2 rich gas), reducing its pressure and drastically lowering its
temperature through the Joule-Thompson effect or isentropic expansion.

[Link]-ethanizer

The Deethanizer Column is responsible for separating C2 hydrocarbons (ethane

and ethylene) from heavier components like propane (C3H8) propylene (C3H6)
and higher hydrocarbons (C4+) which were carried in the bottoms of the
demethanizer.

Fractionation: Lighter components (C2) go upward, heavier components (C3+) go

downward, and the column uses a reboiler at the bottom and a condenser at the
top for vapor-liquid equilibrium.

Operating conditions are:

Top temperature: -20 ° C to - 30 ° C and Bottom Temperature: 60-80°C.

Operating Pressure: 15 - 25kg / cm2g & Reflux ratio: 5.1

7. Pressure Swing Adsorption (PSA)

The PSA unit is designed to recover high-purity hydrogen (H2) from light gas
mixtures, especially the off-gas from the Demethanizer overhead, which typically
contains: Hydrogen (H2) Methane (CH4), Carbon monoxide (CO), and traces of C2
hydrocarbons.

The PSA process uses adsorbent beds (typically activated carbon, zeolites, or
molecular sieves) to selectively adsorb impurities like: Methane (CH4), CO, CO2
Ethane, Nitrogen, while allowing H2 to pass through.

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The adsorbents are regenerated by reducing pressure, hence the term "Pressure
Swing." The unit produces high-purity hydrogen, 99.9985%, which may be used in
hydrogenation, while methane and other remaining gases are sent back as a fuel gas
for furnaces, reboilers, etc.

8. Ethylene Tower

The C2 Splitter, often referred to as the Ethylene Tower, is a very tall and high-
pressure distillation column used to separate ethylene (C2H4) from ethane (C2H6)
after the deethanizer overhead.

It is used to produce polymer-grade ethylene (PGE) with >99.9% purity, while

recovering ethane to recycle to cracking furnaces. Mostly sieve trays are used for
distillation.

Operating conditions are:

Top temperature: - 33 ° C and bottom = - 110 ° C

It has 142 trays and a reflux ratio of 8.3.

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 Area 4 (fourth part of process)

It consists of :
1. Depropanizer Section
2. Propylene Stripper and Rectifier
3. Debutanizer
4. Gasoline Fractionator Section
5. Depentanizer
6. Acetylene Converter Unit (ACU)
7. MAPD Hydrogenation Reactor
1. Depropanizer Section

The Depropanizer column is designed to separate the (propane/propylene) stream

from lighter C4 components and heavier hydrocarbons. This separation is essential
to purify propylene/propane and to prepare the feed for further processing, like
Debutanization.

Feed Composition: Deethanizer bottom stream (which removes lighter C2 gases)

and Condensate Stripper bottom stream.

Operating Conditions:
Top pressure: 7.5kg / cm2g Top temperature: 14 ° C
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Bottom temperature: 71 ° C

This is made up of carbon steel and has 50 ripple trays. Actrene dosing is done to
prevent column fouling.

2. Propylene Stripper and Rectifier

This section is part of the Propylene/Propane separation system, where the goal is
to:
• Strip high-purity propylene (Cs) from the propane/propylene mixture.
• Achieve 99.8% propylene purity in the overhead.
• Recycle propane and other C3S back to the pyrolysis heater for cracking.

This two-column system ensures tight separation due to the close boiling points
of propylene (-47 °C) and propane (-42 °C).

1. Propylene Stripper
• Function: Strips propylene from propane-rich feed.
• Feed Entry: Feed enters somewhere between the top and bottom trays.
Dimensions: Height: 54 meters, Diameter: 3.6 meters,
Trays: 106 valve-type trays
• Operation: Works under controlled reflux to push pure propylene overhead
while sending propane and heavies to the next column.

2. Propylene Rectifier
• Function: Further purifies the overhead propylene stream to 99.8%+ purity.
• Dimensions:
Height: 74.3 meters
Diameter: 3.6 meters
Trays : 124 valve-type trays

This column work as a rectification tower, where propylene rises and is

condensed at the top, traces of propane are stripped out at the bottom.

Since propylene and propane are close-boiling, the system likely uses strong
reflux and precise heat input, and large numbers of trays to maintain sharp
separation.

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3. Debutanizer

The Debutanizer Column is responsible for separating C4 components (butanes

and butenes) from heavier C5+ hydrocarbons. It's the next purification step after
the Depropanizer, where C4S are recovered as a top product, and heavier
hydrocarbons are taken as bottoms.

This operation is crucial to recover valuable C4 components (which may include

1,3-butadiene, isobutane, and n-butane) and to reduce load on downstream units
and improve fuel/oil product quality.

Operating Conditions: Top Pressure: 4.5kg / cm2 Top Temperature: 50 °C and

Balance C4 stream is cooled and sent to storage for 1,3 Butadiene recovery at PTD
(Product Transfer Department)

4. Gasoline Fractionator Section

The Gasoline Fractionator is the next step after the Debutanizer, and its key role
is to separate and recover C5+ hydrocarbons, primarily to produce Pyrolysis
Gasoline (RARFS) and separate lighter and heavier fuel components.

Overhead Product:
Light hydrocarbons (mostly LPG-like) are stripped and sent to the Fuel Oil
Stripper or used as wash oil. These light ends may also be recycled for further
processing or burned as fuel.
Side/Bottom Products:

The bottom product is taken as Pyrolysis Fuel Oil (PFO), used as a heavy fuel
oil or blended. The main product, Pyrolysis Gasoline (RARFS), is recovered
from a side draw and sent to PTD (Product Transfer Department). This contains
aromatics (like benzene, toluene, xylene - BTX), olefins, and [Link]'s a
valuable feedstock for petrochemical units like Aromatics Recovery or BTX
extraction.

5. Depentanizer

The Depentanizer Column is designed to remove pentanes (C5 hydrocarbons)

from heavier [Link], it prepares LPG feed for furnaces by
removing heavier hydrocarbons that could affect combustion performance. If rich
gas is fed (high in heavier components), the depentanizer ensures these are
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stripped out to improve LPG purity.

40 valve-type trays are used.

Operation:
Top product (LPG-rich) is taken for furnace feed.
Bottoms (heavier hydrocarbons) are sent to RARFS to PTD.

6. Acetylene Converter Unit (ACU)

Acetylene (C₂H₂) is an undesirable byproduct formed during the thermal cracking

of hydrocarbons. Though it forms in small quantities, it's:
• Highly reactive, prone to polymerization and explosions.
• A poison for downstream catalysts (especially in polymer-grade ethylene
production).
So, the Acetylene Converter is used to:
• Hydrogenate acetylene to ethylene, which is valuable.
• Remove traces of C₂H₂ to meet polymer-grade ethylene purity
(<5 ppm acetylene).
• It's exothermic and done in controlled conditions to prevent
overhydrogenation. Usually, Pd-based catalysts are used with alumina or
silica support.
Acetylene converters are located after cracked gas compression and caustic
scrubbing, before the ethylene separation tower as part of the final purification
loop for polymer-grade ethylene.

7. MAPD Hydrogenation Reactor

In steam crackers, during propylene production, two reactive impurities are

formed: Methylacetylene (CH3C=CH) and Propadiene (CH2=C=CH2). These are
collectively called MAPD, and they are undesirable in polypropylene production
because they poison polymerization due to their chemical instability and highly
reactive nature. The key hydrogenation reactions are:

Catalyst: Pd-based catalyst on alumina or carbon support. Reactor Design:

Typically fixed-bed tubular reactor. The MAPD Reactor is placed after the
propylene Rectifier and before the storage or polymer-grade product tank.

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 General Safety & Precautions

• Fire and Explosion Prevention: This area handles light hydrocarbons

(methane, ethylene, propylene, LPG, pentanes) which are highly flammable.
Ensure proper grounding and bonding of equipment to avoid static discharge.
Use flameproof electrical fittings and maintain gas detectors (LEL) in working
condition.
• Process Pressure & Temperature Control: All columns operate under
pressure and varying temperatures. Regularly inspect and calibrate pressure
safety valves (PSVs), level controllers, and temperature indicators.
Overpressure or thermal runaway can lead to equipment damage or fire.
• Hydrogenation Units (ACU & MAPD Reactors): These involve exothermic
reactions. Maintain correct H₂-to-hydrocarbon ratio and control reaction
temperature to avoid overhydrogenation (ethylene/propylene to
ethane/propane) and excessive heat buildup. Use multiple temperature zones
with alarms.
• Cryogenic Operations (Demethanizer): Cryogenic hydrocarbons pose
frostbite risks and material embrittlement. Ensure insulation is intact, and
personnel handling cryogenic sections use proper PPE (cryogenic gloves, face
shield, apron).
• Leak and Emission Control: Implement an LDAR (Leak Detection and
Repair) program. Routinely check for hydrocarbon vapor leaks using handheld
detectors. Seal all flanges and valve glands with appropriate torque and
materials.
• Fire Protection & Emergency Systems: Maintain operational firewater lines,
foam extinguishers, and hydrants. Automatic emergency shutdown (ESD)
systems should be tested periodically. All operators must know the location of
the nearest fire alarm and muster points.
• Hot Work and Maintenance Safety: Strict permit-to-work system should be
followed for any welding, grinding, or cutting. Ensure the area is gas-free
before issuing hot work permits. Provide fire watchers during jobs near
columns or reactors.
• Personal Protective Equipment (PPE): Personnel must wear flame-resistant
coveralls, anti-static footwear, helmets, goggles, and hearing protection.
Cryogenic zones require special PPE. Use portable gas detectors during
inspection rounds.
• Training and Drills: Conduct regular training in emergency handling,
firefighting, breathing apparatus usage, and evacuation. Periodic mock drills
should be scheduled to assess readiness.

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