HALDIA PETROCHEMICALS LTD.

TECHNOLOGY TRAINING COURSE

PROCESS OVERVIEW

October 19,1998 Slide No. 1

Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW

Ethylene and Propylene

From

Naphtha and C5’s

October 19,1998 Slide No. 2

Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW

• PLANT - STEAM CRACKER

+ ISBL (Inside Battery Limits)
– Ethylene Unit -- Really an Olefins Unit
> Processing Sections
» Cracking
» Hot & Cold Fractionation
» Refrigeration
+ OSBL (Outside Battery Limits)
– Support Facilities
> Feed & Product Storage
> Utilities Production (except SHP steam)
> Flare
October 19,1998 Slide No. 3
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW

• FEEDS
+ FRESH FEEDS
– Naphtha Liquid
– C5 Recycle
– C3 LPG (alternate feed)
– C4 LPG (alternate feed)

+ RECYCLE FEEDS
– Ethane
– Propane
– Miscellaneous Intraplant Recycles
October 19,1998 Slide No. 4
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW

• PRODUCTS
+ PRODUCTION RATE
– 420,000 MTA ETHYLENE (polymer grade)
– 210,000 MTA PROPYLENE (polymer grade)

• OPERATING HOURS
– 8000 hours/year = 333 days/yr
– 91+ % Onstream Factor => 19 days down

October 19,1998 Slide No. 5

Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW

• BYPRODUCTS
+ Hydrogen
– High Purity 99.5 vol%
– Low Purity 95.0 vol%
+ Mixed C4’s Feed to BD Extraction Unit
+ Raw Pyrolysis Gasoline
+ Fuel
– Methane Fuel Gas (Cracking Heater Fuel)
– Pyrolysis Fuel Oil (PFO)

October 19,1998 Slide No. 6

Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS REACTIONS (ISBL)
+ Steam Cracking
– Thermal decomposition of large HC molecules
– Reaction products are much smaller molecules
– Effluent is mix of all products, good and bad
– Conditions Affect Product Yields
> High temperature, low pressure
> HC mixed with Dilution Steam
> Very short reaction times
– Reaction is endothermic
> Requires great amount of heat
– Reaction occurs in Cracking Heater (Furnace)
October 19,1998 Slide No. 7
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW

• PROCESS REACTIONS (ISBL) Cont’d

+ Additional Reactions
– Hydrogenation of Unsaturated Impurities
> C2 Acetylene C2H2
> C3 Acetylene & Diolefin C3H4 (MAPD)
> Highly exothermic (Release much heat)
– Acid Gas Neutralization
> H2S & CO2
– Adsorption
> Hydrogen (PSA Unit)
> Water (Various Dryers)
> Sulfur (COS in Propylene Product)
– Methanation
> Catalytic conversion of CO to H2O in H2 product

October 19,1998 Slide No. 8

Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PRODUCT RECOVERY STEPS
+ Hot End Heat Removal
– Remove heat that was added to thermally crack
+ Heavy Ends Fractionation
– Condensation & Separation of Fuel Oil (PFO)
from heater effluent
+ Compression
– High pressure is required to fractionate light
gases from the heater effluent
+ Cold Fractionation
– Conventional distillation
October 19,1998 Slide No. 9
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW
+ Feed Handling
– Receive feeds from OSBL
> Naphtha
> C5 Recycle
> C3 & C4 LPG (alternate Cases)
– Vaporize liquids feeds as necessary
> C3 & C4 LPG (alternate Cases)
– Preheat feeds to heater inlet conditions
> Naphtha / C5 is preheated with hot Quench Water
> C3 & C4 LPG is preheated with LP Steam

– Distribute to individual heaters

October 19,1998 Slide No. 10
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Cracking Heaters
– Function
> Heat hydrocarbon feed to cracking temperatures
> Vaporize Naphtha and C5 liquid feed
> Mix feed with dilution steam
> Thermally crack hydrocarbon molecules to produce
others (usually smaller) which are more valuable
> Recover combustion heat
> Perform same functions on internally produced
recycle streams of ethane and propane

October 19,1998 Slide No. 11

Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Cracking Heaters
– Design
> 1 - SRT III
» Ethane recycle
» Propane recycle
> 6 - SRT IV (HS) now called SRT V (includes 1 spare)
» Naphtha & C5’s (Co-cracking)
» C3 & C4 LPG (3 heaters only) (Split cracking)
» Ethane & Propane Recycle (2 heaters only)
> Heater designs differ in radiant coil geometry

October 19,1998 Slide No. 12

Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Cracking Heaters Induced Draft Fan
Flue Gas Damper
Stack
Convection Coils
Heater Feed •Feed Preheat & Vaporization
Dil. Stm •Mixed Preheat (Inc. D/S)
Convection BFW
Heater Outlet •BFW & SHP Coils
SHP
Section to TLE’s
COT Crossover (External Piping)
Bridgewall or Arch
Venturis (SRT IV only)
Radiation Radiant Coils
Section Thermal Cracking
(Firebox) Hearth or Floor Burners (Hearth & Wall)

October 19,1998 Slide No. 13

Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Cracking Heaters
– Considerations
> Ethylene production capacity set by heater feed
rates
> Propylene production set by:
» Feed slate
» Degree of cracking (severity)
> Other byproducts depend on selectivity of the
cracking reaction
> Cracking causes coke formation in the radiant coil
which is removed by decoking
October 19,1998 Slide No. 14
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Cracking Heaters
– Considerations (cont’d)
> Degree of cracking (severity) defined two ways:
» Gas cracking = disappearance of ethane/propane
from heater feed to effluent
» Liquid cracking = Ratio of propylene to ethylene in
heater effluent
> Severity or conversion set by coil outlet temperature from
cracking heater radiant section (COT)
> Higher severity cracking reduces P/E ratio
> Typical moderate severities:
» Ethane = 65% disappearance of ethane
» Propane = 90% disappearance of propane
» Naphtha / C5 = .55 ratio of propylene to ethylene
October 19,1998 Slide No. 15
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Cracking Heaters
– Considerations (cont’d)
> Selectivity determined by:
» Coil geometry
» Residence time
» Hydrocarbon partial pressure
Dilution Steam ratio (S/O) *
Coil outlet pressure (COP) *
* Operator has direct control of these only

» Higher S/O improves selectivity - costs energy

» Lower COP improves selectivity - costs capacity

October 19,1998 Slide No. 16

Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Primary Transfer Line Exchangers (TLE’s)
– Function
> Stop Cracking Reaction
> Recover Heat from Heater Effluent
> Generate SHP Steam
– Design
> Shell and Tube Exchangers (Vertical Thermosyphon)
> Close coupled to Radiant Coil Outlet
> Low Pressure Drop and residence time
> One steam drum per heater provides holdup of BFW
– Considerations
> Susceptible to fouling
October 19,1998 Slide No. 17
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Secondary Transfer Line Exchangers
– Function
> Recover additional Heat from Heater Effluent
> Preheat Mixed feed to Ethane recycle heater
– Design
> One Shell and Tube Exchanger
> Low Pressure Drop
– Considerations
> Doesn’t foul
> Ethane heater only

October 19,1998 Slide No. 18

Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Quench Fittings - Liquid heaters only
– Function
> Fully quench reaction of liquid cracking heaters
> Reduce effluent temperature of liquid cracking TLE’s
to protect downstream equipment
– Design
> Multiple spray nozzles for thorough mixing
> Low pressure drop
> Circulating quench oil cools and condenses effluent

October 19,1998 Slide No. 19

Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Gasoline Fractionation
– Gasoline Fractionator
> Function
» Separate heaviest components from Gasoline
» Remove heat from effluent (Charge Gas)
» Condense Quench Oil (QO) and provide sump for
circulation
> Design
» Tower with multiple packed beds for distillation
» Sidestream liquid draw-off for Pyrolysis Gas Oil
» Baffle tray section for heat transfer
» Large bottoms sump for QO inventory
October 19,1998 Slide No. 20
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Gasoline Fractionation
– Fuel Oil Stripper
> Function
» Control viscosity of Circulating QO
» Strip light components from a slipstream of QO,
and produce the PFO product
» Strips light components from PGO sidedraw from
Gasoline Fractionator
> Design
» Two-part trayed column
» QO Stripping by Ethane heater effluent
» PGO stripping by LP steam
October 19,1998 Slide No. 21
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Gasoline Fractionation
– Hot Oil Circulation
> Function
» Recover High level heat from the Gasoline
Fractionator
» Generates Dilution Steam used in heaters
» Provide QO for use in SRT IV quench fittings
> Design
» Large circulation requires large centrifugal pumps
» Filters provided to remove coke
> Considerations
» Highest bottoms temperature at lowest viscosity
maximizes heat transfer
October 19,1998 Slide No. 22
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Quench Water System
– Quench Tower
> Function
» Cool Charge Gas before compression
» Provide reflux for Gasoline Fractionator
» Condense Dilution steam for recovery
» Provide reservoir for Quench Water (QW)
> Design
» Multiple packed bed tower for heat transfer
» Direct counter current contact with circulating QW
» Large “bulb” at bottom for liquids separation and
inventory
October 19,1998 Slide No. 23
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Quench Water System
– Quench Water (QW) Circulation
> Function
» Remove heat from Quench Tower
> Design
» Large circulation requires large centrifugal pumps
» Water circulation through many process users for
heat exchange
» Cooling water exchangers for final heat rejection
> Considerations
» Maximizing Heat removed by process users
minimizes cooling water requirements
» pH control required to prevent emulsions
October 19,1998 Slide No. 24
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Quench Water System
– Process Water Stripping
> Function
» Strip contaminants from condensed Dilution
Steam
» Provide Process Water (PW) for Dilution Steam
Generation
» Maintain water balance
> Design
» Trayed tower
» Stripping by reboiler and live LP steam
> Considerations
» pH control essential for good stripping
October 19,1998 Slide No. 25
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Quench Water System
– Dilution Steam Generation
> Function
» Remove heat from Hot Quench Oil
» Generate Dilution Steam from Process Water
» Blow down contaminants from closed system
> Design
» Shell and Tube thermosyphon exchangers
» MP steam exchangers to provide balance of
dilution steam requirement
» Superheat of Dilution Steam
> Considerations
» Potentially corrosive system requires pH control
October 19,1998 Slide No. 26
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Charge Gas Compression
– Charge Gas Compressor
> Function
» Compress Charge Gas in order to separate
hydrogen and methane by products
> Design
» 5 stage centrifugal compressor
» Intercoolers and drums to remove heat of
compression and condensed liquids
» Wash oil injection to eliminate fouling
> Considerations
» Controls heater cracking pressure

October 19,1998 Slide No. 27

Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Charge Gas Compression
– Acid Gas Removal
> Function
» Remove Acid gases H2S & CO2 from charge gas
by direct contact with circulating caustic (NaOH)
> Design
» Located between 3rd & 4th compression stages
» 3 section trayed tower
• Water wash
• 2 Caustic Compartments
» Yellow oil draw-off provided
> Considerations
» H2S poisons downstream hydrogenation
» CO2 contaminates ethylene product
» Yellow oil can form, fouling tower internals

October 19,1998 Slide No. 28

Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Charge Gas Compression
– Condensate Stripper
> Function
» Remove C2 and lighter from the 4th & 5th stage
condensed hydrocarbon liquid
» Provide feed to the Depropanizers that bypasses
chilling train, Demethanizer, and Deethanizer
> Design
» Trayed stripping tower with water draw-off
> Considerations
» Large amounts of free water cause problems
» Excess stripping causes large compressor
recycle
October 19,1998 Slide No. 29
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Charge Gas Drying
– Function
> Remove all moisture from Charge Gas before chilling
– Design
> Molecular sieve fixed bed vessel (+1 spare)
> Moisture analyzer monitors water content on-line
> Guard bed below 1st moisture probe for extra time
> Regenerate when saturated
– Considerations
> Water breakthrough freezes in the chilling train and
reduces capacity

October 19,1998 Slide No. 30

Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Charge Gas Chilling Train
– Function
> Provide liquid feeds for Demethanizer
> Cryogenic separation of methane product and crude
hydrogen (95%)
> Interchange heat with cold process streams
> Recover refrigeration from cold product streams
before sending to battery limits
> Recuperate cold for ethylene / propylene refrigerant
streams

October 19,1998 Slide No. 31

Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Charge Gas Chilling Train (Cont’d)
– Design
> Plate fin (Core) exchangers used for close
temperature approaches of process streams and
refrigerant sub-cooling
> Ethylene / Propylene refrigerant exchangers used for
trim chilling when no process streams are available
> Kettle exchangers used for Ethylene / Propylene
refrigeration exchangers
> Separation drums for vapor liquid disengaging
> Coldest core exchangers and drums located in
Coldbox for better insulation
> Permanent strainers on streams to coldbox
> Joule Thompson expansions used for methane
liquefaction

October 19,1998 Slide No. 32

Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Charge Gas Chilling Train (Cont’d)
– Considerations
> Core exchangers have small clearances
» Finest “filters” in the unit -- < 1 mm
» Subject to plugging from construction debris or
hydrates and freezing water
> Highly heat integrated with process
> Temperature profile of charge gas through chilling train
very important for proper separations
> Piping and vessels in Coldbox are aluminum and can
be attacked by liquid mercury if present
> NOx if present can react with diolefins and condense in
Coldbox equipment forming explosive gums
October 19,1998 Slide No. 33
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Hydrogen Purification
– Function
> Produce high purity H2 product
> Remove CO from low purity H2
> Dry low purity H2 used in hydrogenation
> Produce H2 for Acetylene Converter use
– Design
> PSA unit used to produce high purity H 2
> Methanator used to convert CO
> Molecular sieve used for drying
> Ethane wash to provide Acetylene Converter H 2
– Considerations
> Ethylene in methanator feed can cause runaway
> CO in H2 poisons hydrogenation catalyst
October 19,1998 Slide No. 34
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Demethanizer
– Function
> Remove methane from process feeds
> Provide Deethanizer feed as bottoms product
– Design
> Multi-packed bed tower
> Open loop Methane refrigeration used to condense
overhead reflux and some methane product
> Over-condensed methane liquid provides chilling in chill
train by vaporizing
– Considerations
> Proper operation depends on chilling train temperature
profile
> Heat input is integrated with chilling train
October 19,1998 Slide No. 35
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Deethanizer
– Function
> Fractionate C3+ components from C2’s
> Purge C2 Green Oil formed in Acetylene Converter
> Net overhead provides feed to Acetylene Converter
> Bottoms provides feed to Depropanizers
– Design
> Trayed tower with split feeds
– Considerations
> Affects performance of Acetylene converter
> Controls C3’s in ethane recycle
October 19,1998 Slide No. 36
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Acetylene Conversion
– Function
> Hydrogenate acetylene to ethylene and ethane
– Design
> Fixed bed vapor phase catalytic reactor (+1 Spare)
> Heat exchangers provide proper inlet temperatures to
reactor beds and remove heat of reaction
> H2 injection ratioed to Deethanizer net overhead
– Considerations
> Proper operation produces an ethylene gain
> Highly exothermic reaction -- Extremely high temperature
can cause decomposition of ethylene
> Green oil formed can foul downstream equipment if not
removed
> Acetylene is impurity in ethylene product
October 19,1998 Slide No. 37
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ C2 Green Oil Removal
– Function
> Remove Green Oil formed in Acetylene Converter
– Design
> Inline mixer mixes cooled converter effluent with
liquid ethylene sidestream from C2 Fractionator
> Knock-out drum separates liquid containing green oil
> Liquid is pumped to Deethanizer to purge green oil
– Considerations
> Proper operation of Acetylene converter minimizes
green oil formation
> Recycle to Deethanizer acts as reflux

October 19,1998 Slide No. 38

Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Ethylene Fractionation
– Function
> Fractionate ethylene from ethane
> Strip light gases (H2 & Methane) from ethylene
> Produce Ethylene Product as sidestream
> Bottoms is ethane recycle feed to cracking heaters
– Design
> Trayed tower
> Pasteurization section on top for stripping lights
> Multiple heat integrated reboilers
– Considerations
> Large system slow to react
> Heat integration of reboilers requires good fractionation
> Any water freezes in tower
October 19,1998 Slide No. 39
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
+ Polymer Grade Ethylene Key Specifications
> Ethylene 99.95 vol%
> Hydrogen 5 vol ppm
> Methane + Ethane 500 “
> Acetylene 1 “
> Propylene + Propane 10 “
> Propadiene 5 “
> Methyl Acetylene 5 “
> C3’s + C4’s 10 “
> CO 0.2 “
> CO2 2 “
> Methyl Alcohol 1 “
> Ammonia nil
> Total Sulfur 1 “

October 19,1998 Slide No. 40

Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
+ ETHYLENE PRODUCT
– Specifications requiring operator attention
> Acetylene 1 vol ppm
» Acetylene converter operation
> Methane + ethane 500 vol ppm
» Demethanizer and C2 Fractionator operation
> CO2 2.0 vol ppm
» Caustic tower operation
> H2 5 vol ppm
» H2 addition rate to acetylene converter

October 19,1998 Slide No. 41

Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
+ ETHYLENE PRODUCT
– Other “Easier” Specifications requiring operator
attention
> Propylene and heavier 10 vol ppm
» Deethanizer & C2 Fractionator
> CO 0.2 vol ppm
» Methanation
> Sulfur 1.0 vol ppm
» Caustic Tower
> Water 1.0 vol ppm
» Charge Gas & Ethylene Dryers
> Methanol 1.0 vol ppm
» Methanol injection for intermittent de-icing
October 19,1998 Slide No. 42
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Depropanizer
– Function
> Separate C3’s from C4+ components in Deethanizer
bottoms and Condensate Stripper bottoms
> Provide overhead C3 feed to MAPD converters
> Bottoms feeds Debutanizer
> Purge C3 Green Oil formed in MAPD converters
– Design
> 2 trayed towers operating at different pressures
» High pressure tower (No.1) condensed with
cooling water
» Low pressure tower (No. 2) minimizes bottoms
temperature
October 19,1998 Slide No. 43
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Depropanizer (Cont’d)
– Design (Cont’d)
> Water draw-off on reflux drum removes saturate water
from Condensate Stripper bottoms feed
– Considerations
> Controls C4 content of propane recycle
> Controls C3- in Mixed C4 Product
> Potentially fouling bottoms controlled with additive
> Water from Condensate Stripper must be drained from
boot on reflux drum
> MAPD can concentrate in top tower (No. 1) Never
operate on total reflux without adjusting controls
October 19,1998 Slide No. 44
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ MAPD Conversion
– Function
> Hydrogenate MAPD to form propylene and propane
– Design
> Fixed bed liquid phase catalytic reactor (+1 Spare)
> Partial vaporization of liquid controls reactor temperature
> Flash drum disengages effluent and vaporizes net C 3’s
> H2 Injection required
– Considerations
> Proper operation produces a propylene gain
> Recycle of effluent controls MAPD concentration in reactor
feed
> MAPD can concentrate in C3 Fractionator and decompose
spontaneously and violently
October 19,1998 Slide No. 45
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Propylene Fractionator
– Function
> Fractionate propylene from propane
> Strip light gases (H2 & Methane) from propylene
> Produce Propylene Product as sidestream
> Bottoms is propane recycle feed to cracking heaters
– Design
> 2 trayed towers -- super fractionator (230 trays)
> Vent condenser on overhead minimizes C 3- recycle
> Sulfur (COS) removal bed on Propylene product
– Considerations
> Large system slow to react
> Never operate on total reflux when MAPD is present
October 19,1998 Slide No. 46
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
+ Polymer Grade Propylene Key Specifications
> Propylene 99.5 vol%
> Hydrogen 5 vol ppm
> Methane + N2 100 “
> Ethane 200 “
> Ethylene 10 “
> Acetylene 1 “
> Propadiene (PD) 2 “
> Methyl Acetylene (MA) 2 “
> BD 1 “
> C4’s + C5’s 200 “
> CO 0.1 “
> CO2 3 “
> Methyl Alcohol 5 “
> Total Sulfur 1 “
> COS 0.02 “
> Ammonia 5 wt ppm
October 19,1998 Slide No. 47
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
+ PROPYLENE PRODUCT
– Specifications requiring operator attention
> Propylene 99.5 vol %
» C3 Fractionator
> Methane + N2 100 vol ppm
» MAPD Converter
> Ethane 200 vol ppm
» Deethanizer CO2 2.0 vol ppm
> H2 5 vol ppm
» H2 addition rate to MAPD converter
> MAPD 2 vol ppm each
» MAPD Converter
October 19,1998 Slide No. 48
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
+ PROPYLENE PRODUCT
– Other “Easier” Specifications requiring operator
attention
> CO 0.1 vol ppm
» Methanation
> Sulfur 1.0 vol ppm
» Caustic Tower
> Water 1.0 vol ppm
» Condensate Stripper, Depropanizer, C3 Dryers
> Methanol 5.0 vol ppm
» Methanol injection for intermittent de-icing
> COS 0.02 vol ppm
» COS guard bed
October 19,1998 Slide No. 49
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Debutanizer
– Function
> Separate C4’s from C5+ components in Depropanizer
bottoms
> Produce Mixed C4 product as net overhead liquid
> Bottoms is Light Gasoline product
– Design
> Trayed tower
– Considerations
> Potentially fouling bottoms circuit protected by
additive injection

October 19,1998 Slide No. 50

Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW

+ Raw C4 Key Specifications

> Total C3 and lighter 0.2 wt % max
> Total C5 and heavier 0.05 wt % max
> Water 300 wt ppm

+ Specifications requiring operator attention

> Total C3 and lighter 0.2 wt % max
» Depropanizer
> Total C5 and heavier 0.05 wt % max
» Debutanizer
> Water 300 wt ppm
» Condensate Stripper
» Depropanizer water draw-off
October 19,1998 Slide No. 51
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW

+ Pyrolysis Gasoline Key Specifications

> Total C4 and lighter 0.5 wt % max
> End Point (ASTM) 200 °C

+ Specifications requiring operator attention

> Total C4 and lighter 0.5 wt % max
» Debutanizer
> End Point (ASTM) 200 ° C
» Gasoline Fractionator PGO side draw-off
» LP steam stripping Fuel Oil Stripper

October 19,1998 Slide No. 52

Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Refrigeration
– Function
> Provide necessary low temperature cooling and
condensing of process streams that can not be done by
other process streams
– Design
> Two systems, 7 temperature levels
» Propylene -40 -27 -5 +13 °C
» Ethylene -101 -75 -63 ° C
> Multi-stage centrifugal compressors - closed systems
> Kettle exchangers vaporize liquid refrigerant to provide
cooling
» System pressures determine temperatures of
refrigerants
> Interstage drums provide disengaging and liquid holdup
October 19,1998 Slide No. 53
Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
• PROCESS FLOW (Cont’d)
+ Refrigeration (Cont’d)
– Considerations
> Proper operation of process requires refrigerant
temperatures to be as designed
> Achievable temperatures depend on purity of refrigerant
and compressor individual stage suction pressures
> Automatic control of recycle flows to prevent surging
» Necessary for start-up and reduced capacity
operation
» Recycles should be closed over about 80% capacity
if not, refrigeration capacity is reduced
> Make-up to systems from product ethylene and
propylene

October 19,1998 Slide No. 54

Process [Link]
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW
OVERALL MATERIAL BALANCE
FEEDS: kg/h Case 1 Case 2
FRESH
Naphtha 153,942 114,988
C3 LPG (Alternate Feed Cases) --- 34,441
C4 LPG (Alternate Feed Cases) --- ---
Hydrogenated C5’s 6,390 6,761
INTERNAL RECYCLES
Ethane 11,840 12,010
Propane 1,131 4,915

PRODUCTS: kg/h
Ethylene (Polymer Grade) 52,500 52,500
Propylene (Polymer Grade) 26,250 26,250
Hydrogen
High Purity (99.5 vol % H2) 75 75
Low Purity (95.0 vol % H2) 793 793
Methane Off Gas (90 vol% C1) 24,977 26,370
Mixed C4’S (not hydrotreated) 16,115 15,478
Raw Pyrolysis Gasoline 31,939 30,008
Pyrolysis Fuel Oil 7,734 4,796
Acid Gas Rejected 193 176

October 19,1998 Slide No. 55

Process [Link]