-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
1/39
Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission, dissemination, distribution or copying is stricktly prohibited
FurnaceFurnaceFurnaceFurnace RevampsRevampsRevampsRevamps ininininLowLowLowLow Budget TimesBudget TimesBudget TimesBudget Times
Koos OverwaterTechnip Benelux, The Netherlands
Richard KrumpenLyondellBasell Industries, Germany
Prepared for Presentation at the 2010 AIChE Spring Meeting,
San Antonio, Texas, March 21-25, 2010
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
2/39
2Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
I. CRACKING FUNDAMENTALS
III. LYONDELLBASELL OM4 RECOILING
II. FURNACE MODERNIZATION - APPROACH
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
3/39
3Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
I. CRACKING FUNDAMENTALS
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
4/39
4Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
Characteristics of Olefins Production
Strongly endothermic process
Absorbed duty: Q ~1.6 Gcal / tonne of feed
For 1.350 kta cracker: fired heat ~ 840 MW
Feed Products
Q
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
5/39
Radiant Section
Convection Section
~
~Hydrocarbon
Feed
Boiler Feed Water
Dilution Steam
HP Steam
Desuper-heater
Cracked Gas to
Separation Section
Transferline Exchanger
BFW
Radiant efficiency: 40 42%
Overall efficiency: 92 95 %
850 oC1250 oC
120 oC
620 oC
380 oC
520 oC
Steam Drum
Cracking Furnace
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
6/39
6Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
Feedstock Selection and Ethylene Yields
1822981Benzene
2161291417324Other (fuel)
2117440Raffinate-1
1814160Butadiene
605245350Propylene
100100100100100Ethylene
433334300226125Feed
GasoilNaphthaC4-LPGC3-LPGEthane
(Feed and Products in tons per 100 ton of ethylene product)
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
7/39
Mixed
Products
Quench
Drier
Fuel Oil
Hydrogen
Compressor andChilling
Steam
Quench Methane
AcetyleneConverter
Ethane
Ethylene
PropanePropylene
NAPDConverter
MixedButanes
Gasoline
CrackingFurnaces
Ethane
Naphtha
Acid Gas
PrimaryFractionator
Feeds
Material Movements
Utilities
Olefins Complex
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
8/39
Cracking is:
non-catalytic governed by reaction kinetics
intrinsically non-selective
Hence:
looking primitive and unsophisticated, but requires advanced engineering modelling:
SPYRO
Cracking Technology
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
9/39
9Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
SPYRORigorous Simulation of Steam CrackingProcess
CRACKINGCRACKING
SECTIONSECTION
HYDROGENHYDROGEN
METHANEMETHANE
::
ETHYLENEETHYLENEPROPYLENEPROPYLENE
::
GASOLINEGASOLINE
FUEL OILFUEL OIL
SPYROSPYRO == PREDICTION OF EFFLUENT SLATE ASPREDICTION OF EFFLUENT SLATE AS
FUNCTION OF:FUNCTION OF:
1. FEED SPECIFICATIONS1. FEED SPECIFICATIONS
2. OPERATING CONDITIONS2. OPERATING CONDITIONS
3. COIL GEOMETRY3. COIL GEOMETRY
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
10/39
10Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
SPYROModel
THERMODYNAMICTHERMODYNAMICCONSISTENCY WITHCONSISTENCY WITH
REVERSE REACTIONSREVERSE REACTIONS
THERMOCHEMICALTHERMOCHEMICALKINETICKINETIC
THEORIESTHEORIES
LITERATURELITERATURE
DATADATA
COMPLETENESSCOMPLETENESS
AND SIMPLIFICATIONAND SIMPLIFICATION
LEVELLEVEL
KINETICKINETIC
SCHEMESCHEME
ANALOGIESANALOGIES
BETWEEN SIMILARBETWEEN SIMILAR
REACTIONSREACTIONS
NUMERICALNUMERICAL
METHODSMETHODSREACTORREACTOR
MODELMODEL
EXPERIMENTALEXPERIMENTAL
DATADATARESULTSRESULTS
TUNINGTUNING
FACTORSFACTORS
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
11/39
11Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
128 Components + 20 radicals
Hydrocarbon components C1 - C42 Groups
Paraffins, Normal- & Iso-Naphtenics, mono-, di-, poly
Aromatics, mono, di-, poly-Olefins, di-Olefins
Real components Pseudo (lumped) components
H2O, CO, CO2, H2
SPYROComponent Library
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
12/39
12Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
SPYROenables optimization of :
Coil selection
Coil sizing
against :
Yields
Runlengths
Feedstock flexibility
Operating cost
Investment cost
CONVENTIONAL (MK) GK1 OR GK2 GK3
GK4 GK5 GK6
SMK
SPYRO : Tool Kit for Cracking Furnace Design
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
13/39
Radiant Section
Convection Section
~
~Hydrocarbon
Feed
Boiler Feed Water
Dilution Steam
HP Steam
Desuper-heater
Cracked Gas to
Separation Section
Transferline Exchanger
BFW
Radiant efficiency: 40 42%
Overall efficiency: 92 95 %
850 oC1250 oC
120 oC
620 oC
380 oC
520 oC
Steam Drum
SPYRO Simulation Suite covers complete furnace
SPYROFIREBOX
CONVECTES
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
14/39
14Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
II. FURNACE MODERNIZATION - APPROACH
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
15/39
15Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
Furnace Modernization Approach (Phases)
C2=
FeasibilityPhase
Proposal Phase
Project Execution
Modernized Furnace
Increased Production / Reliability
C2=
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
16/39
16Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
Furnace Modernization Approach
Feasibility
Phase
Base Case
Revamp Cases
Validation
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
17/39
17Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
Furnace Modernization Approach
Feasibility
Phase
Base Case
Revamp Cases
Validation
OPERATING DATA
EXISTING DESIGN
PLANT ISSUES
MAINTENANCE
CONTROL
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
18/39
18Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
Furnace Modernization Approach
Feasibility
Phase
VALIDATED MODEL
DEFINITION OF BASE CASE
REFERENCE CASE
Base Case
Revamp Cases
Validation
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
19/39
19Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
Furnace Modernization Approach
TARGETS
TECHNIP COIL DESIGN
COMPARISON
INTERACTION
CHOICE
COMPLETE ADEQUACY CHECK
TECHNIP COIL DESIGN
Feasibility
Phase
Base Case
Revamp Cases
Validation
COMPLETE ADEQUACY CHECK
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
20/39
20Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
Technip Radiant Coil Types - Overview
GK1 OR GK2GK1 OR GK2 GK3GK3 GK4GK4 GK5GK5
CONVENTIONAL (MK)CONVENTIONAL (MK)
GK6GK6
SMKSMK
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
21/39
21Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
Technip Radiant Coil Types GK6 (Liquid Cracking)
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
22/39
22Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
SPYROTM
Technip Radiant Coil Type - Selection
CAPACITYCAPACITY
FEEDSTOCKS FIREBOX DIMENSION
HEAT FLUX
NO. OF NEW COILSTYPE OF COILS
RUNLENGTHRUNLENGTH
COIL SURFACE AREA
FIRED HEAT
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
23/39
23Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
Furnace Modernization Approach
TARGETS
TECHNIP COIL DESIGN
COMPARISON
INTERACTION
CHOICE
COMPLETE ADEQUACY CHECK
Feasibility
Phase
Base Case
Revamp Cases
Validation
COMPLETE ADEQUACY CHECK
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
24/39
24Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
Design Check List has been developed based on Experience of Furnace
Modernization
Check List addresses all furnace items; e.g.
Radiant Section,
Check Refractory
Check Burners (capacity, revamp options if required)
Check (partly) re-use of radiant inlet manifold
Convection Section
Check Capacity
Check Pressure drop (process side + flue gas side) Check Design Pressure, Design Temperature
Check Material adequacy incl. finning
Furnace Modernization Adequacy Check
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
25/39
25Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
Steam System
Check Steam drum size
Check safety valve capacity
Check TLE ID Fan
Check Capacity
Check pressure drop
Check modification options if required
Lines + in-line Instrumentation
Lines around furnace: size, delta P, design temps.
Check size of Cracked gas valves, Check sizing of control valves and safety valves
Furnace Modernization Adequacy Check
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
26/39
26Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
Check Control Philosophy
E.g. Pass balancing,
Check Foundation
For new loading after modernization
Check Structural Steel
For new design after modernization
Review Constructability
Review different scenarios for modernization
Enable short shutdown to minimize production stop of relevant furnace
Review Maintenance
For future maintenance work of modernized furnace design
Furnace Modernization Adequacy Check
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
27/39
27Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
Capacity increase 0-15% 15-25% >25%New Radiant Coil X X X
Crossover piping X X X
Coil Support system X X X
Minor refractory work X X X
Critical Flow Venturi X X X
New Burners ** X X
New flue gas fan ** X X
New inlet cones to TLE X X
New TLE ** X
Convection Sectoin - Partial retubing X
Convection Sectoin - Extensive retubing X
Refractory change X
Piping Modifications - Partial X
Piping Modifications - Extensive X
Instrument Modification - Partial X
Instrument Modification - Extensive X
Scope of Modernization
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
28/39
28Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
III. LYONDELLBASELL OM4 RECOILING
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
29/39
29Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
Study Objectives
History: Original furnace design by Technip (KTI) in 1988 First recoiling design by Technip (KTI) in 1998 Second recoiling design by Technip in 2006
Operational parameters before second recoiling: Feedstock: Heavy liquid Feed Capacity: normal (average) 27 t/h (design: 32 t/h) Steam to Oil Ratio: X
Run length: 42 days, decreasing to less than 30 days over the years
Objectives:
Increase run length to > 30 days Investigate impact of lowering Steam to Oil ratio to STOR=X-10% Evaluate potential for furnace capacity increase
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
30/39
30Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
Validation Case
Simulation by SPYROof existing operating data
Findings: Good match of operating data with simulation results (heat and material
balance matching) Firebox efficiency higher than original design (different flame/heat
release pattern) Coking rate adjusted to match run length data (effect of feedstock
quality)
Convection section performance reasonably good Air preheater shows some bypassing Approx. 5% of false air ingress in firebox
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
31/39
31Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
Reference Case
Capacity: 31 t/h
Tuning parameters Firebox: heat release pattern as per validation case
Coking rate: as per validation case Convection Section: fouling coefficients as per validation case Air preheater efficiency: reduced as per validation case Excess air: as per validation case
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
32/39
32Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
basebasekg/kgSeverity (Propylene/Ethylene ratio)
-3.6%basewt%Methane
+0.6%basewt%Ethylene
-5.5%basewt%Ethane
+0.7%basewt%Propylene
+3.0%baseMWFired Heat
+3.2%baset/hHP steam
+0.6%baset/hOnce through Ethylene Production+0.1%
9
28
X
31
ReferenceSTOR X
base
9
30
X-10%
31
ReferenceSTOR X10%
t/h
%
days
kg/kg
t/h
Ultimate Ethylene Production
STOR
Feedstock
Run length
Excess air
Case
Reference Case Effect of Steam to Oil Ratio
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
33/39
33Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
Observations:
STOR X gives: slightly shorter run length
3.0% more firing 3.2% more HP Steam production
5.5% lower Recycle Gas production
STOR X-10% gives: more margin for capacity expansion
Reference Case Effect of Steam to Oil Ratio contd
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
34/39
34Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
Radiant Coil Selection
Short Medium Kinetics
48 Coils in Two-lane Arrangement
Short Residence Time
High Selectivity
High Capacity
Simple, Robust Design
Coil Design Applying GK6 Technology
92 Furnaces Revamped with GK6Technology
SMK Type
Revamp
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
35/39
35Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
-1.3%baset/hCombustion air
-1.0%baset/hFlue gases
+3.0%baset/hFuel gas
basebasekg/kgSeverity (Propylene/Ethylene ratio)
-4.3%basewt%Methane
+0.9%basewt%Ethylene
-7.5%basewt%Ethane
+0.8%basewt%Propylene
+3.0%baseMWFired Heat
+3.2%baset/hHP steam
+7.4%baset/hOnce through Ethylene Production
+6.6%
4.5
53
X-10%
33
Revamp -max. throughput
base
9
30
X-10%
31
Reference
t/h
%
days
kg/kg
t/h
Ultimate Ethylene Production
STOR
Feedstock
Run length
Excess air
Case
Revamp Case Performance overview
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
36/39
36Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
Revamp Case Adequacy Checks of non-modifiedEquipment
Convection Section materials: Furnace efficiency increased
Lower fluegas temperatures (despite higher capacity)
Materials Convection Section OK
Flue Gas Fan: Lower amount of false air ingress Lower amount of combustion air (despite capacity increase) Lower amount of flue gases
Flue Gas Fan OK
Control Valves Feed: flow rate increased by 3%: OK
Dilution Steam: reduced by 10%: OK
Fuel gas: flow rate increased by 3%: OK
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
37/39
37Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
Summary of Modifications
New Radiant Coil Replace existing coils with SMK coils in two-lane arrangement
New Radiant Coil Inlet Manifolds Replace existing manifolds, including new weld-on brackets
Existing rigid struts will be reused New Radiant Coil Support System
Replace existing counter weights with constant and variable load springs New Critical Flow Venturis
Replace existing venturis with new smaller venturis
New Shadow Box Cover Replace existing shadow box cover, including new protrusion seals
New Trough Replace existing bottom trough with a new larger one
No guide tubes required
R O ti l F db k
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
38/39
38Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
Revamp Operational Feedback
Recoiled furnaces were started up smoothly Average furnace capacity increased from 27 t/h to 29 t/h Run length increased from 30 days to approx. 60 days Excess air could be reduced by approx. 5 %
Room for optimization: Market situation does not require operation at full capacity Critical Flow Venturuis at radiant coil inlets were sized for maximum flow
in combination with minimum supply pressures of feed and dilution
steam During turndown operation the originally anticipated STOR had to be
increased in order to keep the venturis under critical flow conditions Basis of Design may have to be modified in order to arrive at more
optimal venturi sizing for lower capacities
C l i R C t h t th t t f
-
8/13/2019 3 Furnace Furnace Revamps Revamps Revamps in in Low Low Budget Times -- Technip
39/39
39Copyright Technip. The presentation herein is intended for presentation purposes; any unauthorized use, review, transmission,
dissemination, distribution or copying is stricktly prohibited
Conclusion: Revamp Concept has met the target ofincreased run length