Olefin units at MOL Petrochemicals

Dávid Horváth Ph.D.

Olefin Asset Leader Technologist

2

3

5

6

7

8

Olefin-1 plant

(Linde – 1975)

Olefin-2 plant

(Linde – 2004)

Ethylene & Propylene

cryogenic tanks

The Olefin Asset

LD

PE

-2, H

DP

E-1

& 2

, P

P-3

& 4

, B

ors

odC

hem

Ethylene

Propylene

Raw

mate

rials

fro

m D

UF

I and T

IFO

Raw C4

BDEUTankyard

MTBE

9

Olefin-2

10

Olefin-1 plant I/O

Ethane (repyrolysis)

Propane (repyrolysis)

C5 (repyrolysis)

Naphtha

AGO

LPG (propane, butane)

Methane (to fuel gas)

AFG

Electric power

Natural gas

Ethylene

Propylene

Polyethylene production

Polypropylene production

Hydrogen

BT fraction

C8 fraction

C9+ fraction

Quench oil

Power Plant

MOL

MOL

MOL

Carbon Black

Raw C4 BDEU/repyrolysis

Olefin-1

Boiler

11

Olefin production

PYROLYSIS

(800 – 850 °C)

Cracked gas:

Mixture of all products

Cooling and gas separation

(Columns, heat exchangers,

compressors, pumps, reactors)

PRODUCTS

Feed

PyrolysisPrimary

Fractionator

Naphtha AGO

ProcessSteam

Precooling DeethaniserC2

hydrogenationDeep cooling

system

DemethaniserDepropaniserC3 liquid phase hydrogenation

Caustic scrubber

Glycol dryer

WaterScrubber

Cracked gas compressor

Hydrogen

Methane

Quench oil

Ethylene

Propylene

C2 splitterEthylene

cooling cycle

C3 gas phase hydrogenation

Green oil scrubber

C3 stripper C3 splitter

Ethane

Propane

Quench oil cycle

Recycle

C4/C5 C4/C5 hydrogenation

C4 hydrogenation

MTBE

BDEU

Debuthaniser

Pygas stabilizerPygas

hydrogenation I.

Pygas hydrogenation II.

BT fraction

C9+ fraction

C8 fraction

C5/C6+ separation

C6-7/C8+ separation

C8/C9+ separation

Raw C4

12

Olefin-1 Scheme

13

Pyrolysis furnaces

Radiation section: pyrolysis

Convection section: flue gas heat utilizationFeed preheating

Boiler feed water preheating

Process steam superheating

High pressure steam superheating

TLE (Transfer line exchangers):

Stop the pyrolysis-> prevent product losses due to secondary reactions

Heat utilization -> High pressure steam generation

Further cooling-> quench oil injection

Process steam addition

Olefin-1: 11 furnaces

Olefin-2: 4 furnaces

14

Pyrolysis parameters

Coil Outlet Temperature: 800 – 860 °C

Outlet Pressure: 0,3-0,6 barg

Propylene/ethylene ratio = 0,45 – 0,6

Process steam ratio: steam/CH = 0,4 – 0,8

Residence time: 0,1 – 0,5 sec

Furnace runtime (between decokings): 30-80 days

Steam cracker product yields

0

10

20

30

40

50

60

70

80

90

100

Ethane Propane n-butane naphtha AGO

Pro

du

ct

yie

lds

(s

%)

Feed

Hydrogen

Methane

Ethylene

Propylene

BT

C8

C9+

Quenchoil

16

Olefin-1 pyrolysis furnace

Fuel gas

Feed

Process steam

Cracked gas

Flue gas

TL

E

BFW

Saturated steam

17

Olefin-2 furnaces

18

Olefin-2 pyrolysis furnace

Convection section

Radiation section

19

Radiation section

20

Cracked gas quenching

Primary fractionator

Cooling with counter flow of quench oil

Condensation of heavy HCs

Washing the residual oil with counter flow of pygas

Heat recovery of quench oil

Water scrubber

Further cooling with counter flow of wash water

Condensation of pygas and dilution steam

Heat recovery of wash water, used in propane/peopylenesplitter’s reboiler

21

Cracked gas quenching

22

Olefin-2

23

Cracked gas compression in a five stage turbo compressor

(Eliot in Olefin-1; MAN in Olefin-2)

Steam turbine drive

Condensation and separation of residual water and pygas content in the interstage coolers & separators

Caustic scrubber

Glycol dryer in Olefin-1; Molecular sieves in Olefin-2

Suction pressure: 0,4 bar(g)

Final pressure: Olefin-1: 32 bar(g)

Olefin-2: 36 bar(g)

Cracked gas compression

24

Cracked gas compressor at Olefin-2

0,4 barg

36 barg

25

Cracked gas compressor at Olefin-2

PyrolysisPrimary

Fractionator

Naphtha AGO

ProcessSteam

Precooling DeethaniserC2

hydrogenationDeep cooling

system

DemethaniserDepropaniserC3 liquid phase hydrogenation

Caustic scrubber

Glycol dryer

WaterScrubber

Cracked gas compressor

Hydrogen

Methane

Quench oil

Ethylene

Propylene

C2 splitterEthylene

cooling cycle

C3 gas phase hydrogenation

Green oil scrubber

C3 stripper C3 splitter

Ethane

Propane

Quench oil cycle

Recycle

C4/C5 C4/C5 hydrogenation

C4 hydrogenation

MTBE

BDEU

Debuthaniser

Pygas stabilizerPygas

hydrogenation I.

Pygas hydrogenation II.

BT fraction

C9+ fraction

C8 fraction

C5/C6+ separation

C6-7/C8+ separation

C8/C9+ separation

Raw C4

26

Olefin-1 Scheme

27

Precooling

C2-/C3+ separation (deethanizer)

C2 hydrogenation (acetylene → ethylene)

Isoterm front end tube reactor (tail end reactor in SN)

Coldbox (lowest temperature: -146 °C)

C1/C2 separation (demethanizer)

Ethane/ethylene separation (C2 splitter)

C2 line

ethylene

Flue gas, hydrogen

PyrolysisPrimary

Fractionator

Naphtha AGO

ProcessSteam

Precooling DeethaniserC2

hydrogenationDeep cooling

system

DemethaniserDepropaniserC3 liquid phase hydrogenation

Caustic scrubber

Glycol dryer

WaterScrubber

Cracked gas compressor

Hydrogen

Methane

Quench oil

Ethylene

Propylene

C2 splitterEthylene

cooling cycle

C3 gas phase hydrogenation

Green oil scrubber

C3 stripper C3 splitter

Ethane

Propane

Quench oil cycle

Recycle

C4/C5 C4/C5 hydrogenation

C4 hydrogenation

MTBE

BDEU

Debuthaniser

Pygas stabilizerPygas

hydrogenation I.

Pygas hydrogenation II.

BT fraction

C9+ fraction

C8 fraction

C5/C6+ separation

C6-7/C8+ separation

C8/C9+ separation

Raw C4

28

Olefin-1 Scheme

29

C2-/C3+ separation

C3/C4+ separation (depropanizer)

C3 hydrogenation (MAPD)

C3 stripping

Propane/propylene separation

C3 line

propylene

PyrolysisPrimary

Fractionator

Naphtha AGO

ProcessSteam

Precooling DeethaniserC2

hydrogenationDeep cooling

system

DemethaniserDepropaniserC3 liquid phase hydrogenation

Caustic scrubber

Glycol dryer

WaterScrubber

Cracked gas compressor

Hydrogen

Methane

Quench oil

Ethylene

Propylene

C2 splitterEthylene

cooling cycle

C3 gas phase hydrogenation

Green oil scrubber

C3 stripper C3 splitter

Ethane

Propane

Quench oil cycle

Recycle

C4/C5 C4/C5 hydrogenation

C4 hydrogenation

MTBE

BDEU

Debuthaniser

Pygas stabilizerPygas

hydrogenation I.

Pygas hydrogenation II.

BT fraction

C9+ fraction

C8 fraction

C5/C6+ separation

C6-7/C8+ separation

C8/C9+ separation

Raw C4

30

Olefin-1 Scheme

31

C3/C4+ separation (debutanizer)

C4/C5+ separation

C5/C6+ separation

C4/C5 hydrogenation

Pygas hydrogenation

C6-C7/C8+ separation

BT hydrogenation

C8/C9+ separation

C4/C5 and pygas hydrogenation

Raw C4

repyrolysis

BT

C8 and C9+

32

Steam and condensate system

Boiler (Olefin-1)

Boiler feed water preparation

Fuel gas system

Regeneration system

Waste water treatment

Flare system

Cooling water system

Services

Presenting to [name] 33

Thank you for your kind attention!