process intensification of hydrogen plants and naphtha ...process intensification of hydrogen plants...

Process Intensification of Hydrogen Plants and Naphtha Crackers

Koos Overwater – VP Hydrogen Product Line & Technologies

Dutch Process Intensification Network NL (PIN NL) 13 November 2013Dutch Process Intensification Network NL (PIN NL) – 13 November 2013

The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.

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Contents

1. Who we are

2. Hydrogen

3. Ethylene

4. Conclusion


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1. Who we Are


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Technip TodayWith engineering, technologies and project management, on land and at sea, we safely and successfully deliver the best solutions for our clients in the energy business

Worldwide presence with 38,000 people in 48 countries

Industrial assets on all continents, a fleet of 36 vessels (7 of which under construction)

2012 revenue: €8.2 billion

Energy is at the core of TechnipThe presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.

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Three Business Segments, One Technip

Subsea Offshore Onshore Engineering and fabrication of

fixed platforms for shallow waters (TPG 500, Unideck®)

Design, manufacture and supply of deepwater flexible and rigid pipelines, umbilicals and riser

t

Gas treatment and liquefaction (LNG), Gas-to-Liquids (GTL)

Oil refining (refining, hydrogen

Subsea Offshore Onshore

Engineering and fabrication of floating platforms for deep waters (Spar, semi-submersible platforms, FPSO)

L d hi i fl t t h l

systems

Subsea construction, pipeline installation services and Heavy Lift

Six state-of-the-art flexible pipe d / bili l f t i

Oil refining (refining, hydrogen and sulphur units)

Onshore pipelines

Petrochemicals (ethylene, aromatics olefins polymers Leadership in floatover technology

Floating Liquefied Natural Gas (FLNG)

Construction yard

and / or umbilical manufacturing plants

Five spoolbases for reeled pipeline assembly as well as four logistic bases

aromatics, olefins, polymers, fertilizers)

Process technologies (proprietary or through alliances)

Biofuel and renewable energiesbases

A constantly evolving fleet strategically deployed in the world's major offshore markets

Biofuel and renewable energies (including offshore wind)

Non-oil activities (principally in life sciences, metals & mining, construction))

The best solutions across the value chainThe presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.

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A Unique Worldwide Footprint


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Around 38,000 People Throughout the World, Growing Close to ClientsGrowing Close to Clients

4,800 +55%

8,900

8,900

3,900+95% 2,500

+67%

+29%

3,550+97%

+112%

750Fleet & others

4,300+65%

+50%

109 Nationalities across 48 countries June 2013109 Nationalities across 48 countries June 2013

Dec. 2006The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.

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Technip Onshore Activity

Refining & heavy oil Gas Processing Petrochemicals Others Clean fuels Grassroots Heavy oil upgraders

Gas treatment GTL LNG

Ethylene Polyolefins Aromatics

Mining and metals Infrastructures Buildings

Hydrogen Fertilizers Life sciences,…

Project management consultancyProject management consultancyStrong process engineering capabilities Process technologies (Hydrogen, Ethylene, Refining, Petrochemical & GTL)Solid reputation with NOCs & IOCs


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Leading Contractor in Hydrogen Plants

Expertise Multiple feed flexibility

50 years of core H2 competence Proprietary Steam Reformer

technology Tailored advanced solutions for high

• Multiple feed flexibility• Minimized effluents• Advanced modularization

Tailored advanced solutions for high Efficiency and Cost-effectiveness

Highest focus on Reliability and HSE Single-point responsibility from

t t i i iconcept to commissioning Global alliance with Air Products for

“over-the-fence” H2 plants

Key references

• High energy efficiency• High reliability• High quality steam

Technip is consistent global leader in

Key references 223,000 Nm3/h (200 mmscfd ) H2 for

Syncrude, Canada (world’s largest single-train plant) 111 000 N 3/h (100 fd ) H f

Recent State-of-the Art Hydrogen plant in Thailand

Technip is consistent global leader in the design and supply of Hydrogen plants, having >35% market share and >260 plants world-wide

111,000 Nm3/h (100 mmscfd ) H2 for PKN, Poland (1st largest plant on multiple feeds)

128,000 Nm3/h (115 mmscfd ) H2 for Air Products USA (with 100 MW pAir Products, USA (with 100 MW cogeneration)


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Ethylene - Technip is Licensor & Contractor

Expertise One of four ethylene licensors worldwide

S EPC i Strong EPC experience Proprietary cracking furnace technologies Proprietary separation technologies Alliance with Dow (No 1 in ethylene production) Alliance with Dow (No. 1 in ethylene production) Largest ethylene plants in operation World leader of cracking prediction software;

SPYRO® (70% of the market) Ultra Selective Conversion Furnace Technology

(USC®) Ripple TrayTM Technology

Largest cracking furnaces in the world, Yansab, KSA

With respectively 70 years of expertise for Stone & Webster and 40 years for

Key references Ras Laffan, Qatar, 1300kta, 2010

Yansab, Sabic, KSA, 1380kta, 2009 for Stone & Webster and 40 years for Technip, and a total of 150 grassroots plants, Technip is the leader in the field of ethylene

, , , ,

OL2K, Kuwait, 850kta, 2008

10th complex, 1400kta, 2008

SHARQ 3rd Expansion Project, 1300kta, 2010

NOVA E-3, Joffre, Alberta, Canada (1500kta) 2000

PetroRabigh Ethane Cracker (1350kta), 2010The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.

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Hydrogen Centers

The Hague (formerly KTI)

Los Angeles (formerly KTI)

Delhi (formerly KTI)


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Ethylene Centers

The Hague (formerly KTI)London (formerly Stone & Webster)

P i (f l T h i )

Los Angeles (formerly KTI)

Houston (formerly Stone & Webster)

Paris (formerly Technip)

Rome (formerly Technipetrol)

Delhi


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Hydrogen competences

Hydrogen and Syngas Plants Steam Reformers Steam Reformers Revamps / Capacity Increase

Process intensificationProcess intensification


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Ethylene competences

Grass-root Cracking FurnacesProcess intensification

Grass root Cracking Furnaces Cracking Furnace revamps Grass-root ethylene plant Separation Section Ethylene plant Separation Section revamps


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Why revamping?

E i ti l tExisting plot area

Existing interfacing of utilities

Operational staff and facilities in place

Maintenance staff in place and familiar with plantMaintenance staff in place and familiar with plant

Plant life cycle extension

Fast track in conjunction with turnaround schedule

Cost effective plant capacity increase


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2. Hydrogen


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Refining Landscape and Role of Hydrogen

“Inconvenient Consequence”

CO2Energy and

Cost IntensityDemand growth

RefineryRefinery Product slate

Crudemix

Heavier &

Sourer

Lighter &

CleanerslatemixSourer Cleaner

HH22

CarbonManagement

B‐o‐B Strategies

Typical 25% of the refinery CO2 emission is related to hydrogen production for crude to product shift


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Refining Landscape and Role of Hydrogen

Refinery Hydrogen Consumers:

Hydrocracking 1500 - 3000 scf/bbl

Hydrotreating VGO 800 - 1200 scf/bbl Distillate 300 - 800 scf/bbl Naphtha 200 - 500 scf/bblNaphtha 200 500 scf/bbl

Aromatics saturation 200 - 500 scf/bbl

Isomerization 50 - 100 scf/bbl


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Hydrogen Plant Typical Flow Sheet

SteamVentSteam

BFWSteam Drum

Purge GasTo Burners

LP Steam

Degassifier

Reformer

ConvectionSection

ProductProduct

HydrogenHydrogenPSAPSA

UnitUnit

Process SteamColdSeparator

HydrogenHydrogenDeaerated DM Water

B ilSteam

HTShift

FeedPre-warmer

CW

AirCooler

CoMoX/ZnOReactor

Boiler warmerHot Separator

BFW

FeedPreheat

FeedFeed Preheat


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Characteristics of Steam Reforming

Highly endothermic• Requires external heat input

Catalytic process• Tubular reactor• Sensitive to catalyst• Sensitive to catalyst

poisoning: apply feed pre-treatment

Severe conditions• 850 - 920 oC• 850 - 920 oC• 25 - 35 bar


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Heating and Cooling ...

H d b F dHydrocarbon Feed Hydrogen Product

Feed Purification

Reforming Shift Conversion

Product purificationPurification Conversion purification

Process Steam

40 400 900 400 40 °C55040 400 900 400 40 C550


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Composite heating/cooling curves

Red line : Hot stream providing heatBl li C ld t i i h tBlue line : Cold stream receiving heat

ture

External heat demand

Tempe

rat

T

St ti

Enthalpy exchangedExternal cooling demand

Steam generation

Enthalpy exchanged


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Technip’s Parallel Regenerative Reformer (TPR)

Feed +Feed + steam High temperature

reactor/exchanger

Uses reformer effluent as

Catalyst tubes

Uses reformer effluent as heat source

Advanced process and Lined Shell

mechanical design

Reformer

• Up to 30% more H2• Reduced fuel firing • Reduced Carbon emissionReformer

Effluent Reduced Carbon emission

• Minimized export steam

To process


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TPR Retrofit Model


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Recent TPR Revamps Overview

Project 1 Project 2 Project 3 Project 4 Project 5

Start‐up 2003 2009 2010 2010 2012

Pre‐revamp capacity (kNm3/h) 13.5 34 16.5 38 96

Add on capacity (kNm3/h) 3 4 9 5 9 21Add‐on capacity (kNm3/h) 3.4 9 5 9 21

Capacity increase (%) 25 26 30 24 22

Feedstock NaphthaNG Naphtha NG NG NG

25The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.

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3. Ethylene


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Characteristics of Olefins Production

Strongly endothermic processg y p

Ab b d d t Q 1 6 G l / t f f dAbsorbed duty: Q ~1.6 Gcal / tonne of feed

Feed Products

Q

For 1 350 kta cracker: fired heat ~ 840 MWFor 1.350 kta cracker: fired heat 840 MW


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A cracking furnace….


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Convection SectionCracking Furnace

Convection Section

~Hydrocarbon Feed

Boiler Feed Water

120 oC

Steam Drum

~Boiler Feed Water Steam Drum

Dilution Steam Cracked Gas toSeparation Section

380 oC

Desuper-heater

BFW

HP Steam Transferline Exchanger

BFW520 oC

Radiant efficiency: 40 – 42%O ll ffi i 92 95 %

850 oC1250 oC620 oC

Radiant Section

Overall efficiency: 92 – 95 %


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Feedstock Selection and Ethylene Yields

Ethane C3-LPG C4-LPG Naphtha Gasoil

Feedstock Selection and Ethylene Yields

Feed 125 226 300 334 433

Eth l 100 100 100 100 100Ethylene 100 100 100 100 100

Propylene 0 35 45 52 60

Butadiene 0 6 1 14 18

Raffinate-1 0 4 4 17 21

Benzene 1 8 9 22 18

Other (fuel) 24 73 141 129 216

(Feed and Products in tons per 100 ton of ethylene product)(Feed and Products in tons per 100 ton of ethylene product)


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Olefins Complex

HydrogenMixedButanesGasoline

Acid GasMaterial Movements

Utilities

Quench

DrierCompressor andChilling

Steam

Ethylene

PropanePropylene

NAPDConverter

Acid Gas

PrimaryFractionator

FeedsMixedProducts

Quench

Quench Methane

AcetyleneConverter

Ethane

Ethane

Feeds

Fuel Oil

Quench

CrackingFurnacesNaphtha Furnaces


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Cracking Technology

“Cracking” is:

non-catalytic governed by reaction kinetics intrinsically non-selective

Hence:

l ki i iti d hi ti t d b t looking primitive and unsophisticated, but requires advanced engineering modelling:

SPYRO®


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Features of SPYRO® Suite 7

Updated Graphical User Interface

Generic Feed Model Generic Feed Model

Instant feed characterization

Updated Kinetic Scheme Updated Kinetic Scheme

240 Components

More than 7000 reactions More than 7000 reactions

More detail in heavy components

Improved accuracy Naphtha crackingImproved accuracy Naphtha cracking

yields

Multi Furnace Simulation

Economic Module

Integrated “SPYRO® / CONVEC / Integrated SPYRO / CONVEC / FIREBOX® / TES®”The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.

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SPYRO®: Tool Kit for Cracking Furnace design

SPYRO® enables optimization of :

Coil selection

Coil sizing

against : CONVENTIONAL (MK) GK1 OR GK2 GK3SMK

Yields

Runlengths

Feedstock flexibility

Operating costp g

Investment cost GK4 GK5 GK6

34The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.

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Process intensification

GK6 two-lane design

in-line arrangement two-lane arrangemente a a ge e t t o a e a a ge e t

pitch / OD 1.5-1.8 pitch / OD 2.8-3.0

Proper selection of tube spacing allows effective application of 2-lane lay-outeffective application of 2-lane lay-out


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GK6 Coil Design


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GK6 Development History

1988-1998: GK5 (for liquid ) and SMK (for gas) furnace widely li d GK3 f i l li tiapplied, GK3 for special applications

1996 Ch ll t d l t f f SRT1 t 1996: Challenge to develop new concept for revamp of SRT1 at DOW TERNEUZEN

Challenge: double capacity, improve runlength, increase thermal efficiency, lower NOx, lower noise

Answer: GK6 dual lane concept in combination with furnace overhauloverhaul


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GK6 Project highlights

F rnace HC feedrate Selecti it

DOW Terneuzen – results: Furnace HC feedrate Q2 ‘97 : 11.2 mt/hr Q2 ‘98 : 24.0 mt/hr (+ 114 %)

Selectivity Q2 ‘97 : base Q2 ‘98 : base + 0.24 wt % C2H4( )

Thermal efficiencyQ2 ‘9 8 %

NOx emissionsQ2 ‘9 b Q2 ‘97 : 87 %

Q2 ‘98 : 92 % Q2 ‘97 : base Q2 ‘98 : base - 45 %

Furnace run length Q2 ‘97 : < 35 days

Noise Q2 ‘97 : base

Q2 ‘98 : 60 days Q2 ‘98 : base - 10 %

1998 – 2013: 81 GK6 furnaces builtCracking LPG through VGOCracking LPG through VGOYearly Ethylene capacity 6.9 million tons


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From GK6 to GK7…….

GK6 in 2 lanes

(radiant coil top view)

GK6 in 3 lanes

= GK7= GK7


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Circumferential Distribution of View Factors

1.0180o

0.6

0.7

0.8

0.9

SMK outlet

GK6 3-Lane outlet

GK6 tl t

0 2

0.3

0.4

0.5GK6 outlet

0.0

0.1

0.2

GK7 OUTLETS

90o 270o

GK6 OUTLETS

SMK OUTLETS

0o


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New development: Swirl Flow Technology

GK6 Coil Design with Swirl Flow Technology• Swirl Flow Tubes are small amplitude helical tubesSwirl Flow Tubes are small amplitude helical tubes

• Internal heat transfer considerably higher

• 15% higher capacity15% higher capacity

Swirl Flow Tube performance evaluated using

CFD calculations

Laboratory scale testsThe presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.

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Technip Radiant Coil DesignsLiquid CrackingLiquid Cracking

GK6 2-Lane Coil Design

GK6 3-Lane Coil Design

GK6-SFT Coil Designg

GK6-2 GK6-3 GK6-SFT


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Maximum Tube Metal TemperatureComparisonComparison

GK6 2 GK6 3 GK6 SFTGK6-2 GK6-3 GK6-SFT


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4. Conclusion

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Concluding remarks

For hydrogen plants TPR® technology enables 20-30 % capacity increase while keeping the steam reforming furnace the same

Coil replacements in steam cracking furnaces can enhance capacity by 10 – 100% from the same firebox

Three lane GK6 reduces TMT and increases capacity further

Study new coils like: GK6 - Swirl Flow Tubes (Helical coils)

Process Technology and simulation tools (such as SPYRO®) are key for new developments

Process intensification is a natural way to go for revamps


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Questions?

Contact details: [email protected]


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process intensification of hydrogen plants and naphtha ...process intensification of hydrogen plants...

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