Supplementary Information

Design and economic analysis of industrial-scale

methanol-to-olefins plants

1. Process flow diagrams and stream tables of the base design

1.1 Reaction and conditioning section
P-101 E-101 E-110 E-104 C-101 E-108 C-102 E-109 S-101 C-103
Methanol HPS Preheater Cooler Raw olefins Cooler Raw olefins Cooler Phase Stripped vapor
pump generator compressor compressor separator compressor

E-104 S-101
E-109
Feed 25 bar 27
CW
Methanol 2 33ɗ
25°C 1 bar 103.3ɗ 24 25
280369 kg/h
E-220 115.8ɗ A-101
Deprop-reb
28
1 C-102
101.5ɗ Comp. Ratio = 2.887 26
P-201 E-211 35ɗ
Deeth-reb 23 Waste D-102
Feed 98.6ɗ E-108 Water 31
HPS E-217 CW
254ʚ 41 bar ConSplit-reb-1
7009.22 kg/h 22
D-101 30
12
97.4ɗ
4 E-222 C-101
C3Split-reb Comp. Ratio = 2.887 From To Distillation
89.4ɗ
29
Condensate Train
21
Splitter
125.8ɗ 36.11ɗ
13
35ɗ
1 1
To Condensate
E-110 122.9ɗ 2 15
35ɗ Splitter
T-101 E-105
E-106
NT=3 CW
5
R-101 CW
D=1.88 m
8 400°C 150ɗ 36.6ɗ 20
3 bar
9 2 4 14
62.5ɗ
T-102
3 6 NT=6
E-217
D=1.53 m
ConSplit-reb-2

10
E-102 7
18
6 16
69.3ɗ
Waste
11
266.5ɗ Water
17 19
E-103 35ɗ
150ɗ 3
E-107 Waste water
CW
R-101 E-102 E-103 E-107 T-101 T-102 E-105 E-106 D-101 A-101 D-102
MTO Heat Heat Cooler Quench Quench Cooler Cooler Water CO2 Water
reactor exchanger exchanger tower tower removal Removal removal

Figure S1. Process flow diagram of reaction and conditioning section for base design

1
 Table S1. Stream table of reaction and conditioning section for base design
Stream 1 2 3 4 5 6 7 8
Methanol
HPS Feed
feed
Temperature(℃) 25 25 150 254 200.8 161.3 310 400
Pressure(bar) 1 3 3 41 3 3 3 3
Vapor frac 0 0 1 1 1 1 1 1
Mole Flow (kmol/hr) 8750 8750 8750 3890.7 3890.7 12640.7 12640.7 16016.6
Mass Flow (kg/hr) 280369 280369 280369 70092.2 70092.2 350461.2 350461.2 350461.2
Molar composition (%)
H2 0 0 0 0 0 0 0 0.56
CO 0 0 0 0 0 0 0 0.21
CH4 0 0 0 0 0 0 0 1.15
C2H4 0 0 0 0 0 0 0 10.32
C2H6 0 0 0 0 0 0 0 0.21
CO2 0 0 0 0 0 0 0 0.54
C3H6 0 0 0 0 0 0 0 6.88
C3H8 0 0 0 0 0 0 0 0.09
C4H8 0 0 0 0 0 0 0 1.59
C4H10 0 0 0 0 0 0 0 0.01
C5H10 0 0 0 0 0 0 0 0.52
C6H12 0 0 0 0 0 0 0 0.33
MEOH 100 100 100 0 0 69.22 69.22 0.1
H2O 0 0 0 100 100 30.78 30.78 77.55

2
 Table S1. Stream table of reaction and conditioning section for base design (continued)
Stream 9 10 11 12 13 14 15 16

Temperature(℃) 150 126.57 126.575 125.88 89.4 36.6 35 69.3

Pressure(bar) 3 3 3 3 3 3 3 3
Vapor frac 1 0 0 1 0.3 0 0 0
Mole Flow (kmol/hr) 16016.64 1242.22 7768.457 15148.84 15148.84 2000 2000 36501.1
Mass Flow (kg/hr) 350461.2 22381.4 139966.5 335042.9 335042.9 36101.2 36101.2 658798.46
Molar composition (%)
H2 0.56 0 0 0.59 0.59 0 0 0
CO 0.21 0 0 0.22 0.22 0 0 0
CH4 1.15 0 0 1.22 1.22 Trace Trace 0
C2H4 10.32 0 0 10.91 10.91 0 0 0
C2H6 0.21 Trace 0 0.22 0.22 0 0 0
CO2 0.54 0 0 0.57 0.57 0 0 0
C3H6 6.88 0 0 7.28 7.28 0 0 0
C3H8 0.09 0 0 0.1 0.1 0 0 0
C4H8 1.59 0 0 1.68 1.68 Trace Trace 0
C4H10 0.01 0 0 0.01 0.01 0 0 0
C5H10 0.52 0 0 0.55 0.55 0 0 0
C6H12 0.33 0 0 0.35 0.35 0 0 0
MEOH 0.1 0.01 0.01 0.2 0.2 0.25 0.25 0.24
H2O 77.55 99.99 99.99 76.16 76.16 99.75 99.75 99.76

3
 Table S1. Stream table of reaction and conditioning section for base design (continued)
Stream 17 18 19 20 21 22 23 24

Temperature(℃) 69.3 35 69.3 35 36.1 105.7 35 180.9

Pressure(bar) 3 3 3 3 3 8.66 8.66 25
Vapor frac 0 0 0 0 1 1 1 1
Mole Flow (kmol/hr) 6900.66 6900.66 25000 25000 3647.74 3647.74 3647.74 3647.74
Mass Flow (kg/hr) 124548.16 124548.16 451218.19 451218.19 127462.6 127462.60 127462.60 127462.6
Molar composition (%)
H2 0 0 0 0 2.45 2.45 2.45 2.45
CO 0 0 0 0 0.91 0.91 0.91 0.91
CH4 0 0 0 0 5.07 5.07 5.07 5.07
C2H4 0 0 0 0 45.33 45.33 45.33 45.33
C2H6 0 0 0 0 0.92 0.92 0.92 0.92
CO2 0 0 0 0 2.35 2.35 2.35 2.35
C3H6 0 0 0 0 30.22 30.22 30.22 30.22
C3H8 0 0 0 0 0.39 0.39 0.39 0.39
C4H8 0 0 0 0 6.99 6.99 6.99 6.99
C4H10 0 0 0 0 0.05 0.05 0.05 0.05
C5H10 0 0 0 0 2.29 2.29 2.29 2.29
C6H12 0 0 0 0 1.44 1.44 1.44 1.44
MEOH 0.24 0.24 0.24 0.24 0.1 0.1 0.1 0.1
H2O 99.76 99.76 99.76 99.76 1.74 1.74 1.74 1.74

4
 Table S1. Stream table of reaction and conditioning section for base design (continued)
Stream 25 26 27 28 29 30 31

Temperature(℃) 33 33 32.95 33 -19.67 40 -10.91

Pressure(bar) 25 25 25 25 19 25 19
Vapor frac 0.76 0 1 0 0.73 1 0
Mole Flow (kmol/hr) 3647.74 782.62 2640.42 44.7 2000 2952.45 27.71
Mass Flow (kg/hr) 127462.6 34905.07 91749.9 807.6 58607.7 94409.94 830.88
Molar composition (%)
H2 2.45 0.10 3.14 0 0 3 0
CO 0.91 0.08 1.16 0 0 1.1 0
CH4 5.07 0.99 6.28 Trace 0 6.3 0
C2H4 45.33 23.92 51.98 0 38.1 56 5.9
C2H6 0.92 0.63 1.02 0 61.9 1.1 93.8
CO2 2.35 1.07 2.74 Trace 0 0 0
C3H6 30.22 41.08 27.69 0 trace 27 0.3
C3H8 0.39 0.58 0.35 0 0 0.3 0
C4H8 6.99 16.91 4.35 0 0 4.2 0
C4H10 0.05 0.13 0.03 Trace 0 trace 0
C5H10 2.29 7.79 0.79 Trace 0 0.8 0
C6H12 1.44 5.84 0.20 0 0 0.2 0
MEOH 0.1 0.33 0.02 0.39 0 0 0
H2O 1.74 1.53 0.25 99.54 0 0 0

5
1.2 Product separation and recovery section

C-201 C-202 T-201 T-202 T-203

Light olefins Stripped vapor Demethanizer Deethanizer C2-Splitter
compressor compressor
Light gas product
Light olefin mixture
from Reaction section H2、CO、CH4
-30.7ɗ
25 bar 3
E-207
40ɗ 1 -95.6ɗ C2H4
E-208
T-203 11

19 bar

S7
C-201 E-205 10
E-206
T-201 -17.2ɗ
595.9 kW 2 C2 E-214
Comp Ratio = 1.28 32 bar 9 40ɗ

6 C2H6 C3H6
Stripped vapor back 12 24
-10.9ɗ
to Reaction and E-203
Conditioning section
18
4 S5 E-204
12.8ɗ
E-202 T-202 E-201 T-206
23
27 bar 21 16.5 bar
C-202 17 15.4 ɗ
59.3 kW C3 P-201
Comp Ratio = 1.39 -21.5ɗ E-212 C3H8
Heavy olefin E-209 W = 27.2 kW
71.5ɗ 25
mixture form Phase 8
48ɗ
separator T-205 E-215
20
27 bar 13 16 9 bar
33ɗ
E-211
15
14
19 C4、C5+
T-204
18 bar 22
80.7ɗ
E-213
C3+
68.4ɗ
E-210
T-204 T-205 P-201 T-206
Condensate Depropanizer Olefins pump C3-Splitter
Splitter

Figure S2. Process flow diagram of product separation and recovery section for base design

6
 Table S2. Stream table of product separation and recovery section for base design
Stream 1 2 3 4 5 6 7 8

Temperature(℃) 40 58.66 -95.27 12.89 -4.04 6.05 -17.24 71.55

Pressure(bar) 25 32 32 32 27 27 27 27
Vapor frac 1 1 1 0 0.43 1 0 0
Mole Flow (kmol/hr) 2952.45 2952.45 323.74 2628.71 1200 1200 1670.61 958.1
Mass Flow (kg/hr) 94409.94 94409.94 4539.06 89870.88 33723.2 33723.2 46935.64 42935.24
Molar composition (%)
H2 3 3 27.6 0 0 0 0 0
CO 1.1 1.1 10.3 0 0 0 0 0
CH4 6.3 6.3 57.1 0 0 0 0 0
C2H4 56 56.0 5.1 62.3 96.8 96.8 98.0 0
C2H6 1.1 1.1 0 1.3 3.1 3.1 2.0 0
CO2 0 0 0 0 0 0 0 0
C3H6 27 27 0 30.3 trace trace trace 83.2
C3H8 0.3 0.3 0 0.4 0 0 0 1
C4H8 4.2 4.2 0 4.7 0 0 0 12.8
C4H10 trace trace 0 trace 0 0 0 trace
C5H10 0.8 0.8 0 0.8 0 0 0 2.3
C6H12 0.2 0.2 0 0.2 0 0 0 0.6
MEOH 0 0 0 0 0 0 0 0
H2O 0 0 0 0 0 0 0 0

7
 Table S2. Stream table of product separation and recovery section for base design (continued)
Stream 9 10 11 12 13 14 15 16
Ethylene
Product
Temperature(℃) -19.67 -19.67 -30.69 -10.91 33.00 24.09 46.09 35.38
Pressure(bar) 19 19 19 19 25 18 18 18
Vapor frac 0.73 0 0 0 0 0.11 0 0
Mole Flow (kmol/hr) 2000 2000 1642.90 27.71 768.05 768.05 1500 1500
Mass Flow (kg/hr) 58607.7 58607.7 46104.76 830.88 34606.63 34606.63 52272.4 52272.4
Molar composition (%)
H2 0 0 0 0 trace trace trace trace
CO 0 0 0 0 trace trace trace trace
CH4 0 0 trace 0 1 1 0.2 0.2
C2H4 38.1 38.1 99.5 5.9 24.4 24.4 21.1 21.1
C2H6 61.9 61.9 0.5 93.8 0.6 0.6 0.8 0.8
CO2 0 0 0 0 1.1 1.1 0.7 0.7
C3H6 trace trace 0 0.3 41.9 41.9 74.3 74.3
C3H8 0 0 0 0 0.6 0.6 0.7 0.7
C4H8 0 0 0 0 17.2 17.2 2
C4H10 0 0 0 0 0.1 0.1 trace trace
C5H10 0 0 0 0 7.9 7.9 0.1 0.1
C6H12 0 0 0 0 5 trace trace
MEOH 0 0 0 0 0 0 0 0
H2O 0 0 0 0 0 0 0 0

8
 Table S2. Stream table of product separation and recovery section for base design (continued)
Stream 17 18 19 20 21 22 23 24 25
Propylene
Product
Temperature(℃) -21.51 9.8 68.42 58.23 15.44 80.70 16.32 40.04 49.04
Pressure(bar) 18 27 18 18 9 9 16.5 16.5 16.5
Vapor frac 1 1 0 0.15 0 0 0 0 0
Mole Flow (kmol/hr) 225.64 225.64 542.4 1500.5 1116.68 383.83 1116.68 1107.31 9.37
Mass Flow (kg/hr) 6587.2 6587.20 28019.42 70954.66 47022.74 23931.92 47022.74 46606.65 416.09
Molar composition (%)
H2 0.3 0.3 0 0 0 0 0 0 0
CO 0.3 0.3 0 0 0 0 0 0 0
CH4 3.4 3.4 0 0 0 0 0 0 0
C2H4 83 83 trace 0 0 0 0 0 0
C2H6 2.2 2.2 0 0 0 0 0 0 0
CO2 3.7 3.7 0 0 0 0 0 0 0
C3H6 7.1 7.1 56.3 73.5 98.7 trace 98.7 99.5 0.1
C3H8 trace trace 0.8 1 1.3 trace 1.3 0.5 97.2
C4H8 0 0 24.4 17 trace 66.4 trace 0 2.7
C4H10 0 0 0.2 0.1 0 0.5 0 0 0
C5H10 0 0 11.2 5.6 0 21.7 0 0 0
C6H12 0 0 7.0 2.9 0 11.4 0 0 0
MEOH 0 0 0 0 0 0 0 0 0
H2O 0 0 0 0 0 0 0 0 0

9
1.3 Refrigeration cycles

E-304 E-302 E-117

-15979.2 kW -928.98 kW -4581.7 kW
CW
-30.7 ɗ 89.62 濎 166024 kg/hr
5 4 3 2 1

C-302
Propylene refrigerant 19.36 bar
6846.15 kW
62333.9 kg/hr
9

S-301
11
7 -97.4ɗ
Psat = 1.46 bar -12.6 濎
V.f. = 0.38
C-301
5.32 bar
4809.34 kW

10

E-208
13522 kW
20293.2 kg/hr

Figure S3. Process flow diagram of ethylene refrigeration cycle for base design

172771 kg/hr
E-401 C-404 C-403
-52351.7 kW 14.7 bar 4.55 bar
CW 11642.5 kW 2279.25 kW
9.89 濎
35 ɗ 494858 kg/hr 69.3 濎 -8.62 濎
1 31 30

2 C-402
3.14 bar
819.54 kW
4

28807 kg/hr 9
29
30335.3 kg/hr
16

S-401 S-402 S-403 S-404

3 23
-8.08ɗ -19.24ɗ -23.5ɗ -32.4ɗ
Psat = 4.55 bar Psat = 3.14 bar Psat = 2.7 bar Psat = 1.96 bar -15.72 濎
V.f. = 0.33 V.f. = 0.09 V.f. = 0.1 V.f. = 0.42
22
E-302 E-303 C-401
E-301 928.98 kW 11
360.82 kW 2.7 bar
3326.79 kW 6
8267.8 kg/hr 3172 kg/hr 25 1495 kW
30673.1 kg/hr E-304
10 15 15979.2 kW
17 18
5
112018 kg/hr
21
E-205 24
252692 kg/hr 28
2309.5 kW
20554.3 kg/hr E-216 E-207
322088 kg/hr 1166.4 kW 12077.4 kW
12 13 10253.8 kg/hr
7 8 103927 kg/hr
19 20
26 27
272727 kg/hr
14

Figure S4. Process flow diagram of propylene refrigeration cycle for base design

10
 Table S4. Stream table of ethylene refrigeration cycle for base design
Stream 1 2 3 4 5 6 7 8

Temperature(℃) 89.6 35 -6 -17.3 -21.5 -30.7 -97.4 -97.4

Pressure(bar) 19.36 19.36 19.36 19.36 19.36 19.36 1.46 1.46
Vapor frac 1 1 1 1 1 0 0.38 0
Mole Flow (kmol/hr) 5916.1 5916.1 5916.1 5916.1 5916.1 5916.1 5916.1 3694.6
Mass Flow (kg/hr) 166024.4 166024.4 166024.4 166024.4 166024.4 166024.4 166024.4 103690.47
Molar composition (%)
H2 0 0 0 0 0 0 0 0
CO 0 0 0 0 0 0 0 0
CH4 0 0 0 0 0 0 0 0
C2H4 99.5 99.5 99.5 99.5 99.5 99.5 99.5 99.5
C2H6 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05
CO2 0 0 0 0 0 0 0 0
C3H6 0 0 0 0 0 0 0 0
C3H8 0 0 0 0 0 0 0 0
C4H8 0 0 0 0 0 0 0 0
C4H10 0 0 0 0 0 0 0 0
C5H10 0 0 0 0 0 0 0 0
C6H12 0 0 0 0 0 0 0 0
MEOH 0 0 0 0 0 0 0 0
H2O 0 0 0 0 0 0 0 0

11
Table S4. Stream table of ethylene refrigeration cycle for base design (continued)
Stream 9 10 11

Temperature(℃) -97.4 -97.3 -12.6

Pressure(bar) 1.46 1.46 5.32
Vapor frac 1 1 1
Mole Flow (kmol/hr) 2221.49 5916.1 5916.1
Mass Flow (kg/hr) 62333.93 166024.4 166024.4
Molar composition (%)
H2 0 0 0
CO 0 0 0
CH4 0 0 0
C2H4 99.5 99.5 99.5
C2H6 0.05 0.05 0.05
CO2 0 0 0
C3H6 0 0 0
C3H8 0 0 0
C4H8 0 0 0
C4H10 0 0 0
C5H10 0 0 0
C6H12 0 0 0
MEOH 0 0 0
H2O 0 0 0

12
 Table S5. Stream table of propylene refrigeration cycle for base design
Stream 1 2 3 4 5 6 7 8

Temperature(℃) 69.3 35. -8.1 -8.1 -8.1 -8.1 -8.1 -19.3

Pressure(bar) 14.7 14.7 4.55 4.55 4.55 4.55 4.55 3.14
Vapor frac 1 0 0.29 1 0 1 0 0.06
Mole Flow (kmol/hr) 11757.21 11757.21 11757.21 4104.87 728.75 728.75 7652.34 7652.34
Mass Flow (kg/hr) 494858.46 494858.46 494858.46 172770.14 30673.12 30673.12 322088.3 322088.3
Molar composition (%)
H2 0 0 0 0 0 0 0 0
CO 0 0 0 0 0 0 0 0
CH4 0 0 0 0 0 0 0 0
C2H4 0 0 0 0 0 0 0 0
C2H6 0 0 0 0 0 0 0 0
CO2 0 0 0 0 0 0 0 0
C3H6 99.5 99.5 99.5 99.5 99.5 99.5 99.5 99.5
C3H8 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05
C4H8 0 0 0 0 0 0 0 0
C4H10 0 0 0 0 0 0 0 0
C5H10 0 0 0 0 0 0 0 0
C6H12 0 0 0 0 0 0 0 0
MEOH 0 0 0 0 0 0 0 0
H2O 0 0 0 0 0 0 0 0

13
 Table S5. Stream table of ethylene refrigeration cycle for base design (continued)
Stream 9 10 11 12 13 14 15 16

Temperature(℃) -19.3 -19.3 -19.3 -19.27 -19.25 -19.27 -23.54 -23.54

Pressure(bar) 3.14 3.14 3.14 3.14 3.14 3.14 2.7 2.7
Vapor frac 1 0 1 0 1 0 0.09 1
Mole Flow (kmol/hr) 684.42 196.43 196.43 488.34 488.34 6479.58 6967.92 720.74
Mass Flow (kg/hr) 28806.75 8267.80 8267.8 20554.34 20554.34 272727.08 293281.42 30335.34
Molar composition (%)
H2 0 0 0 0 0 0 0 0
CO 0 0 0 0 0 0 0 0
CH4 0 0 0 0 0 0 0 0
C2H4 0 0 0 0 0 0 0 0
C2H6 0 0 0 0 0 0 0 0
CO2 0 0 0 0 0 0 0 0
C3H6 99.5 99.5 99.5 99.5 99.5 99.5 99.5 99.5
C3H8 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05
C4H8 0 0 0 0 0 0 0 0
C4H10 0 0 0 0 0 0 0 0
C5H10 0 0 0 0 0 0 0 0
C6H12 0 0 0 0 0 0 0 0
MEOH 0 0 0 0 0 0 0 0
H2O 0 0 0 0 0 0 0 0

14
 Table S5. Stream table of ethylene refrigeration cycle for base design (continued)
Stream 17 18 19 20 21 22 23 24

Temperature(℃) -23.54 -23.5 -23.54 -23.5 -23.54 -32.12 -32.12 -32.12

Pressure(bar) 2.7 2.7 2.7 2.7 2.7 1.96 1.96 1.96
Vapor frac 0 1 0 1 0.04 0.08 1 0
Mole Flow (kmol/hr) 720.74 75.36 75.36 243.61 243.61 6247.18 6247.18 3781.27
Mass Flow (kg/hr) 30335.34 3171.99 3171.99 10253.82 10253.82 262946.08 262946.08 159153.23
Molar composition (%)
H2 0 0 0 0 0 0 0 0
CO 0 0 0 0 0 0 0 0
CH4 0 0 0 0 0 0 0 0
C2H4 0 0 0 0 0 0 0 0
C2H6 0 0 0 0 0 0 0 0
CO2 0 0 0 0 0 0 0 0
C3H6 99.5 99.5 99.5 99.5 99.5 99.5 99.5 99.5
C3H8 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05
C4H8 0 0 0 0 0 0 0 0
C4H10 0 0 0 0 0 0 0 0
C5H10 0 0 0 0 0 0 0 0
C6H12 0 0 0 0 0 0 0 0
MEOH 0 0 0 0 0 0 0 0
H2O 0 0 0 0 0 0 0 0

15
 Table S5. Stream table of ethylene refrigeration cycle for base design (continued)
Stream 25 26 27 28 29 30 31

Temperature(℃) 32.1 -32.12 -32.1 -32.11 -16.52 -8.62 3.69

Pressure(bar) 1.96 1.96 1.96 1.96 2.7 3.14 4.55
Vapor frac 1 0 1 1 1 1 1
Mole Flow (kmol/hr) 2661.36 2465.95 2465.95 6247.22 6967.96 6967.96 11757.21
Mass Flow (kg/hr) 112019.71 103794.68 103794.68 262947.90 293283.25 293283.25 494858.46
Molar composition (%)
H2 0 0 0 0 0 0 0
CO 0 0 0 0 0 0 0
CH4 0 0 0 0 0 0 0
C2H4 0 0 0 0 0 0 0
C2H6 0 0 0 0 0 0 0
CO2 0 0 0 0 0 0 0
C3H6 99.5 99.5 99.5 99.5 99.5 99.5 99.5
C3H8 0.05 0.05 0.05 0.05 0.05 0.05 0.05
C4H8 0 0 0 0 0 0 0
C4H10 0 0 0 0 0 0 0
C5H10 0 0 0 0 0 0 0
C6H12 0 0 0 0 0 0 0
MEOH 0 0 0 0 0 0 0
H2O 0 0 0 0 0 0 0

16
1.4 Heat exchanger network
500

400

300
Shifted Temperature (°C)

Steam
generation
200 (HPS)

100

CW(25ɗ ~35ɗ )

0
0 20000 40000 60000 80000 100000 120000 140000 160000

-100

Refrigerant
Net Heat Flow (kW)
-200

Figure S5. GCC of base design (∆ T min=10℃)

Net Heat Flow (kW)

17
 Pinch
400ɗ
E-101 E-110
39572.6 6386.7
kW kW
Reactor 400ɗ
(Heat of 400ɗ
reaction) E-102 E-103
27879.3 24315.3
kW kW
400ɗ 266.5ɗ
R8 150ɗ
E-109
8482.6
kW
107.78ɗ
R24 C 33ɗ
E-104 E-213 E-212 E-210 E-215-1
81376.04 6538.4 10574.2 4200.8 28767.56
kW kW kW kW kW
125.76ɗ 103.3ɗ 101.5ɗ 98.6ɗ 97.4ɗ
R12 89.4ɗ
E-107
5373.6
kW
69.3ɗ
R17 C 35ɗ
E-215-2 E-106
3864.5 15601.96
kW kW
69.3ɗ 62.5ɗ
R19 C 35ɗ
E-105
72.4
kW
36.6ɗ
R14 C 35ɗ
E-108
4469.45
kW
105.7ɗ
R22 C 35ɗ

115.76ɗ 25ɗ
150ɗ R2
122.9ɗ
49ɗ 48.5ɗ
49.04ɗ C3Split-reb

57.97ɗ ConSplit-
68.4ɗ reb

68.15ɗ
71.55ɗ Deeth-reb

74.29ɗ
80.7ɗ Deprop-reb

161.32ɗ
310ɗ R6

254ɗ HPS
254ɗ
generation

Note: Stream name begins with R, such as R2, denotes the stream in the reaction and conditioning section.

Figure S6. Above ambient temperature HEN of base design

18
 E-214
31760.5 kW
C3Split- 40.04ɗ
cond C 40.04ɗ
E-211
2000 kW
ConSplit- 46.09ɗ
side cond C 35.38ɗ
E-201 E-202
2763.8 kW 5714.2 kW
Deprop- 15.44ɗ
cond F 15.44ɗ
E-203 E-204
459.58 kW 2459.5 kW
Deeth-side -4.54ɗ
cond C -6.05ɗ
E-205 E-206
2309.5 kW 5387 kW
-17.25ɗ
Deeth-cond P -17.25ɗ
E-209
1166.4 kW
ConSplit- -21.5ɗ
cond P -21.5ɗ
E-207
12077.4 kW
C2Split- -30.1ɗ
cond P -30.1ɗ
E-208
13522 kW
Demeth- -97.3ɗ
cond E -97.3ɗ

-19.67ɗ C2Split-
-19.67ɗ side reb

-11.71ɗ
-10.92ɗ C2Split-reb

5.57ɗ
12.86ɗ Demeth-reb

Figure S7. Below ambient temperature HEN of base design

19
1.5 Column targeting analysis

The CGCC (column grand composite curve) of the condensate-splitter using

a simple column design is shown in Fig. S8(a). As the rectifying section of the

column involves below ambient temperature and the condenser temperature is -

22℃, the column improvement is focused on the rectifying section. The adjusted

design employs a side-condenser and the reduction of the thermodynamic driving

force can be observed by comparing the areas between the curve of the rectifying

section and the ordinate at x=0 in Fig. S8(a) and (b). A low-temperature

refrigeration duty of about 2000 kW can be replaced by a cooling water duty of

1740 kW.

(a) simple column design (b) with side-condenser design

Figure S8. CGCCs of condensate-splitter

The CGCC and CCC of the demethanizer with simple column design are

shown in Fig. S9. Although the stripping section of the column also operates at

below ambient temperature, instead of high above ambient temperature, there is

no incentive to use side-reboiler. With respect to the rectifying section of the

column, because of the small thermodynamic driving force, as shown in Fig.

S9(a) and (b), a side-condenser is not necessary. Therefore, the demethanizer

adopts the simple column design.

20
 (a) CGCC (b) CCC
Figure S9. CGCC and CCC of demethanizer

For the deethanizer, as the temperature level of the stripping section is only

slightly above ambient, the improvement is focused on the rectifying section.

The use of a side-condenser can raise 2000 kW of the sub-ambient cooling duty

by 6℃ and the CGCCs of the simple column design and the design with side-

condenser are shown in Fig. S10.

(a) simple column design (b) with side-condenser design

Figure S10. CGCC of deethanizer

Because of the close-boiling of ethane and ethylene, the rectifying section

of the C2-splitter is operated under almost constant temperature with very close

vapor and liquid temperature, there is no potential for improvement. A side-

reboiler with 2000 kW at -19.7℃ can be energy integrated with the condenser of

the deethanizer. The CGCCs of the simple column design and the design with

side-reboiler are shown in Fig. S11.

21
 (a) simple column design (b) with side-reboiler design
Figure S11. CGCC of C2-splitter

Because of the near ambient operation temperature, as shown in Fig. S12

and Fig. S13, no improved design from the simple column design is considered

for the depropanizer and C3-splitter.

(a) CGCC (b) CCC

Figure S12. CGCC and CCC of depropanizer

(a) CGCC (b) CCC

Figure S13. CGCC and CCC of C3-splitter

22
2. Process flow diagrams and stream tables of the alternative design
2.1 Reaction and conditioning section
The design of this section is the same as the base design.

2.2 Product separation and recovery section

P-201 C-202 T-201 T-202 T-203
Olefins pump Stripped Vapor Demethanizer Deethanizer C2-Splitter
compressor
Light gas product
H2、CO、CH4 E-207
Light olefin mixture 3
from Cold box -30.7ɗ
30 bar -95.6ɗ C2H4
-60.21ɗ E-208
T-203 11

19 bar
1
7
10
E-205
P-201 2
T-201 E-206
44.3 kW 32 bar -17.2ɗ 9 40ɗ E-214
T-202 6 C2H6 C3H6
12
Stripped vapor back 27 bar 24
E-203 -10.9ɗ
to Reaction and 18
5
E-204
S4
Conditioning section 12.8ɗ
E-202 E-201 T-206
C-202 21
23

59.3 kW 16.5 bar

17 15.4 ɗ
Comp Ratio = 1.39 P-202
Heavy olefin mixture E-209 71.5ɗ W = 27.2 kW C3H8
from Phase separator -21.5ɗ
27 bar E-212 8 25

T-205 48ɗ
33ɗ 20 E-215
13
T-204 16
E-211 9 bar
18 bar
15
S14
19 C4、C5+
22
80.7ɗ
E-213
C3+
68.4ɗ
E-210
T-204 T-205 P-202 T-206
Condensate Depropanizer Olefins pump C3-Splitter
Splitter

Figure S14. Process flow diagram of separation and purification section of alternative design

23
 Table S6. Stream table of separation and purification section of alternative design
Stream S1 S2 S3 S4 S5 S6 S7 S8

Temperature(℃) -60.26 -59.71 -94.84 12.86 -4.04 6.05 -17.24 71.55

Pressure(bar) 25 32 32 32 27 27 27 27
Vapor frac 0 0 1 0 0.43 0 0
Mole Flow (kmol/hr) 2851.31 2851.31 219.76 2631.54 1200.00 1200.00 1673.45 958.10
Mass Flow (kg/hr) 93507.35 93507.35 3557.05 89950.3 33723.2 33723.2 47015.18 42935.12
Molar composition (%)
H2 0.8 0.8 10.9 0 0 0 0 0
CO 0.8 0.8 10.3 0 0 0 0 0
CH4 5.8 5.8 75.1 0 0 0 0 0
C2H4 57.8 57.8 3.7 62.3 96.8 96.8 98.0 0
C2H6 1.2 1.2 0 1.3 3.1 3.1 2.0 0
CO2 0 0 0 0 0 0 0 0
C3H6 27.9 27.9 0 30.3 trace trace trace 83.2
C3H8 0.3 0.3 0 0.4 0 0 0 1
C4H8 4.3 4.3 0 4.7 0 0 0 12.8
C4H10 trace trace 0 trace 0 0 0 trace
C5H10 0.8 0.8 0 0.8 0 0 0 2.3
C6H12 0.2 0.2 0 0.2 0 0 0 0.6
MEOH 0 0 0 0 0 0 0 0
H2O 0 0 0 0 0 0 0 0

24
 Table S6. Stream table of separation and purification section of alternative design (continued)
Stream S9 S10 S11 S12 S13 S14 S15 S16
Ethylene
Product
Temperature(℃) -19.67 -19.67 -30.69 -10.92 33 24.09 46.09 35.38
Pressure(bar) 19 19 19 19 25 18 18 18
Vapor frac 0.73 0 0 0 0.00 0.11 0 0
Mole Flow (kmol/hr) 2000 2000.00 1645.77 27.68 768.05 768.05 1500 1500
Mass Flow (kg/hr) 58607.7 58607.7 46185.34 829.84 34606.63 34606.63 52272.40 52272.40
Molar composition (%)
H2 0 0 0 0 trace trace trace trace
CO 0 0 0 0 trace trace trace trace
CH4 0 0 trace 0 1 1 0.2 0.2
C2H4 38.1 38.1 99.5 5.9 24.4 24.4 21.1 21.1
C2H6 61.9 61.9 0.5 93.8 0.6 0.6 0.8 0.8
CO2 0 0 0 0 1.1 1.1 0.7 0.7
C3H6 trace trace 0 0.3 41.9 41.9 74.3 74.3
C3H8 0 0 0 0 0.6 0.6 0.7 0.7
C4H8 0 0 0 0 17.2 17.2 2
C4H10 0 0 0 0 0.1 0.1 trace trace
C5H10 0 0 0 0 7.9 7.9 0.1 0.1
C6H12 0 0 0 0 5 trace trace
MEOH 0 0 0 0 0 0 0 0
H2O 0 0 0 0 0 0 0 0

25
 Table S6. Stream table of separation and purification section of alternative design (continued)
Stream S17 S18 S19 S20 S21 S22 S23 S24 S25
Propylene
Product
Temperature(℃) -21.51 9.8 68.42 58.23 15.44 80.7 16.32 40.04 49.04
Pressure(bar) 18 27 18 18 9 9 16.5 16.5 16.5
Vapor frac 1 1 0 0.15 0 0 0 0 0.00
Mole Flow (kmol/hr) 225.64 225.64 542.40 1500.50 1116.67 383.83 1116.67 1107.31 9.37
Mass Flow (kg/hr) 6587.20 6587.2 28019.42 70954.54 47022.62 23931.92 47022.62 46606.53 416.09
Molar composition (%)
H2 0.3 0.3 0 0 0 0 0 0 0
CO 0.3 0.3 0 0 0 0 0 0 0
CH4 3.4 3.4 0 0 0 0 0 0 0
C2H4 83 83 trace 0 0 0 0 0 0
C2H6 2.2 2.2 0 0 0 0 0 0 0
CO2 3.7 3.7 0 0 0 0 0 0 0
C3H6 7.1 7.1 56.3 73.5 98.7 trace 98.7 99.5 0.1
C3H8 trace trace 0.8 1 1.3 trace 1.3 0.5 97.2
C4H8 0 0 24.4 17 trace 66.4 trace 0 2.7
C4H10 0 0 0.2 0.1 0 0.5 0 0 0
C5H10 0 0 11.2 5.6 0 21.7 0 0 0
C6H12 0 0 7.0 2.9 0 11.4 0 0 0
MEOH 0 0 0 0 0 0 0 0 0
H2O 0 0 0 0 0 0 0 0 0

26
2.3 Cold-box

CB7 CB6 CB5 CB4 CB3 CB2 CB1

Multi-stream Multi-stream heat Multi-stream heat Multi-stream heat Multi-stream Multi-stream Multi-stream
heat exchanger exchanger exchanger exchanger heat exchanger heat exchanger heat exchanger

Chilled water
generation Refrigerant Refrigerant Refrigerant Refrigerant
33.89 kW 982.2 kW 2330.3 kW 52.2 kW 40.6 kW
13.4ɗ -32.1ɗ -62ɗ -88ɗ -104ɗ

15.4ɗ -23.5ɗ -32.1ɗ -62ɗ -93ɗ -105.7ɗ -113.9ɗ -152ɗ

15.4ɗ -23.5ɗ -32.1ɗ -62ɗ -92.8ɗ -105.7ɗ -113.9ɗ -169.5ɗ
22 15.4ɗ -23.5ɗ -32.1ɗ -62ɗ -92.8ɗ -105.7ɗ
21
-23.5ɗ -32.1ɗ -62ɗ -92.8ɗ
CB7 -30.1ɗ -60ɗ -86ɗ -103ɗ
-30.1ɗ CB1
-120ɗ
CH4 rich gas 12 CB2
mole frac=0.63 -23.5ɗ CB6 CB5 -60ɗ CB4 CB3
-21.5ɗ -86ɗ
CB9 CB8 14 16 18
19 20
3 4
-21.5ɗ 2
6 7
10 15
9
H2 rich gas
CW 38.6ɗ
mole frac=0.82 Refrigerant 17
CBC-1
35.86 kW CB10
1 40ɗ S-201 S-202 S-203 S-204 S-205
78.9ɗ 13 25 bar -60ɗ -86ɗ -102ɗ -108ɗ -152ɗ
35 bar
Light olefins from 25 bar 25 bar 8 25 bar 11 35 bar 35 bar
4bar 4bar
reaction section 5 23 To demethanizer

CB9 CB8 CBC-1 CB10 S-201 S-202 S-203 S-204 S-205

Cooler Cooler Cold box Cooler Phase separator Phase separator Phase separator Phase separator Phase separator
compressor (1st stage) (2nd stage) rd
(3 stage) (4th stage) th
(5 stage)

Figure S15. Process flow diagram of cold-box for alternative design

27
 Table S7. Stream table of cold-box for alternative design
Stream 1 2 3 4 5 6 7 8

Temperature(℃) 40 -21.5 -60 -60. -6 -86 -86 -86

Pressure(bar) 25 25 25 25 25 25 25 25
Vapor frac 1 0.18 0.04 1 0 0.85 1 0
Mole Flow (kmol/hr) 2952.45 2952.45 2952.45 128.52 2823.94 128.52 109.77 18.74
Mass Flow (kg/hr) 94409.94 94409.94 94409.94 1645.17 92764.77 1645.17 1127.14 518.03
Molar composition (%)
H2 3.02 3.02 3.02 50.91 0.84 50.91 59.44 0.95
CO 1.13 1.13 1.13 8.64 0.78 8.64 9.9 1.28
CH4 6.26 6.26 6.26 1 5.72 18. 19.29 10.42
C2H4 56 56 56 21.06 57.59 21.06 11.21 78.76
C2H6 1.14 1.14 1.14 0.26 1.18 0.26 0.09 1.22
CO2 0 0 0 0 0 0 0 0
C3H6 26.99 26.99 26.99 1.1 28.16 1.10 0.07 7.12
C3H8 0.34 0.34 0.34 0.01 0.35 0.01 0 0.07
C4H8 4.15 4.15 4.15 0.03 4.34 0.03 0 0.17
C4H10 0.03 0.03 0.03 0 0.03 0 0 0
C5H10 0.76 0.76 0.76 0 0.79 0 0 0.01
C6H12 0.19 0.19 0.19 0 0.20 0 0 0
MEOH 0 0 0 0 0 0 0 0
H2O 0 0 0 0 0 0 0 0

28
 Table S7. Stream table of cold-box for alternative design (continued)
Stream 9 10 11 12 13 14 15 16

Temperature(℃) -102 -102 -102 -23.5 78.89 -21.5 -108 -108

Pressure(bar) 25 25 25 25 35 35 35 35
Vapor frac 0.92 1 0 1 1 1 0.96 1
Mole Flow (kmol/hr) 109.77 101.15 8.63 101.15 101.15 101.15 101.15 97.47
Mass Flow (kg/hr) 1127.14 902.60 224.54 902.6 902.6 902.6 902.6 811.72
Molar composition (%)
H2 59.44 64.42 0.96 64.42 64.42 64.42 64.42 66.80
CO 9.9 10.59 1.77 10.59 10.59 10.59 10.59 10.89
CH4 19.29 19.58 15.92 19.58 19.58 19.58 19.58 19.38
C2H4 11.21 5.37 79.63 5.37 5.37 5.37 5.37 2.93
C2H6 0.09 0.03 0.85 0.03 0.03 0.03 0.03 0.01
CO2 0 0 0 0 0 0 0 0
C3H6 0 0 0 0 0 0 0 0
C3H8 0 0 0 0 0 0 0 0
C4H8 0 0 0 0 0 0 0 0
C4H10 0 0 0 0 0 0 0 0
C5H10 0 0 0 0 0 0 0 0
C6H12 0 0 0 0 0 0 0 0
MEOH 0 0 0 0 0 0 0 0
H2O 0 0 0 0 0 0 0 0

29
 Table S7. Stream table of cold-box for alternative design (continued)
Stream 17 18 19 20 21 22 23

Temperature(℃) -120.67 -152 -152 -169.51 14.92 15.44 -60.26

Pressure(bar) 4 35 35 1 1 35 25
Vapor frac 0.14 0.81 1 0.18 1 1 0
Mole Flow (kmol/hr) 3.68 97.47 78.87 18.6 22.28 78.87 2851.3
Mass Flow (kg/hr) 90.87 811.72 460.81 350.92 441.79 460.81 93507.3
Molar composition (%)
H2 1.49 66.8 81.91 2.72 2.52 81.91 0.84
CO 2.83 10.89 10.75 11.48 10.05 10.75 0.79
CH4 24.98 19.38 7.31 70.56 63.03 7.31 5.79
C2H4 70.12 2.93 0.03 15.19 24.27 0.03 57.8
C2H6 0.51 0.01 0 0.05 0.13 0 1.18
CO2 0 0 0 0 0 0 0
C3H6 0 0 0 0 0 0 27.94
C3H8 0 0 0 0 0 0 0.35
C4H8 0 0 0 0 0 0 4.3
C4H10 0 0 0 0 0 0 0.03
C5H10 0 0 0 0 0 0 0.78
C6H12 0 0 0 0 0 0 0.2
MEOH 0 0 0 0 0 0 0.84
H2O 0 0 0 0 0 0 0.79

30
2.4 Refrigeration cycles
10

E-304 E-303 E-302 E-301 E-117 C-303

-3587.24 kW -81.46 kW -209.742 kW -751.16 kW -316.47 kW 6.91 bar
-32.1 ɗ -23.5ɗ -19.24 ɗ -8.08 ɗ 308.25 kW
-52.08ɗ
-30.1 ɗ 5943.22 kg/hr
5 4 3 2 1 28
27

C-304 C-302
CW 19.4 bar 2.35 bar
Propylene refrigerant
52.08 ɗ 74.81 kW

1202.2 kg/hr
16
21

S-301 S-302 S-303 S-304

26
7
-62.3ɗ -88ɗ -96.9ɗ -104ɗ
17
Psat = 6.91 bar Psat = 2.35 bar Psat = 1.5 bar Psat = 1 bar
V. f. = 0.5 V. f. = 0.14 V. f. = 0.1 22 V. f. = 0.95

CB-5 CB-4 C-301

2330 kW 52.2 kW 1.5 bar
20293.2 kg/hr 580 kg/hr 52.69 kW
9

8 13 14
563.6 kg/hr 24
18
25
Demeth-cond
825.8 kW 23 CB-3
15
6194 kg/hr 40.7 kW
8686.8 kg/hr 306.93 kg/hr
19 20
11 12
7484.6 kg/hr

Figure S19. Process flow diagram of ethylene refrigeration cycle for alternative design

Figure S16. Process flow diagram of propylene refrigeration cycle for alternative design

31
 Table S8. Stream table of ethylene refrigeration cycle for alternative design
Stream 1 2 3 4 5 6 7 8

Temperature(℃) 52.08 35 -6.05 -17.25 -21.5 -30.10 -62.32 -62.31

Pressure(bar) 19.36 19.36 19.36 19.36 19.36 19.36 6.91 6.91
Vapor frac 1 1. 1 1 0 0.23 0
Mole Flow (kmol/hr) 1336.36 1336.36 1336.36 1336.36 1336.36 1336.36 1336.36 723.14
Mass Flow (kg/hr) 37498.02 37498.02 37498.02 37498.02 37498.02 37498.02 37498.02 20293.24
Molar composition (%)
H2 0 0 0 0 0 0 0 0
CO 0 0 0 0 0 0 0 0
CH4 0 0 0 0 0 0 0 0
C2H4 99.5 99.5 99.5 99.5 99.5 99.5 99.5 99.5
C2H6 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
CO2 0 0 0 0 0 0 0 0
C3H6 0 0 0 0 0 0 0 0
C3H8 0 0 0 0 0 0 0 0
C4H8 0 0 0 0 0 0 0 0
C4H10 0 0 0 0 0 0 0 0
C5H10 0 0 0 0 0 0 0 0
C6H12 0 0 0 0 0 0 0 0
MEOH 0 0 0 0 0 0 0 0
H2O 0 0 0 0 0 0 0 0

32
 Table S8. Stream table of ethylene refrigeration cycle for alternative design (continued)
Stream 9 10 11 12 13 14 15 16

Temperature(℃) -62 -62.31 -62.31 -88 -88 -88 -88 -88

Pressure(bar) 6.91 6.91 6.91 2.35 2.35 2.35 2.35 2.35
Vapor frac 1 1 0 0.14 0 0.71 0 1
Mole Flow (kmol/hr) 723.14 1026.81 309.55 309.55 20.67 20.67 246.03 42.85
Mass Flow (kg/hr) 20293.24 28811.22 8686.8 8686.8 580.08 580.08 6904.51 1202.2
Molar composition (%)
H2 0 0 0 0 0 0 0 0
CO 0 0 0 0 0 0 0 0
CH4 0 0 0 0 0 0 0 0
C2H4 99.5 99.5 99.5 99.5 99.5 99.5 99.5 99.5
C2H6 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
CO2 0 0 0 0 0 0 0 0
C3H6 0 0 0 0 0 0 0 0
C3H8 0 0 0 0 0 0 0 0
C4H8 0 0 0 0 0 0 0 0
C4H10 0 0 0 0 0 0 0 0
C5H10 0 0 0 0 0 0 0 0
C6H12 0 0 0 0 0 0 0 0
MEOH 0 0 0 0 0 0 0 0
H2O 0 0 0 0 0 0 0 0

33
 Table S8. Stream table of ethylene refrigeration cycle for alternative design (continued)
Stream 17 18 19 20 21 22 23 24

Temperature(℃) -96.9 -96.9 -96.9 -88 -96.9 -103.97 -103.97 -103.97

Pressure(bar) 1.5 1.5 1.5 1.5 1.5 1.01 1.01 1.01
Vapor frac 0.1 0 0 1 1 0 0 1
Mole Flow (kmol/hr) 266.71 20.08 220.71 220.71 25.91 240.79 10.93 229.86
Mass Flow (kg/hr) 7484.59 563.47 6193.99 6193.99 727.13 6757.46 306.95 6450.51
Molar composition (%)
H2 0 0 0 0 0 0 0 0
CO 0 0 0 0 0 0 0 0
CH4 0 0 0 0 0 0 0 0
C2H4 99.5 99.5 99.5 99.5 99.5 99.5 99.5 99.5
C2H6 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
CO2 0 0 0 0 0 0 0 0
C3H6 0 0 0 0 0 0 0 0
C3H8 0 0 0 0 0 0 0 0
C4H8 0 0 0 0 0 0 0 0
C4H10 0 0 0 0 0 0 0 0
C5H10 0 0 0 0 0 0 0 0
C6H12 0 0 0 0 0 0 0 0
MEOH 0 0 0 0 0 0 0 0
H2O 0 0 0 0 0 0 0 0

34
Table S8. Stream table of ethylene refrigeration cycle for alternative design (continued)
Stream 25 26 27 28

Temperature(℃) -103.96 -80.35 -8.6 -27.85

Pressure(bar) 1.01 1.50 2.35 6.91
Vapor frac 1 1 1 1
Mole Flow (kmol/hr) 240.79 240.79 309.55 1336.36
Mass Flow (kg/hr) 6757.46 6757.46 8686.78 37498.02
Molar composition (%)
H2 0 0 0 0
CO 0 0 0 0
CH4 0 0 0 0
C2H4 99.5 99.5 99.5 99.5
C2H6 0.5 0.5 0.5 0.5
CO2 0 0 0 0
C3H6 0 0 0 0
C3H8 0 0 0 0
C4H8 0 0 0 0
C4H10 0 0 0 0
C5H10 0 0 0 0
C6H12 0 0 0 0
MEOH 0 0 0 0
H2O 0 0 0 0

35
 Table S9. Stream table of propylene refrigeration cycle for alternative design
Stream 1 2 3 4 5 6 7 8

Temperature(℃) 70.26 35 -8.09 -8.09 -8.05 -8.09 -8.05 -8.09

Pressure(bar) 14.70 14.70 4.55 4.55 4.55 4.55 4.55 4.55
Vapor frac 1 0 0.29 0 1 0 1 0
Mole Flow (kmol/hr) 10443.93 10443.93 10443.93 164.55 265.2 100.66 100.66 7179.77
Mass Flow (kg/hr) 439583.25 439583.25 439583.25 6925.74 11162.38 4236.63 4236.63 302197.78
Molar composition (%)
H2 0 0 0 0 0 0 0 0
CO 0 0 0 0 0 0 0 0
CH4 0 0 0 0 0 0 0 0
C2H4 0 0 0 0 0 0 0 0
C2H6 0 0 0 0 0 0 0 0
CO2 0 0 0 0 0 0 0 0
C3H6 99.5 99.5 99.5 99.5 99.5 99.5 99.5 99.5
C3H8 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
C4H8 0 0 0 0 0 0 0 0
C4H10 0 0 0 0 0 0 0 0
C5H10 0 0 0 0 0 0 0 0
C6H12 0 0 0 0 0 0 0 0
MEOH 0 0 0 0 0 0 0 0
H2O 0 0 0 0 0 0 0 0

36
 Table S9. Stream table of propylene refrigeration cycle for alternative design (continued)
Stream 9 10 11 12 13 14 15 16

Temperature(℃) -19.27 -8.09 -19.27 -19.25 -19.27 -19.25 -19.27 -19.27

Pressure(bar) 3.14 4.55 3.14 3.14 3.14 3.14 3.14 3.14
Vapor frac 0.06 1 0 1 0 1 0.07 1
Mole Flow (kmol/hr) 7179.77 3264.16 44.35 44.35 488.34 488.34 6677.58 502.20
Mass Flow (kg/hr) 302197.78 137385.47 1866.68 1866.68 20554.34 20554.34 281060.93 21137.15
Molar composition (%)
H2 0 0 0 0 0 0 0 0
CO 0 0 0 0 0 0 0 0
CH4 0 0 0 0 0 0 0 0
C2H4 0 0 0 0 0 0 0 0
C2H6 0 0 0 0 0 0 0 0
CO2 0 0 0 0 0 0 0 0
C3H6 99.5 99.5 99.5 99.5 99.5 99.5 99.5 99.5
C3H8 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
C4H8 0 0 0 0 0 0 0 0
C4H10 0 0 0 0 0 0 0 0
C5H10 0 0 0 0 0 0 0 0
C6H12 0 0 0 0 0 0 0 0
MEOH 0 0 0 0 0 0 0 0
H2O 0 0 0 0 0 0 0 0

37
 Table S9. Stream table of propylene refrigeration cycle for alternative design (continued)
Stream 17 18 19 20 21 22 23 24

Temperature(℃) -23.54 -23.54 -23.5 -23.54 -23.50 -23.54 -23.5 -23.54

Pressure(bar) 2.7 2.7 2.7 2.7 2.70 2.7 2.7 2.7
Vapor frac 0.1 0 1 0 1 0 1 1
Mole Flow (kmol/hr) 6677.58 17 17 243.61 243.61 2160.05 2160.05 655.59
Mass Flow (kg/hr) 281060.93 716.14 716.14 10253.82 10253.82 90917.37 90917.37 27593.45
Molar composition (%)
H2 0 0 0 0 0 0 0 0
CO 0 0 0 0 0 0 0 0
CH4 0 0 0 0 0 0 0 0
C2H4 0 0 0 0 0 0 0 0
C2H6 0 0 0 0 0 0 0 0
CO2 0 0 0 0 0 0 0 0
C3H6 99.5 99.5 99.5 99.5 99.5 99.5 99.5 99.5
C3H8 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
C4H8 0 0 0 0 0 0 0 0
C4H10 0 0 0 0 0 0 0 0
C5H10 0 0 0 0 0 0 0 0
C6H12 0 0 0 0 0 0 0 0
MEOH 0 0 0 0 0 0 0 0
H2O 0 0 0 0 0 0 0 0

38
 Table S9. Stream table of propylene refrigeration cycle for alternative design (continued)
Stream 25 26 27 28 29 30 31 32

Temperature(℃) -23.54 -32.12 -32.12 32.1 -32.12 -32.10 -32.12 -32.10

Pressure(bar) 2.7 1.96 1.96 1.96 1.96 1.96 1.96 1.96
Vapor frac 0.4 0.44 0 1 0 1 0 1
Mole Flow (kmol/hr) 6021.98 6021.98 597.45 597.45 2468.88 2468.88 200.54 200.54
Mass Flow (kg/hr) 253467.48 253467.48 25147.37 25147.36 103917.98 103917.98 8441.13 8441.13
Molar composition (%)
H2 0 0 0 0 0 0 0 0
CO 0 0 0 0 0 0 0 0
CH4 0 0 0 0 0 0 0 0
C2H4 0 0 0 0 0 0 0 0
C2H6 0 0 0 0 0 0 0 0
CO2 0 0 0 0 0 0 0 0
C3H6 99.5 99.5 99.5 99.5 99.5 99.5 99.5 99.5
C3H8 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
C4H8 0 0 0 0 0 0 0 0
C4H10 0 0 0 0 0 0 0 0
C5H10 0 0 0 0 0 0 0 0
C6H12 0 0 0 0 0 0 0 0
MEOH 0 0 0 0 0 0 0 0
H2O 0 0 0 0 0 0 0 0

39
Table S9. Stream table of propylene refrigeration cycle for alternative design (continued)
Stream 33 34 35 36

Temperature(℃) -32.11 -16.48 -9.4 4.64

Pressure(bar) 1.96 2.7 3.14 4.55
Vapor frac 1 1 1 1
Mole Flow (kmol/hr) 6021.98 6677.58 7179.77 10443.93
Mass Flow (kg/hr) 253467.48 281060.93 302197.74 439583.25
Molar composition (%)
H2 0 0 0 0
CO 0 0 0 0
CH4 0 0 0 0
C2H4 0 0 0 0
C2H6 0 0 0 0
CO2 0 0 0 0
C3H6 99.5 99.5 99.5 99.5
C3H8 0.5 0.5 0.5 0.5
C4H8 0 0 0 0
C4H10 0 0 0 0
C5H10 0 0 0 0
C6H12 0 0 0 0
MEOH 0 0 0 0
H2O 0 0 0 0

40
2.5 Heat exchanger network
500

400

300
Shifted Temperature (°C)

Steam
generation
200
(HPS)

100

CW(25ɗ ~35ɗ )

0
0 20000 40000 60000 80000 100000 120000 140000 160000

-100

Refrigerant
Net Heat Flow (kW)
-200

Figure S17. GCC of alternative design (∆ T min=10℃)

Net Heat Flow (kW)

41
 Pinch
400ɗ
E-101 E-110
39572.6 6386.7
kW kW
Reactor 400ɗ
(Heat of 400ɗ Heat of reaction
reaction) E-102 E-103
27879.3 24315.3
kW kW
400ɗ 266.5ɗ
R8 150ɗ
E-109
8482.6
kW
107.78ɗ
R24 C 33ɗ
E-104 E-213 E-212 E-210 E-215
81376.04 6538.4 10574.2 4200.8 28767.56
kW kW kW kW kW
125.76ɗ 103.3ɗ 101.5ɗ 98.6ɗ 97.4ɗ
R12 89.4ɗ
E-107
5373.6
kW
69.3ɗ
R17 C 35ɗ
E-215 E-106
3864.5 15601.96
kW kW
69.3ɗ 62.5ɗ
R19 C 35ɗ
E-105
72.4
kW
36.6ɗ
R14 C 35ɗ
E-108
4469.45
kW
105.7ɗ
R22 C 35ɗ

115.76ɗ 25ɗ
150ɗ R2
122.9ɗ
49ɗ 48.5ɗ
49.04ɗ C3Split-reb

57.97ɗ
68.4ɗ ConSplit-reb

68.15ɗ
71.55ɗ Deeth-reb

74.29ɗ
80.7ɗ Deprop-reb

161.32ɗ
310ɗ R6

254ɗ HPS
254ɗ generation

Note: Stream name begins with R, such as R2, denotes the stream in the reaction and conditioning section.

Figure S18. Above ambient temperature HEN of alternative design

42
 E-214
31760.5 kW
C3Split- 40.04ɗ
C 40.04ɗ
cond
CB9
35.2 kW
78.89ɗ
CB-9 C 40ɗ
E-211
2000 kW
ConSplit- 46.09ɗ
side cond C 35.38ɗ
E-201 E-202
2763.8 kW 5714.2 kW
Deprop- 15.44ɗ
F 15.44ɗ
cond E-203 E-204
459.5 kW 2459.5 kW
Deeth- -4.54ɗ 5.2ɗ
side cond C -6.05ɗ
E-205 E-206
2309.5 kW 5387 kW
-17.25ɗ
Deeth-cond P -17.25ɗ
E-209
1166.4 kW
ConSplit- -21.5ɗ
P -21.5ɗ
cond
CB-10
10342.1 kW
40ɗ
CB-10 P -21.5ɗ
E-207
12090.9 kW
C2Split- -30.1ɗ
P -30.1ɗ
cond
CB-6
82.2 kW
-30.1ɗ
CB-6 E -30.1ɗ
CB-5
2330.3 kW
-60ɗ
CB-5 E -60ɗ
CB-4
52.2 kW
-86ɗ
CB-4 E -86ɗ
E-208
825.8 kW
Demeth- -94.84ɗ
E -94.84ɗ
cond
CB-3
40.6 kW
-102ɗ
CB-3 -102ɗ
E

-19.67ɗ C2Split-
-19.67ɗ side reb

-11.71ɗ
-10.92ɗ C2Split-reb

5.57ɗ
12.86ɗ Demeth-reb

Figure S19. Below ambient temperature HEN of alternative design

2.6 Column targeting analysis

The alternative design adopts the same column configurations as determined
from the column targeting analysis of the base design.
43
3. Exergy loss analysis
Exergy losses of the heat exchangers appear in two sections due to heat
integration are taken into account only once and assigned to the preceding
process section, for example RCS instead of PSRS or PSRS instead of
refrigeration cycle.

Table S10. Exergy loss of RCS1

Unit Exergy loss (kW) Unit Exergy loss (kW)
E-101 2117.7 E-110 6.3
E-102 2710.4 E-210 413.5
E-103 610.1 E-212 833.2
E-104 7342.7 E-213 43.8
E-105 0.3 E-215-1 816.8
E-106 148.8 E-215-2 18.3
E-107 341.9 R-101 14203.3
E-108 193.4 P-101 10.1
E-109 1286.4 V-101 145.5
1
Same for both base design and alternative design

Table S11. Exergy loss of PSRS for the base design

Unit Exergy loss (kW) Unit Exergy loss (kW)
E-201 76.7 P-201 902.1
E-202 678.1 C-201 831.2
E-203 1209.7 C-202 109.9
E-204 16.7 V-201 133.1
E-205 1264.1 T-201 5291.1
E-206 1770.1 T-202 1645.3
E-207 1160.1 T-203 484.2
E-208 284.0 T-204 888.8
E-209 49.7 T-205 613.0
E-211 261.2 T-206 840.4
E-214 1540.5

Table S12. Exergy loss of PSRS for the alternative design

Unit Exergy loss (kW) Unit Exergy loss (kW)
E-201 76.7 P-201 902.1
E-202 678.1 P-202 462.0
E-203 52.9 C-202 109.9
E-204 426.4 V-201 6.6
E-205 1495.5 T-201 749.4
E-206 770.1 T-202 1645.3
E-207 1160.1 T-203 484.2
E-208 284.0 T-204 888.8
E-209 49.7 T-205 613.0
E-211 261.2 T-206 840.4
E-214 1540.5

44
45
 Table S13. Exergy loss of cold-box for the alternative design
Unit Exergy loss (kW) Unit Exergy loss (kW)
CBEX-1 1285.5 CB-5 266.0
CBEX-2 1185.3 CB-6 31.9
CB-1 18.7 CB-7 5.1
CB-2 0.5 CBC-101 116.4
CB-3 4.6 V-202 4.9
CB-4 8.2 V-203 0.5

Table S14. Exergy loss of ethylene refrigeration cycle for the base design
Unit Exergy loss (kW) Unit Exergy loss (kW)
V-301 2427.4 C-302 1625.1
C-301 1602.7

Table S15. Exergy loss of ethylene refrigeration cycle for the alternative design
Unit Exergy loss (kW) Unit Exergy loss (kW)
V-301 283.9 C-301 23.2
V-302 6.6 C-302 28.8
V-303 91.5 C-303 76.0
V-304 0.5 C-304 289.4

Table S16. Exergy loss of propylene refrigeration cycle for the base design
Unit Exergy loss (kW) Unit Exergy loss (kW)
V-401 1578.7 C-401 488.4
V-402 82.5 C-402 259.5
V-403 61.2 C-403 674.9
V-404 89.7 C-404 2881.3

Table S17. Exergy loss of propylene refrigeration cycle for the alternative design
Unit Exergy loss (kW) Unit Exergy loss (kW)
V-401 1032.4 C-401 470.8
V-402 58.0 C-402 248.7
V-403 57.1 C-403 635.9
V-404 517.4 C-404 2571.8

Table S18. Comparison of exergy loss for base design and alternative design1
Section Base design Alternative design
Reaction and conditioning 31242.5 (49.5%) 31242.5 (57.8%)
Product separation and recovery 20050 (31.8%) 13496.9 (25%)
Cold-box - 2927.6 (5.4%)
Ethylene refrigeration cycle 5655.2 (9%) 799.9 (1.5%)
Propylene refrigeration cycle 6116.2 (9.7%) 5592.1 (10.3%)
1
The unit of exergy loss is kW and the data in () is % to the total exergy loss.

46