HALDIA PETROCHEMICALS LTD.

TECHNOLOGY TRAINING COURSE

PROCESS OVERVIEW

October 19,1998 Slide No. 1

Process overview.ppt
 HALDIA PETROCHEMICALS LTD.
TECHNOLOGY TRAINING COURSE
PROCESS OVERVIEW

Ethylene and Propylene

From

Naphtha and C5’s

October 19,1998 Slide No. 2

Process overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt
 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 overview.ppt