09-05-Sulzer-Key to Success in Ethylene Plant-VF
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Transcript of 09-05-Sulzer-Key to Success in Ethylene Plant-VF
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Sulzer Chemtech
14th ROPTC PATTAYA, THAILAND October 19 22, 2009
Sulzer Chemtech Pte Ltd
Key to Success in Ethylene Plant
Quench Water Column Revamp
Lee Siang Hua
Senior Process Engineer
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Sulzer Chemtech
Background
A Naphtha Cracker in Asia Pacific intended to revamp the existing quench watertower from random packing to structured packing.
Sulzer worked closely with customer and provide full support on process andhydraulic evaluation of the column.
Two cases was considered , i.e. base case and alternative case, to ensure therevamp will enable the column to handle slightly changes of feedstock and
flexibility in operations.
The revamp study was conducted in second quarter of 2007, installation in firstquarter 2008 and the column was started-up successfully in Mid 2008.
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Sulzer Chemtech
Furnace Oil Quench Water
Quench
3-Stage Gas
Compression
Caustic
Tower
Feedstock
e.g. Naphtha, Ethane, Gasoil
4th-Stage Gas
Compression
Fuel
Oil
Dehydration Unit:Activated alumina
Molsieves TEG System
Refrigeration Unit
Cold
Section
Caustic
Soda
Water
Aromatics
Olefins
Steam
PFD - HOT SECTION
Background
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Sulzer Chemtech
Deethanizer
C2Hx
Acetylene Recoverycatalytic hydrogenation
C2H2 Acetylene
C3+
C2H4
Ethylene
C2H6
Ethane (recycle)
C2 Splitter
C4+
C3
Splitter
C3H6
Propylene
C3H8Propane
Demethanizer
C2+
CH4, H2
Depropanizer
C3Hx
Debutanizer
C5+
Hot
Section
EO Plant
PFD - COLD SECTION
Background
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Sulzer Chemtech
Background
Reason for Revamp
1. Replacement of existinginternals due to timeworn
2. Upgrade of internals for more
flexibility, higher capacity andlower pressure drop
ID 5.3m
ID 6.7m
Random
packing
Random
packing
Radial vaporinlet device
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Sulzer Chemtech
Content
Background
Process Evaluation
Column Internals Selection
Mechanical Design
Job List
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Sulzer Chemtech
Process Evaluation
Figure: Nusselt Diagram
Bed1-btm
Bed2-top
Bed2-btm
Bed1-top
0
20
40
60
80
100
120
140
160
180
200
220
0 5000 10000 15000 20000 25000
Reynolds Num ber
Nusselt/Prandtl^(1
/3)
Heat exchange calculation based on paper"Direct Heat and Mass Transfer in StructuredPackings" by L.Spiegel, P.Bomio and R.Hunkelerin Chem. Eng. Process. 35 (1996) 479-485
Experimental tests with the system air/water andair/dibutylphthalate
Calculation of the overall heat transfer coefficient
Plotting the results of this tests against theReynolds Number shows the goodcorrespondence of the different calculationmethods and the possibility of a regressionanalysis
Examination of different industrial columns showsgood results with this calculation
Direct Heat Transfer Correlation
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Sulzer Chemtech
Process Evaluation
Packing hydraulic calculation result with Sulzer hydraulic program
The % capacity < Sulzer guideline of 80%.
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Sulzer Chemtech
Process Evaluation
Design S/U Operation
ID 5.3m
ID 6.7m
T = 1.5C
p 2.83 mbar
504 t/h, 106C
30.5C
29C
53C
90C
894 kg/h
943 kg/h
MELLAPAK
MELLAGRID
MELLAPAK
Schoepentoeter
ID 5.3m
ID 6.7m
T = 2Cp 50 mbar
596 t/h, 98C
< 33C
31C
43C
89C
880 kg/h
880 kg/h
MELLAPAK
MELLAGRID
MELLAPAK
Schoepentoeter
p 5.37 mbar
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Sulzer Chemtech
Content
Revamp Objective
Process Evaluation
Column Internals Selection
Mechanical Design
Job List
Summary
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Selection of Internals
Key Characteristics:
Concerns:
Sensitivity to fouling
Heat and mass transfer
Pressure drop essential
Capacity
Capacity limitation with existing internals
Fouling problems
Vapor and liquid mal distribution
Bad efficiencies
High energy consumption
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Sulzer Chemtech
Selection of Internals
Packing
Top mixed bed
Mellapak M2X 2 m height
Mellapak M170.X 0.9 m height
Bottom mixed bed
Mellapak M170.X 2.5 m height
Mellagrid MG90.X 0.5 m height
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Sulzer Chemtech
Mellapak or MellapakPlus
High Mass Transfer Efficiency
Smooth Surface Good resistance to fouling
Suitable for uplift resistance if needed
Mellagrid:
Geometrical structure as Mellapak
Higher efficiency than conventional grids
Smooth surface
Great resistance to fouling and or Coking
High mechanical stability
Suitable for dismantling and cleaning viawater and or steam jetting
Selection of Internals
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Selection of Internals
Liquid Distributors
VKH2 distributor with drip tube
IV pre-distrubutors
H-pipes transmit liquid to pre-distributors
Hats on arm channels
Advantages
Good for high liquid loads, e.g. greater than 20 m3/m2h
Liquid is discharged laterally from rectangular channels onto the packing
Revamp issues
Large 14" and 20" feed pipes had to be modified and re-used
Welding on-site for modification of existing feed pipe
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Selection of Internals
Vapor Inlet
Schoepentoeter vane inlet device
High velocity vapor feed in 49" nozzle F-factor of 88 Pa0.5
Advantages
Even distribution of vapor ensures proper vapor / liquid contact
Eliminates erosion of column shell
Can be segmented to fir through vapor nozzle
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Content
Background
Process Evaluation
Column Internals Selection
Mechanical Design
Job List
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Sulzer Chemtech
Mechanical Design
Modified and reused existing feed pipe
New H-pipe from first elbow, welding toexisting feed pipe at site
New trough type liquid distributor
New mixed bed (Mellapak) for bettercapacity and better heat exchange
Modified and reused existing feed pipe
New H-pipe from first flange
New trough type liquid distributor
New mixed bed for better capacity andbetter heat exchange
New Schoepentoeter radial vapor inletdevice
Reuse existing support beam
Reuse existing support beam
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Content
Background
Process Evaluation
Column Internals Selection
Mechanical Design
Job List
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Sulzer Chemtech
Job List
1 Gas Cracker
2 Grassroots
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Sulzer Chemtech
Job List
1 Gas Cracker
2 Grassroots
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Sulzer Chemtech
THANKS FOR ATTENTION!
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