Ethylene Production From Tennessee Fracked Natural Gas

University of Tennessee at ChattanoogaENGR 5910/ENCH 4300

4/26/2012

Brandon Dodd Valentine Mbamalu

Outline

• Introduction• Design Basis• Cracking Reaction• Process Flow Diagram• Equipment Design• Project Economics• Conclusion

Introduction

www.timesonline.com

Design Basis

• Analyze 500,000 metric tons Ethane feedstock per year

• Feedstock will be considered as 100% Ethane

• Negligible reaction byproducts not to be considered for this level of design

Ethane Cracking Reaction

Byproducts

Methane Propane

Hydrogen Gas

Generalized Process Flow Diagram

Steam Cracker• 170 MW heat duty

• Modeled as 2 100MW separate pyrolysis

furnaces

• Each furnace 100 MW capacity

• Operates at 80% capacity.

Transfer Line Exchanger

• Shell and Tube Model

• 73 MW Heat Removed from Product Stream

• 820 m2 Total Exchange Area

• 2 Units in Series

Distillation Columns

• 3 Total Columns• 8 stage de-methanizer– 10m high– 3m diameter

• 20 stage de-ethylenizer– 15m high– 3m diameter

• 40 stage de-ethanizer– 27m high– 3m diameter

Other Equipment Estimated

• Quench Tower

• Compressors

• Refrigeration

• Pumps

• Fans

Unit Cost SummaryUnit Description # Units Cost (Millions)C-101 Compressor 1 2C-102 Compressor 1 12.7K-101 Drier 1 1.2E-101 Transfer Line Heat Exchanger 1 0.5E-102 Refrigeration Train 1 0.4E-103 Regrigeration Train 1 0.6F-101 Fans 20 0.3H-101 Pyrolysis Furnace/Cracker 1 21.5H-102 Pyrolysis Furnace/Cracker 1 12.6P-101 Pump 10 2.9R-101 Acetylene Converter 1 0.2T-101 De-methanizer - tower 1 3.7T-102 De-ethylenizer - tower 1 5.4T-103 De-ethanizer - tower 1 9.3V-101 Product Holding Tank 1 2.7Z-101 Quench Tower 1 2

Unit Cost Estimation Summary

Costs – In Millions

• Capital Costs - $121– Includes land cost

• Total Annual Operating Costs - $617– Utility Cost - $142– Raw Material Cost - $475– Labor Cost – estimated $1

Revenue – In Millions

Total Yearly Revenue - $960

•Ethylene – 560,000 metric tons– $955

•Methane – 3000 metric tons– $0.7

•Propane – 3000 metric tons– $0.7

Revenue Vs. Cost

Payback Period

ENVIRONMENTAL IMPACT

• Air pollution• Primary – Nitrogen dioxide, Particulate Matters, Volatile Organic Component

. Secondary – Ozone

. Incinerators

Conclusions

• Costing based on key component• Project is profitable• Economic activities will receive boost• Jobs and revenue to state and local gov.