Natural Gas Liquids to Olefins
Crackers
Travis Wells
Scott Chase
Mohammed Alzain
Salman Almutawa
Project Definition
• Introduction:
 Production of olefins
 North Dakota Plant
• The project’s objectives:
 Location
 E...
Business Opportunity
• Ethylene :
 Polyethylene, PVC, ethylene glycol and styrene monomer [2]
 Packaging, televisions, V...
Plans
• Fall semester:-
1- Built an olefin unit in Aspen+
2- Decide the location of our plant
3- Decide weather to use eth...
Material Balance
• Size: (1.5 billion lb/yr )
Recycle Ratio = 65.34%
(lb/hr) Ethane Propane Ethylene Propylene Methane H2 ...
Process Flow Diagram
Thermal Vs. Catalytic Cracking
[1]
Thermal Cracker Catalytic Cracker
No catalyst Uses a catalyst
Higher reaction condition...
Reactions
• In steam cracking, initiation usually involves breaking a chemical
bond between two carbon atoms, rather than ...
Cracker Yields:
[3]
Cracker
Cracker
Ethane Recycle
Propane Recycle
Quench Tower
Quench Tower
Quench
Tower
Dehydration System
Dehydration System
3 Phase
Separator
Depropanizer
Molecular
sieve
Fractionation Towers
Fractionation Towers
Demethanizer
Fractionation Towers
Methane &
H2 Splitter
Deethanizer
C2 Splitter
C3 Splitter
Ethane Recycle
Propane Recycle
Capital Cost
Installed ISBL MM$ 383
Installed OSBL MM$ 38.3
The overall capital cost at this point is $421.24 million doll...
Capital Cost Summary
NPV0 $15,500.00
NPV20 $3,500.00
IRR 51.2%
PBP (approx) (yrs) 2.9
MARR 12%
NPV, IRR, and payback perio...
Sensitivity
NPV0 $15,000.00
NPV20 $3,000.00
IRR 30.70%
PBP (approx) (yrs) 3.6
MARR 12%
NPV and IRR based on triple capital...
Assignments
• Travis: Distillation and fractionation research, Simulation
assistance, Papers and progress reports, and Con...
References:
[1] N. K. Ibrahim, "Scribd," 26 May 2011. [Online]. Available:
http://www.scribd.com/doc/56377886/24/Compariso...
Questions?
of 24

Natural Gas to Olefins, Symposium[2]

Published on: Mar 3, 2016
Source: www.slideshare.net


Transcripts - Natural Gas to Olefins, Symposium[2]

  • 1. Natural Gas Liquids to Olefins
  • 2. Crackers Travis Wells Scott Chase Mohammed Alzain Salman Almutawa
  • 3. Project Definition • Introduction:  Production of olefins  North Dakota Plant • The project’s objectives:  Location  Ethane and propane • Goals and Aims:  Successfully design a plant that will convert NGLs to olefins with a 1.5 billion lb/yr capacity  Use ethane and propane as a feedstock from the North Dakota reserves  Place the plant in North Dakota and send products out by railroad  Design the plant to produce high purity (99.8%) ethylene and propylene
  • 4. Business Opportunity • Ethylene :  Polyethylene, PVC, ethylene glycol and styrene monomer [2]  Packaging, televisions, VCRs, cameras and other electronic equipment[2] • Propylene:  Propylene oxide, acrylonitrile, cumene and polypropylene[2]  Furniture and bedding, batteries, automobile interior parts, carpeting, clothing and other textiles[2] • By-products:  Hydrogen (H2)  Methane (CH4) 4
  • 5. Plans • Fall semester:- 1- Built an olefin unit in Aspen+ 2- Decide the location of our plant 3- Decide weather to use ethane and propane as a mixture in the feed or separate, in terms of economics 4- Estimate the recycle streams 5- Estimate most of the equipment cost 6- Produce more products (e.g. produce polyethylene and polypropylene) • Spring Semester:- 1- Decide what to do with the heavies in the by-products 2- Liquefied our products (ethylene and propylene) 3- Finish all the economic and pricing estimations 4- Heat integration (e.g. Heat exchanger) 5- Refrigeration system 6- Moving the plant to the gulf coast 7- Optimize our unit 8- Environmental issues
  • 6. Material Balance • Size: (1.5 billion lb/yr ) Recycle Ratio = 65.34% (lb/hr) Ethane Propane Ethylene Propylene Methane H2 Heavies Feed 180000 60000 - - - - - Main Products - - 166561 21624 - - - By-products - - - - 24937 19563 7315 Recycle 125489 31335 - - - - -
  • 7. Process Flow Diagram
  • 8. Thermal Vs. Catalytic Cracking [1] Thermal Cracker Catalytic Cracker No catalyst Uses a catalyst Higher reaction condition Lower reaction condition Free radical reaction Ionic reaction High gas yields Low gas yields Low octane number High octane number High yield of C2 & C3 olefins and low yields of gasoline and other distillates High yield of C4 olefins and high yields of gasoline and other distillates 8
  • 9. Reactions • In steam cracking, initiation usually involves breaking a chemical bond between two carbon atoms, rather than the bond between a carbon and a hydrogen atom. [4] CH3CH3 → 2 CH3• • Hydrogen abstraction occurs where a free radical removes a hydrogen atom from another molecule, turning the second molecule into a free radical. [4] CH3• + CH3CH3 → CH4 + CH3CH2• • Radical decomposition occurs where a free radical breaks apart into two molecules, one an alkene, the other a free radical. This is the process that results in the alkene products of steam cracking. [4] CH3CH2• → CH2=CH2 + H•
  • 10. Cracker Yields: [3]
  • 11. Cracker Cracker Ethane Recycle Propane Recycle
  • 12. Quench Tower
  • 13. Quench Tower Quench Tower
  • 14. Dehydration System
  • 15. Dehydration System 3 Phase Separator Depropanizer Molecular sieve
  • 16. Fractionation Towers
  • 17. Fractionation Towers Demethanizer
  • 18. Fractionation Towers Methane & H2 Splitter Deethanizer C2 Splitter C3 Splitter Ethane Recycle Propane Recycle
  • 19. Capital Cost Installed ISBL MM$ 383 Installed OSBL MM$ 38.3 The overall capital cost at this point is $421.24 million dollars Compressor $18,500,000.00 Furnace/ Crackers $22,000,000.00 Heat Exchangers $3,200,000.00 Vessels $544,000.00 Towers & Trays $5,300,000.00 Pumps $5,000,000.00 TOTAL ISBL FOB $54,544,000.00
  • 20. Capital Cost Summary NPV0 $15,500.00 NPV20 $3,500.00 IRR 51.2% PBP (approx) (yrs) 2.9 MARR 12% NPV, IRR, and payback period (Millions of dollars)
  • 21. Sensitivity NPV0 $15,000.00 NPV20 $3,000.00 IRR 30.70% PBP (approx) (yrs) 3.6 MARR 12% NPV and IRR based on triple capital cost (Millions of dollars) The overall capital cost at this point is $1.263 Billions of dollars
  • 22. Assignments • Travis: Distillation and fractionation research, Simulation assistance, Papers and progress reports, and Consulting. • Scott: Cracker research, Simulation, Economics and sizing, Database, Proofreading, and Advisor consulting. • Mohammed: Distillation and fractionation research, Physical properties, Economics and sizing, Simulation, and Proofreading. • Salman: Cracker research, Economics and sizing, PowerPoint presentations, Simulation, and Proofreading.
  • 23. References: [1] N. K. Ibrahim, "Scribd," 26 May 2011. [Online]. Available: http://www.scribd.com/doc/56377886/24/Comparison-between-thermal-and-catalytic-cracking. [Accessed 12 September 2012]. [2] "Flint Hills Resources," chemicals and biofuels Productions, [Online]. Available: http://www.fhr.com/about/default.aspx. [Accessed 03 December 2012]. [3] L. Kniel, O. Winter and K. Stork, Ethylene, keystone to the petrochemical industry, New York: Marcel Dekker Inc, 1980. [4] R. M. Rioux, "The Pennsylvania State University," [Online]. Available: http://www.research.psu.edu/events/expired-events/naturalgas/presentations/Rioux.pdf. [Accessed 04 September 2012].
  • 24. Questions?

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