Académique Documents
Professionnel Documents
Culture Documents
Petrochemical Furnaces
Volkmar Lemme
Munich, Sep 14 , 2011
TABLE OF CONTENT
1.
INTRODUCTION - OVERVIEW
2.
EDC FURNACES
3.
KETENE FURNACES
4.
CS2 FURNACES
5.
ETHYLENE FURNACES
SELAS-LINDE
INTRODUCTION OVERVIEW
SELAS has experience in designing and building diverse Specialty Furnaces which are not very
common and require specific know how in design.
SELAS-LINDE
EDC Heater
KETEN Heater
TiCl4 and O2
CS2
MTP
Ethylene
132 altogether
31 since 1987
SELAS has done EDC Furnace Design for all major Process Licensors:
B.F. Goodrich
Hoechst
Solvay
Stauffer
Monsanto
ICI
DOW
Mitsui Toatsu
PPG Industries
SELAS-LINDE
>> GEON
>> Oxy-Vinyls
>> Vinnolit (Contractor: Uhde)
>> EVC
SELAS-LINDE
EDC FURNACES
SELAS-LINDE PROPIETARY COMPUTER PROGRAMS
VCM
CAPFA
CONVX
Stack design
SELAS-LINDE
EDC FURNACES
DUAL FUEL SUPPLY SYSTEM ( i.e. VESTOLIT / QVC )
SELAS-LINDE
EDC FURNACES
TYPICAL FORCED DRAFT NOZZLE MIX BURNER BY HCEL
SELAS-LINDE
SELAS-LINDE
SELAS-LINDE
10
KETENE - WACKER
SELAS-LINDE
11
April 2013
Content Overview
1
2
3
4
5
6
7
SELAS-LINDE
Introduction
Radiant Coil
Firing System
Quench Exchanger
Process Control
Decoking
Summary
13
SELAS-LINDE
Mixed firing
Ultra LowNOx-burners
Cyclone decoking
14
62% conversion
Firebox decoking
SELAS-LINDE
15
250
150
100
50
0
1980
1985
1990
1995
2000
2005
2010
2015
Year
SELAS-LINDE
16
Reliability of Furnaces
Most important causes for furnace outage:
Radiant Coil (recoil, repair, plugging)
Quench Exchanger Cleaning
Instrumentation
Quench Exchanger Repair
Refractory
Source:
Decoking Piping
Other Piping
Other
Participation of 67 plants
worldwide
Fans
Burners
0
SELAS-LINDE
10
20
17
30
40
50
Content Overview
1
2
3
4
5
6
7
SELAS-LINDE
Introduction
Radiant Coil
Firing System
Quench Exchanger
Process Control
Decoking
Summary
18
PYROCRACK - Coil
SELAS-LINDE
19
PyroCrack
Coil Type
4-2
2-2
1-1
0.40 - 0.60
0.25 - 0.40
0.15 - 0.25
0.45 - 0.65
Schematic
arrangement
Residence
Time [sec]
Tube I.D. [mm]
80-110 / 110-150
Equivalent
number of coils
SELAS-LINDE
16-24
20
90 - 125
6
10
20
30
40
50
21
or
Center of Gravity
(Top View)
IMPROVED SOLUTION
C) S-shaped return bends
flexible system
low stresses
no guide-pins required
extended coil life
SELAS-LINDE
22
S-Bends
No guide pins
and bumpers
Inline coil
arrangement
no coil bending
no hot spots
reduced stress
increased coil life and run length
SELAS-LINDE
23
SELAS-LINDE
Content Overview
1
2
3
4
5
6
7
SELAS-LINDE
Introduction
Radiant Coil
Firing System
Quench Exchanger
Process Control
Decoking
Summary
25
Sidewall Burner
Typical Firing Capacity
0.3 - 0.45 MW per Burner
Typical design:
partial premix
(but also nozzle mix)
Typical: staged fuel for
NOx reduction
Floor Burner
Typical Firing
Capacity
1.0 - 3.3 MW per
Burner
Typical design:
nozzle mix
NOx reduction by
staged fuel or
staged air and
flue gas recirculation
26
Fuel-Air Mixture
Fuel Gas
Flue Gas
SELAS-LINDE
Air
Fuel Gas
Flue Gas
SELAS-LINDE
Floor Firing
Sidewall Firing
Mix Firing
Few burners /
less maintenance
High automation
(duty & comb. air)
Avoids back-firing
Combines
advantages
29
SELAS-LINDE
Content Overview
1
2
3
4
5
6
7
SELAS-LINDE
Introduction
Radiant Coil
Firing System
Quench Exchanger
Process Control
Decoking
Summary
31
Reliability of Furnaces
Most important causes for furnace outage:
Radiant Coil (recoil, repair, plugging)
Quench Exchanger Cleaning
Instrumentation
Quench Exchanger Repair
Refractory
Source:
Decoking Piping
Other Piping
Other
Participation of 67 plants
worldwide
Fans
Burners
0
SELAS-LINDE
10
20
32
30
40
50
TLE type
Tube Blockage
conventional
both
Waterside Corrosion
Inlet Tube Sheet Erosion
Failure of Tube to Tube Sheet Weld
Refractory Failures
conventional
both
LQE
Tube Erosion
Other Weld Failures
both
Waterside Fouling
Failure of the Outer Tube or Shell
Bowing of Tube Sheet
conventional
0
SELAS-LINDE
10
20
30
40
33
50
SL / Volkmar Lemme / Petrochemical Furnaces 220413
SELAS-LINDE
Quench Concepts
stages
TLE type
two/three
single
conventional
both
linear (LQE)
gas cracking
liquid cracking
application
ca. 500 C
330 - 380 C
330 390 C
200C
350C
SELAS-LINDE
35
Conventional TLE
Arch Lining
Fire-box
Source: Borsig
Coil Outlet
Tubes
SELAS-LINDE
36
Reduced maintenance
Maximum availability
37
Content Overview
1
2
3
4
5
6
7
SELAS-LINDE
Introduction
Radiant Coil
Firing System
Quench Exchanger
Process Control
Decoking
Summary
38
Hydrocarbons
Dilution Steam
Dilution Steam
Convection Preheat
and superheat
Firing adjusted
individually per zone
Cross-over-Headers
(here: 2 x 3 zones)
Venturi nozzles
Radiant Section
Equal cracking
conditions in all coils:
XOT
severity
selectivity
coking
Fuel
TLEs
Cracked Gas
SELAS-LINDE
39
Flue gas
H
T
Cracked gas
BFW
HC
DS
HPS
T
HH
H
HH
H
P
P
L
Fuel
H
T
P
L
= Partial Shut-down (HSSB)
H
P
= Total Shut-Down
L
SELAS-LINDE
Content Overview
1
2
3
4
5
6
7
SELAS-LINDE
Introduction
Radiant Coil
Firing System
Quench Exchanger
Process Control
Decoking
Summary
41
Equal coil inlet conditions (XOT) due to collecting header at convection outlet
Venturi nozzles at coil inlet ensure same throughput of steam and air for each coil
Individual control of coil outlet temperature for each radiant coil group
No undefined distribution
Each radiant coil outlet tube is directly linked with one individual quench exchanger tube
All quench exchanger tubes have the same throughput of steam and air too
All radiant coils and quench exchanger tubes are evenly and reliably decoked
SELAS-LINDE
42
Cell decoking
SELAS-LINDE
DECOKING
CRACKING
43
BP "GOFER" Project
Cologne, Germany, 2008
5 new furnaces replace
18 (!) old ones
100 kta Ethylene
Capacity per furnace
Naphtha, LPG, UCO
Cell Decoking Feature
(4.5 + 0.5 concept)
SELAS-LINDE
44