A Sabic - Clariant Partnership Company Confidential Information of Scientific Design Company, Inc

Confidential Information of Scientific Design Company, Inc.
Confidential Information of Scientific Design Company, Inc. A SABIC Clariant Partnership Company
A SABIC Clariant Partnership Company
LICENSEES
FEEDBACK
RICHARD GENESTE
Senior Process Engineer
MAY 16, 2016

CATALYST LOADING METHOD
Catalyst Loading Method
4% 13%
LOADING PLATE
MACHINE LOADING
INSERT LOADING
21%
62% OTHER

TIME REQUIRED FOR CATALYST CHANGEOUT
>3
3
Weeks
0% 10% 20% 30% 40% 50%

% of Respondents
EO REACTOR INCIDENTS FROM 2012 - 2014
CARBONATE CARRYOVER
POST IGNITION
HIGH REACTOR OUTLET TEMP.
INLET IGNITION/DETONATION
OTHER INCIDENT LEADING TO EXTENDED SHUTDOWN
CYCLE WATER CARRYOVER
ANY OTHER FIRE
OXYGEN FIRE
GAS GAS EXCHANGER RUPTURE DISC BLOWN
REACTOR RUPTURE DISC BLOWN
0 1 2 3 4 5 6 7 8 9
Total # of Reported Incidents in 3 Years

AVERAGE # OF SHUTDOWNS PER PLANT
9
8 Average Number of
7
Shutdowns Since 2010, Number of
6 Shutdowns have been
5 below average
4
3
Illustrates that operators
2 are becoming more
1 experienced
0
2008 2009 2010 2011 2012 2013 2014

MAJOR CAUSES OF EO REACTOR SHUTDOWN
2012-2014
16% 19% Instrument Malfunction Power Failure
Loss Of Oxygen Loss Of Utility Steam

3%
4% Mechanical Failure Recycle Compressor Trip
11%
6% Loss Of Ethylene Fast Acting Thermocouples
Malfunction
Human Error Loss Of Other Utilities
6%
11% Other
8%
8% 9%

MAJOR CAUSES OF EO REACTOR SHUTDOWNS
Top 5 Causes of EO Reactor Shutdown
2005-2009 2009-2011 2012-2014
Instrument Malfunction Instrument Malfunction Instrument Malfunction
Loss of Oxygen Loss of Oxygen Power Failure
Power Failure Power Failure Loss of Oxygen
Mechanical Failure Mechanical Failure Loss of Utility Steam
Loss of Ethylene Loss of Ethylene Mechanical Failure

PREVENTING INSTRUMENT MALFUNCTION
Upgrade solenoid valves
Use robust, low frequency of failure transmitters
Shorter instrument impulse lines
Redundant 2 o o 3 field and I/O devices when appropriate

SULFUR IN PETRO ETHYLENE
>5 ppm <1 ppm
21% 21%
2 - 5 ppm
4%
1 - 2 ppm
54%
ETHYLENE RECOVERY UNIT
Plants Containing an ERU
YES
34%
NO
66%

CO2 SECTION OPERATIONAL ISSUES
Mechanical Problems
Rupture Disk Failure
Instrument Plugging
Other Problems
Excessive Carbonate
Consumption
0% 5% 10% 15% 20% 25%
% of Respondents

ANTIFOAM IN CO 2 SYSTEM
Antifoam Type Dosing Methodology
100%
Percent of Respondents
Continuous
32%
75%
As
50% Needed
68%
25%
0%
UCON 50 HB5100 OTHER
RECOMMENDED

MEG CONC. IN CARBONATE SOLUTION
35%
30%
25%
20%
15%
10%
5%
0%
<2 2-4 4-6 6-8 8 - 10 >10
Normal wt% MEG

HYDROCARBONS IN REGENERATOR VENT
Measure Hydrocarbons? Hydrocarbon Concentration
As Needed
NO 52% >1000
31%
ppm vol
500 - 1000
100 - 500
<100
Continuously 0% 10% 20% 30% 40%

17% Percent of Respondents

EO SCRUBBER OPERATIONAL ISSUES
High EO in the Overheads
Other Problems
Foaming
0% 5% 10% 15% 20% 25% 30% 35% 40% 45%

% of Respondents

EO IN SCRUBBER OVERHEADS
Normal Months Summer Months
14% 4%
25% 0 - 50 ppm
51 - 100 ppm 11%
53% 4% 101 - 200 ppm
18% Over 200 ppm 71%

EO STRIPPER FEED LINE
Vibrational Issues In Column Feed?
Yes
19%
No
81%

CYCLE WATER ANTIFOAM TYPE AND
DOSING METHODOLOGY
Antifoam Type Dosing Methodology
100%
Continuous
75% 30%
Batch
50% 70%
25%
0%
Oleyl Alcohol Other RECOMMENDED

REABSORBER OPERATIONAL ISSUES
High Overhead Pressure
Plugging
Other Problems
0% 5% 10% 15% 20% 25% 30%

% of Respondents
FREQUENCY OF REABSORBER VENTING
Times/Year for Process Condition
>= 3
5%
2
19%
1
9%
0
67%
Average Vent Duration = 1.7 hours

PURIFICATION COLUMN RELIEF VALVE LIFT
YES 13%
NO 87%

GLYCOL REACTOR OUTLET pH
30%
25%
20%
15%
10%
5%
0%
<4 4-5 5-6 6-7 >7
pH
DI UNIT CYCLE TIME
SOR Avg = 57 hours EOR Avg = 39 hours
9% 14%
19%
23%
48%
<24 hours
25 - 48 hours 33%
49 - 72 hours
54%
>72 hours

DI UNIT CRITERIA FOR SWITCHOVER
Time
UV Transmittance
Conductivity
pH
Total Cumulative Flow
0% 10% 20% 30%

% of Respondents

ALDEHYDE IN PURIFIED EO
Concentration of Aldehydes in PEO Method of Measuring Aldehydes in PEO
(ppm) / per sales spec
100 ppm 10 ppm
5% 10%
15 ppm Titration Method
50 ppm 5%
25%
MBTH S-63
20 ppm
10 ppm 15%
15 ppm HPLC RECOMMENDED
20 ppm
30 ppm 0% 20% 40% 60% 80%
50 ppm
100 ppm 30 ppm
40%
AVERAGE MEG PRODUCT UVs
Before PTR After PTR Sales Spec.
100
% Transmittance
90
80
70
60
@ 220 nm @ 250 nm @ 275 nm @ 350 nm
MEG Product meets spec before PTR @ 220, 275 &
350 nm
PTR improves transmittance for all reported UVs

CONCLUSION
Data collected will help SD:

Design plants to our clients needs
Aid in helping clients operate more efficiently
Identify and troubleshoot any issues which may occur during
plant operation
Reduce the number of issues which may occur in the field
THANK YOU!!


A Sabic - Clariant Partnership Company Confidential Information of Scientific Design Company, Inc

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0% 10% 20% 30% 40% 50%

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Confidential Information of Scientific Design Company, Inc.

Loss Of Oxygen Loss Of Utility Steam

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Rupture Disk Failure

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Continuously 0% 10% 20% 30% 40%

Confidential Information of Scientific Design Company, Inc.

High EO in the Overheads

0% 5% 10% 15% 20% 25% 30% 35% 40% 45%

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Confidential Information of Scientific Design Company, Inc.

Confidential Information of Scientific Design Company, Inc.

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High Overhead Pressure

0% 5% 10% 15% 20% 25% 30%

Average Vent Duration = 1.7 hours

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Confidential Information of Scientific Design Company, Inc.

Total Cumulative Flow

0% 10% 20% 30%

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Confidential Information of Scientific Design Company, Inc.

Data collected will help SD:

Confidential Information of Scientific Design Company, Inc.

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