1.

Introduction

Ethylene is a critical building block in the petrochemical industry. Commercially, ethylene is

produced in industries by cracking naphtha, ethane, propane or a mixture of them.

Ethylene is used as a raw material, mainly for the production of the production of polyethylene,
which has a growing global consumption of 3.6% from 2005 to 2014 (source: CIS).

Ethylene has therefore a growing demand in developing countries such as India which have a low per
capita consumption of polyethylene - 9 kg per person in comparison with developed countries in
Western Europe and North America that have per capita consumption of around 45 - 55 kg per
person. This gap suggests that there will be a sharp increase in developing countries consumption of
ethylene derivatives which motivates us to study the manufacturing of ethylene.

An attempt has been made by us to study the manufacturing of ethylene through gas cracking process
which is predominantly based in Maharashtra and Gujarat.

1
 2. Properties

IUPAC name: Ethene

Chemical structure:

Properties[3]

Chemical formula C2H4

Molar mass 28.05 g/mol

Appearance Colorless gas

Density 1.178 kg/m3 at 15 °C, gas

Melting point −169.2 °C (−272.6 °F; 104.0 K)

Boiling point −103.7 °C (−154.7 °F; 169.5 K)

Solubility in water 3.5 mg/100 mL (17 °C); 2.9 mg/L

Solubility in ethanol 4.22 mg/L

Solubility in diethyl ether Good

Acidity (pKa) 44

Magnetic susceptibility (χ) -15.30·10−6 cm3/mol

2
 Structure[3]

Molecular shape D2h

Dipole moment Zero

Thermochemistry[3]

Std molar 219.32 J·K−1·mol−1

entropy (So298)

Std enthalpy of +52.47 kJ/mol

formation (ΔfHo298)

Flash Point −136 °C (−213 °F; 137 K)

Autoignition Temperature 542.8 °C (1,009.0 °F; 815.9 K)

3
 3. History

Some geologists and scholars believe that the famous Greek Oracle at Delphi (the Pythia) went into
her trance-like state as an effect of ethylene rising from ground faults.

Ethylene appears to have been discovered by Johann Joachim Becher, who obtained it by
heating ethanol with sulfuric acid; he mentioned the gas in his PhysicalSubterranean(1669). Joseph
Priestley also mentions the gas in his Experiments and observations relating to the various branches
of natural philosophy: with a continuation of the observations on air (1779), where he reports that Jan
Ingenhousz saw ethylene synthesized in the same way by a Mr. Enée in Amsterdam in 1777 and that
Ingenhousz subsequently produced the gas himself. The properties of ethylene were studied in 1795
by four Dutch chemists, Johann Rudolph Deimann, Adrien Paets van Troostwyck,
AnthoniLauwerenburgh and Nicolas Bondt, who found that it differed from hydrogen gas and that it
contained both carbon and hydrogen. This group also discovered that ethylene could be combined
with chlorine to produce the oil of the Dutch chemists, 1,2-dichloroethane; this discovery gave
ethylene the name used for it at that time, olefiant gas (oil-making gas.)[1-3]

In the mid-19th century, the suffix -ene (an Ancient Greek root added to the end of female names
meaning "daughter of") was widely used to refer to a molecule or part thereof that contained one
fewer hydrogen atoms than the molecule being modified. Thus, ethylene (C2H4) was the "daughter
of ethyl" (C2H5). The name ethylene was used in this sense as early as 1852.

In 1866, the German chemist August Wilhelm von Hofmann proposed a system of hydrocarbon
nomenclature in which the suffixes -ane, -ene, -ine, -one, and -une were used to denote the
hydrocarbons with 0, 2, 4, 6, and 8 fewer hydrogens than their parent alkane. In this system, ethylene
became ethene. Hofmann's system eventually became the basis for the Geneva nomenclature
approved by the International Congress of Chemists in 1892, which remains at the core of
the IUPAC nomenclature. However, by that time, the name ethylene was deeply entrenched, and it
remains in wide use today, especially in the chemical industry [4].

4
Following experimentation by Luckhardt, Crocker, and Carter at the University of Chicago, ethylene
was used as an anesthetic It remained in use through the 1940s use even while chloroform was being
phased out. Its pungent odor and its explosive nature limit its use today [5, 6].

5
 4. Ethylene derivatives & uses

Major industrial reactions of ethylene include in order of scale: 1) Polymerization, 2) Oxidation,

3) Halogenation and Hydrohalogenation, 4) Alkylation, 5) Hydration, 6) Oligomerization, and
7) Hydroformylation. In the United States and Europe, approximately 90% of ethylene is used to
produce ethylene oxide, ethylene dichloride, ethylbenzene and polyethylene. Most of the reactions
with ethylene are electrophilic addition.

4.1 Polymerization

Polyethylene consumes more than half of the world's ethylene supply. Polyethylene, also
called polyethene, is the worlds most widely used plastic. It is primarily used to make films
in packaging, carrier bags and trash liners. Linear alpha-olefins, produced
by oligomerization (formation of short polymers) are used
as precursors, detergents, plasticizers, synthetic lubricants, additives, and also as co-monomers in the
production of polyethylene.[7,9,10]

4.2 Oxidation

Ethylene is oxidized to produce ethylene oxide, a key raw material in the production
of surfactants and detergents by ethoxylation. Ethylene oxide is also hydrolyzed to produce ethylene
glycol, widely used as an automotive antifreeze as well as higher molecular weight glycols, glycol
ethers and polyethylene terephthalate.

Ethylene undergoes oxidation by palladium to give acetaldehyde. This conversion remains a major
industrial process (10M kg/y). The process proceeds via the initial complexation of ethylene to a
Pd(II) center.[7,10,13]

4.3 Halogenation and hydrohalogenation

Major intermediates from the halogenation and hydrohalogenation of ethylene include ethylene
dichloride, ethyl chloride and ethylene dibromide. The addition of chlorine entails "oxychlorination,"
i.e. chlorine itself is not used. Some products derived from this group are polyvinyl chloride,
trichloroethylene, perchloroethylene, methyl chloroform, polyvinylidene chloride and copolymers,
and ethyl bromide.[9,10]

6
4.4 Alkylation

Major chemical intermediates from alkylation reactions using ethylene is ethylbenzene, precursor
to styrene. Styrene is used principally in polystyrene for packaging and insulation, as well as
in styrene-butadiene rubber for tires and footwear. On a smaller scale, ethyl toluene, ethyl anilines,
1,4-hexadiene, and aluminum alkyls. Products of these intermediates
include polystyrene, unsaturated polyesters and ethylene-propylene terpolymers.[10]

4.5 Oxo reaction

The hydroformylation (oxo reaction) of ethylene results in propionaldehyde, a precursor to propionic

acid and n-propyl alcohol. [13]

4.6 Hydration

Ethylene has long represented the major nonfermentive precursor to ethanol. The original method
entailed its conversion to diethyl sulfate, followed by hydrolysis[13,14]. The main method practiced
since the mid-1990s is the direct hydration of ethylene catalyzed by solid acid catalysts:

C2H4 + H2O → CH3CH2OH

4.7 Dimerization to n-Butenes

Ethylene can be dimerized to n-butene’s using processes licensed by Lummus or IFP. The Lummus
process produces mixed n-butene’s (primarily 2-butenes) while the IFP process produces 1-butene. [12]

4.8 Niche uses

An example of a niche use is as an anesthetic agent (in an 85% ethylene/15% oxygen ratio). It can
also be used to hasten fruit ripening, as well as a welding gas. [8, 11]

7
8
Ethylene in our daily uses

9
 5. Market Survey

Manufacture of ethylene using feedstock ethane and propane mixture produces mostly ethylene as the
main product and propylene as the bi-product. Ethylene & propylene are used as a monomer/building
blocks for producing the polymer. These polymers find a lot of application which are used in our
daily life. Ethylene is mainly used in the manufacture of the following polymer products:

• Polyethylene
a. High Density Polyethylene (HDPE)
b. Linear Low-Density polyethylene (LLDPE)
c. Low Density Polyethylene (LDPE)
• Ethylene Oxide
• Ethylene Glycol
• Styrene
• Polyvinyl Chloride (PVC)
• Alpha Olefins (AO)

5.1 Applications of ethylene derivatives

• HDPE has got a very vide application range covering woven sacks for industrial packaging,
handling crates, Jerry cans, containers for edible oils, Pipes, cosmetics and toiletries etc.[23]

• LLDPE finds application in areas of carrier bags, pickup bags, Grocery bags, Baker &
confectionary packaging, detergent packaging, drip irrigation etc.[23]

• Ethylene Oxide (EO)/Ethylene Glycol (EG)/Styrene/ Polyvinyl Chloride (PVC)/Alpha Olefins

(AO) -Ethylene Oxide used in making mono ethylene glycol (MEG). This finds application in
polyesters, food packaging, engine coolant etc. Styrene used in making synthetic rubber,
consumer electronics, automotive etc. PVC plastics used in medical equipment. AO is

10
 premium grade surfactant.[23]

• Polypropylene (PP)/Polypropylene Co polymer (PPCP) - Homo Polymer used in primarily in

automotive industries. Poly propylene co polymer (PPCP) is used in low temperature
application due to better mechanical properties than homopolymer.

5.2 Consumption of polymers:

5.2.1 Demand scenario

• The demand scenario of polymers LLDPE/HDPE/LDPE is expected to be growing at 10.6%

annually from year 1991 onwards till year 2021 in India.[21]

• The demand scenario of EO/EG/Styrene/PVC, EO/EG is growing at 7.5% annually from year
1991 onwards till year 2021. Styrene /PVC showing a negative growth at negative (-) 9%
from year 2016 up to year 2021 in India.[21]

• The demand scenario of PP is growing at 11.8% annually from year 1991 onwards till year
2021 in India.[21]

India is one of the lowest consumers of plastics per person in the world and is expected to increase
consumption in the coming future. More than 18% of world population reside in India and economic
growth (7-8 % average) fueling the increase in consumption. 30 % of the world population consumes
approximately 30 kg per Person. 58% of World Population consumes 9 kg per person. The global
market for the polyolefins currently stands at 145 MMTPA year 2014/15 against 103 MMTPA in the
year 2005. The average global growth rate during the period is 4% for PE and 4.3 % for PP market.
In India, the consumption of polyolefins stands to 9 kg per person as of year 2014, China at 35 kg per
person, North America at 52 kg per Person. India as a developing country has a huge potential for the
growth based on the per capita consumption basis.

11
Norms of Ethylene Consumption Per MT of Product Produced:

MT of Ethylene Required
HDPE 1.03
LLDPE 0.95
LDPE 1.01
STYRENE 0.3(BENZENE
0.82)
AO 1.03
EO/MEG 0.745

5.3 Demand /Supply gap analysis:

5.3.1Polyolefins-India vs. World: Global ranks in polymer consumption

It can be seen from the below table that India consistently moving up in consumption from
16th place in year 1988 to 3rd largest consumer of polymers in year 2015. This gives an
average consumption of 10 kg per person in India. The main drivers for the consumption
being population & economic growth.[21]
Polymers: India Vs World
Global Rank in Polymer Consumption
Rank Country 1988 Country 2000 Country 2015 2015/2000
MMT MMT MMT %
1 USA 16.6 USA 27.3 USA 38.9 3.6
2 Japan 6.4 China 14.4 China 31.3 8.1
3 Germany 4.3 Japan 9.1 India 12.5 14.0
4 China 3.7 Germany 6.4 Japan 11.5 2.3
5 Italy 3.1 S.Korea 4.7 Germany 9.4 3.9

12
 6 CIS 2.4 Italy 4.7 S.Korea 7.4 4.8
7 France 2.4 France 4.1 Italy 6.8 3.8
8 UK 2.2 UK 3.5 Brazil 6.7 7.0
9 Taiwan 1.9 India 3.4 CIS 6.2 9.1
10 S.Korea 1.8 Brazil 3.4 France 6.1 4.1
16 India 1.6 Taiwan 3.3 UK 5.2 4.0

5.3.2 India– Ethylene /Propylene Derivatives–Gap Analysis(*)

Product KTA Demand /Supply Gap (KTA)

Year 2020 Year 2035
Prod. Demand Gap Prod. Dema Gap
Cap Cap nd
Ethylene 7945 12510 5365 7945 24830 16885
Derivatives(PE/PVC/MEG/EVA/Styren
e)
Propylene Derivatives 5274 6935 1661 5274 13436 8162
(PP/ACN/PO/Phenol)
TOTAL ETHYLENE Gap 3200 12800
TOTAL PROPYLENE Gap 1450 7700

*Based on Name Plate Production Capacity, Announced Expansions and Expected Growth. [21]

From the above India needs to have at least 2 Large Crackers of at least 1500 KTA production of
Ethylene size operating by 2020 to meet the Gap and reduce the import. This will not only create the
ample job opportunity but also save precious foreign exchange. Availability of continuous supply of
committed Feedstock is the most challenging for building the petrochemicals projects. India continues
to face this challenge. To overcome India can consider following options for a quick forward path:

• Mixed Crackers

13
• Pool Naphtha from existing /new refining sources
• Reverse SEZ Offshore – Opportunity for existing plants expansion
• Import Naphtha/condensate from Middle East/other countries
• Import Ethane from US

14
 6. Process Selection

1) Availability of feedstock

Refineries in India generally have a naphtha cracker for ethylene production due to the case of
naphtha being ever-present in the surrounding region. In the case of feedstock availability in
Maharashtra there is no source of naphtha available. So, we use ethane/propane as our feedstock for
the production of ethylene.
2) Cost of feedstock

a) Cost of ethane/propane feed= ₹15000/- per ton

b) Cost of naphtha feed=₹ 25000/- per ton
3) Co-product yield

Naphtha though a predominant feedstock for cracking operations in India produces a larger yield of
co-products per ton of ethylene as compared to ethane and propane feedstock. This is shown below

15
Type of Feedstock determines co-product yield per tonne of ethylene

Naptha Gas oil Ethane Propane Butane

Feedstock 3.2 3.8 1.2 2.4 2.5
Required

Propylene 0.5 0.55 0.03 0.5 0.4

Butadiene 0.4 0.35 0.03 0.08 0.26
Pygas 0.75 0.70 0.02 0.15 0.18
Benzene 0.15 0.23 0.01 0.05 0.06
Toulene 0.1 0.12 - - 0.03
C5 olefins 0.07 0.08 - - 0.01
Fuel oil 0.1 0.7 - 0.02 0.04
Fuel 0.45 0.5 0.17 0.65 0.62
Gas/Other

The greater the number of co-products produced the more the processes are required to treat them.
This increases the equipment required for treatment and increases the overall cost of production of
ethylene.

16
Typical naphtha (liquid cracker) yield

NAPHTHA
YIELDS, WT%
HYDROGEN 0.841
METHANE 16.268
ACETYLENE 0.326

ETHYLENE 26.152
ETHANE 3.857

MAPD 0.978

PROPYLEN 16.943

PROPANE 0.540

13BUTD 4.793

BUTENES 6.741
BUTANES 1.347 52.5 %
13CPD 1.767

ISOPRENE 0.979

C13PND 0.500

1PENTENE 0.924

PENTANES 1.377

1HEXENE 2.082

BTXENZENE 10.604

C9-200C 0.910

FUEL OIL 2.031

TOTAL Approx. 100.000

17
Typical ethane (gas cracker) yield

ETHANE

YIELDS, WT%
HYDROGEN 3.446
CO 0.065

METHANE 4.486

ACETYLENE 0.403

ETHYLENE 52.267

ETHANE 34.590

MAPD 0.014

PROPYLEN 1.089

PROPANE 0.139 4.7 %

13BUTD 1.309

1BUTENE 0.140

BUTANE 0.095

13CPD 0.353

C13PND 0.024

1PENTENE 0.170

1HEXENE 0.078

BENZENE 0.833

TOLUENE 0.112

OXYLENE 0.065

C9-200C 0.050

18
FUEL OIL 0.272

TOTAL Approx. 100.000

It is clear that by using Ethane/Propane as a feedstock gives a greater yield of ethylene low co-
products.

19
7. Block Flow Diagram

20
 8. Process Description

The process is a steam-cracking process for ethylene production from an ethane-propane mixture.

The process can be divided into three main parts: cracking and quenching; compression and drying;

and separation.

1) Cracking and quenching: Initially, an ethane-propane mixture is fed to furnaces in which, under
high-severity conditions, it is cracked, forming ethylene, propylene and other byproducts. The
furnace outlet stream is subsequently fed to a water-based quench, to prevent further reactions and
formation of undesirable byproducts.

From a decanter downstream from the quench tower, heavies, condensed dilution steam, tar and coke
are removed. Cracked gas from the quench is then directed to compression and separation.

2) Compression and drying: The compression of the cracked gas is performed across five stages.
After the third stage of compression, carbon dioxide and sulfur are removed from the cracked gas by
caustic soda and water washes in a caustic scrubber. The compressed cracked gas is cooled and
subsequently dried by molecular sieves that remove most of the water.

3) Separation: The dried cracked gas is fed to a cold box for the removal of hydrogen and light
hydrocarbons, while minimizing ethylene losses.

At this point, condensates from the chilling train are fed to a series of separation columns. In the first
column (demethanizer), methane is obtained from the top and further used in the cold box, while the
bottom stream is fed to a second column (deethanizer).

The top of the deethanizer, composed primarily of ethylene and ethane, is fed to an acetylene
converter and then fractionated in the C2-splitter. In this column, lights are removed from the
overheads and recycled to the compression system, while polymer-grade (PG) ethylene is drawn from

21
the column as a side stream. Ethane, from C2-splitter bottoms, is recycled to the cracking furnaces.

The deethanizer bottom stream is fed to a depropanizer, which distills C3 components in the
overheads. This overhead stream is catalytically hydro treated for methyl acetylene and propidine
removal, and then fed to the C3-splitter. In this column, lights are removed from the overheads and
recycled to the compressors, while polymer-grade (PG) propylene is drawn from the column as a side
stream. Propane from C3-splitter bottoms is recycled to the cracking furnaces. A C4+ stream is
obtained from the depropanizer bottoms.

22
 9. Material Balance

9.1 Sample Material Balance of Furnace reactor

Sr no Reaction % Conversion
1 C2H6 C2H4 + H2 90
2 2C2H6 C2H4 + 2CH4 11
3 C3H8 C3H6 + H2 72
4 C3H8 C2H4 + CH4 95
5 C4H10 C4H6 + 2H2 80

Reaction 1:
C2H6 C2H4 + H2

Assumptions
• 70% of total ethane in feed reacted by reactions
• Ethane conversion is 90%

Reaction 2:
2C2H6 C2H4 + 2CH4

Assumptions
• 30% of total ethane in feed reacted by reaction 2
• Ethane conversion is 11%

Reaction 3:
C3H8 C3H6 + H2

Assumptions
• 30% of total propane in feed reacted by reaction 3
• Propane conversion is 72%

Reaction 4:
C3H8 C2H4 +CH4

Assumptions

23
 • 70% of total propane in feed reacted by reaction 4
• Propane conversion is 90%

Reaction 5:
C4H10 C4H6 + 2H2

Assumptions
• 100% of total propane in feed reacted by reaction 5
• butane conversion is 85%

Note: Data on conversion has been obtained through various reference journals and books

24
9.2 Sample Material Balance of distillation column

Deethanizer
Stream 15

Stream 14
DISTLLATION

COLUMN

Stream 11
D1001
Stream 16

Feed 1 (from DM) (Stream 14)

Sr. No. Component Flowrate(kg/h)
1 Ethylene 44718.52
2 Ethane 18881.31
3 Acetylene 327.58
4 Propylene 3038.85
5 Propane 2446.4
6 Butadiene 174.24
7 C 5’s 34.849
8 Benzene 6.9669
9 Other C 4’s 69.698
Total 69698.45

Feed 2 (from DMPS) (Stream 11)

Sr. No. Component Flowrate(kg/h)
1 Ethylene 9642
2 Ethane 7523.97
3 Acetylene 115.70
4 Propylene 5659.85
5 Propane 5399.52
6 Butadiene 1529.86
7 C 5’s 996.34
8 Benzene 674.94
9 Other C 4’s 591.376
Total 32140.45

25
Assumptions made
Top (light key)
Recovery of ethylene at top product=98.96%(ζlk1=0.9896)
Therefore 54360.52(feed 1 + feed 2) *0.9898 = 53796.00kg/h
Recovery of ethaneat top product=100%(ζlk2=1)
Therefore 26405.28(feed 1 + feed 2) *1=26405.39kg/h
Bottom (heavy key)
Recovery of propyleneat bottom product=99.98%(ζhk1=0.9998)
Therefore 8698.7(feed 1 + feed 2) *1 = 8696.96 kg/h
Recovery of propaneat bottom product=99.80%(ζhk2=0.9980)
Therefore 7845.92(feed 1 + feed 2) *1 = 7830.22kg/h

Top Product (Stream 15)

Sr. No. Component Flowrate(kg/h)

1 Ethylene 53796.00
2 Ethane 26405.39
3 Acetylene 446
Total 80647.39

Bottom Product (Stream 16)

Sr. No. Component Flowrate(kg/h)

1 Propylene 8696.96
2 Propane 7830.22
3 Butadiene 1907.23
4 C 5’s 1040.50
5 Benzene 692.96
6 C 4’s 676
7 Unaccounted 347.64
Total 21191.51

26
9.3 Material Balance across various units
Plant Capacity= 4, 00,000 TPA.
Plant Operating Time = 326 days.
Therefore mass flow rate of ethylene produced=51124.744 kg/h.

9.3.1. Ethane/Propane fractionator

Stream 3

DISTLLATION
Stream 1
COLUMN

Stream 2

Stream 4

Top Feed (Stream 1)

Sr. No. Component Flowrate(kg/h)
1 Methane 281
2 Ethane 33723
3 Propane 20402
4 Butane 1686
5 C5’s 113
Total 56205

Bottom Feed (Stream 2)

Sr. No. Component Flowrate(kg/h)
1 Methane 95
2 Ethane 11398
3 Propane 6896
4 Butane 569
5 C5’s 40
Total 18998

27
Top Product (Stream 3)
Sr. No. Component Flowrate(kg/h)
1 Methane 375
2 Ethane 44880
3 Propane 430
Total 45684

Bottom Product (Stream 4)

Sr. No. Component Flowrate(kg/h)
1 Butane 2256
2 Ethane 240
3 Propane 26868
4 C5’s 151
Total 29516

9.3.2 Furnace reactor

Stream 5

Furnace

Stream 7
Stream 6

Reactions
Sr no Reaction % Conversion
1 C2H6 C2H4 + H2 90
2 2C2H6 C2H4 + 2CH4 11
3 C3H8 C3H6 + H2 72
4 C3H8 C2H4 + CH4 95
5 C4H10 C4H6 + 2H2 80
And other complex reactions

28
Ethane Feed (Stream 5)
Sr. No. Component Flowrate (kmol/h)
1 Methane 23.4
2 Ethane 2353.3
3 Ethylene 7
4 Propane 9.7
5 Propylene 4.8
Total 2398.2

Propane Feed (Stream 6)

Sr. No. Component Flowrate (kmol/h)
1 Methane 0.1
2 Ethane 8
3 Propane 826.2
4 Propylene 11.5
5 Butane 38.8
6 Other C4’s 1.6
7 C5+ 2.1
Total 888.3

Furnace Product (Stream 7)

Sr. No. Component Flowrate(kmol/h)
1 Hydrogen 1674.5
2 Methane 651
3 Acetylene 15.6
4 Ethylene 1789.5
5 Ethane 860.6
6 C3 Acetylene 8.8
7 Propylene 196.8
8 Propane 174.1
9 Butadiene 32.1
10 Other C4’s 34
11 C5’s 17.6
12 Benzene 10.7
Total 5445.1

29
9.3.3 Caustic tower

Caustic

Caustic Tower Stream 8

Stream 7

Spent Caustic

Feed (Stream 7)
Sr. No. Component Flowrate(kg/h)
1 Cracked gas 116749
2 CO2 142
3 H2S 13
total 116904

Product (Stream 8)
Sr. No. Component Flowrate(kg/h)
1 Cracked gas 116749
2 CO2 0
3 H2S 0
Total flow rate 116749

9.3.4 Dryer
Recovery of water at dryer is 99.98% using 3Å molecular sieves.

30
9.3.5 Demethanizer pre-stripper

Stream 12

DISTLLATION
Stream 10
COLUMN

Stream 11

Feed (Stream 10)

Sr. No. Component Flowrate(kg/h)
1 Hydrogen 22.209
2 Methane 781.78
3 Acetylene 173.23
4 Ethylene 16564.04
5 Ethane 10900.55
6 Propylene 6294.24
7 Propane 5898.91
8 Butadiene 1559.12
9 C 5’s 977.22
10 Benzene 666.29
11 Other C 4’s 604.10
Total 44419.53

Top Product (to DM) (Stream 12)

Sr. No. Component Flowrate(kg/h)
1 Hydrogen 22.209
2 Methane 751.430
3 Acetylene 57.992
4 Ethylene 6885.03
5 Ethane 3254.96
6 Propylene 708.24

31
7 Propane 571.29
8 Butadiene 53.05
9 C 5’s 12.338
10 Benzene 2.46
11 Other C 4’s 22.028
Total 12338.76

Bottom Product (Stream 11)

Sr. No. Component Flowrate(kg/h)
1 Ethylene 9642
2 Ethane 7523.97
3 Acetylene 115.70
4 Propylene 5659.85
5 Propane 5399.52
6 Butadiene 1529.86
7 C 5’s 996.34
8 Benzene 674.94
9 Other C 4’s 591.376
Total 32140.45

9.3.6 Demethanizer

Stream 13

DISTLLATION
Stream 12
COLUMN

Stream 14

Feed (Stream 12)

Sr. No. Component Flowrate(kg/h)
1 Hydrogen 22.209

32
2 Methane 751.43
3 Acetylene 57.992
4 Ethylene 6885.02
5 Ethane 3254.96
6 Propylene 708.24
7 Propane 571.28
8 Butadiene 53.05
9 C 5’s 12.338
10 Benzene 2.46
11 Other C 4’s 22.028
Total 12338.75

Bottom Product (Stream 14)

Sr. No. Component Flowrate(kg/h)
1 Ethylene 44718.52
2 Ethane 18881.31
3 Acetylene 327.58
4 Propylene 3038.85
5 Propane 2446.41
6 Butadiene 174.24
7 C 5’s 34.85
8 Benzene 6.97
9 Other C 4’s 69.69
Total 69698.45

33
9.3.7 Deethanizer
Stream 15

Stream 14
DISTLLATION

COLUMN

Stream 11
D1001
Stream 16

Feed 1 (from DM) (Stream 14)

Sr. No. Component Flowrate(kg/h)
1 Ethylene 44718.52
2 Ethane 18881.31
3 Acetylene 327.58
4 Propylene 3038.85
5 Propane 2446.4
6 Butadiene 174.24
7 C 5’s 34.849
8 Benzene 6.9669
9 Other C 4’s 69.698
Total 69698.45

Feed 2 (from DMPS) (Stream 11)

Sr. No. Component Flowrate(kg/h)
1 Ethylene 9642
2 Ethane 7523.97
3 Acetylene 115.70
4 Propylene 5659.85
5 Propane 5399.52
6 Butadiene 1529.86
7 C 5’s 996.34
8 Benzene 674.94
9 Other C 4’s 591.376
Total 32140.45

34
Top Product (Stream 15)

Sr. No. Component Flowrate(kg/h)

1 Ethylene 53796.00
2 Ethane 26405.39
3 Acetylene 446
Total 80647.39

Bottom Product (Stream 16)

Sr. No. Component Flowrate(kg/h)

1 Propylene 8696.96
2 Propane 7830.22
3 Butadiene 1907.23
4 C 5’s 1040.50
5 Benzene 692.96
6 C 4’s 676
7 Unaccounted 347.64
Total 21191.51

35
9.3.8 Depropanizer

Stream 18

DISTLLATION
Stream 16
COLUMN

Stream 17

A) Feed (Stream 16)

Sr. No. Component Flowrate(kg/h)
1 Propylene 8696.96
2 Propane 7830.22
3 Butadiene 1907.23
4 C 5’s 1040.50
5 Benzene 692.96
6 C 4’s 676
7 Unaccounted 347.64
Total 21191.51

B) Top Product (Stream 18)

Sr. No. Component Flowrate(kg/h)
1 Propylene 8367.97
2 Propane 8020.53
Total 16388.51

C) Bottom Product (Stream 17)

Sr. No. Component Flowrate(kg/h)
1 Butadiene 1907.75
2 C 4’s 663.29
3 Benzene 761.75
4 C 5’s 1137.83
Total 4803

36
9.3.8.1 C3 Hydrogenator

DISTLLATION
Stream 18 Stream 21
COLUMN

A) Feed (Stream 18)

Sr. No. Component Flowrate(kg/h)
1 Propylene 8367.97
2 Propane 8020.53
Total 16388.51

B) Product (Stream 21)

Sr. No. Component Flowrate(kg/h)

1 Propylene 7167.97
2 Propane 9662
Total 16388.51

37
9.3.8.2 Propylene Stripper
Stream 22

DISTLLATION
Stream 21
COLUMN

Stream 23

Feed (Stream 21)

Sr. No. Component Flowrate(kg/h)
1 Propylene 7167.97
2 Propane 9662
Total 16388.51

Top Product (Stream 22)

Sr. No. Component Flowrate(kg/h)
1 Propylene 574
2 Propane 9562
Total 10136

Bottom Product (Stream 23)

Sr. No. Component Flowrate(kg/h)
1 Propylene 6593.97
2 Propane 100
Total 6693.97

38
9.3.9 Acetylene Column

Stream 20

DISTLLATION
Stream 15
COLUMN

Stream 19

Feed (Stream 15)

Sr. No. Component Flowrate(kg/h)

1 Ethylene 53796.00
2 Ethane 26405.39
3 Acetylene 446
Total 80647.39
Top Product (Stream 20)
Sr. No. Component Flowrate(kg/h)
1 Ethylene 51381.68
2 Ethane 26105.39
Total 77487.08
Bottom Product (Stream 19)
Sr. No. Component Flowrate(kg/h)
1 Ethylene 2151.84
2 Acetylene 442
Total 2593.84

39
9.3.10 Ethylene Tower
Stream 25

DISTLLATION
Stream 20
COLUMN

Stream 24

Feed (Stream 20)

Sr. No. Component Flowrate(kg/h)
1 Ethylene 51381.68
2 Ethane 26105.39
Total 77487.08

Output: (Stream 25)

Sr. No. Component Flowrate(kg/h)
1 Ethylene 51124.74
2 Ethane 256.94
Total 51381.68

Bottom Product (Stream 24)

Sr. No. Component Flowrate(kg/h)
1 Ethylene 256.94
2 Ethane 25848.44
Total 26105.39

40
 10. Site selection and plot plan

For the plant the site which has been selected is at Nagothane, near Alibaug, Maharashtra. [17] The site
is suitable due to the following factors:

1) Feedstock availability:

Feedstock requirements i.e. ethane-propane gas mixture in liquid state (ethane-60%, propane 40%) is
supplied through a cross country pipeline at high pressure from Uran. A small quantity of feedstock
propane is imported from Middle East and from Jamnagar refinery to meet the capacity.

2) Market for Finished Product:

Ethylene manufactured from Nagothane Manufacturing Division (NMD) cracker is sent to

downstream plants (LDPE, HDPE, LLDPE EOEG and PP) located within the complex.

3) Support from State Government:

This factor is also very important especially in a country like India where the administrative delays in
approvals and licensing can transform a possible fortune-making project to a hapless one. The
Maharashtra government promotes the chemical industries by providing the facilities and
infrastructure as required

4) Location and Access:

Nagothane is situated near Alibag and nearest city is Mumbai at 110 km .It is well connected with
Nagothane railway station and Mumbai-Goa highway.

41
 5) Electricity:

Electricity requirement is met by the MSEB.However there is a captive power plant within the
complex for meeting the electricity requirements.

6) Water:

Water is provided by MIDC for meeting the complex (plant + township) water requirements.

7) Support Facilities:

Fire station, bank, police station, hospital, schools, hotels and plots in the Industrial Area.

8) Roads:

Roads provide connection to the Mumbai-Goa highway.

9) Connectivity:

Communication facilities like telephone exchange, ISDN, etc. are available.

42
 11. Industries and licensors

11.1 List of top 10 ethylene producers worldwide

Rank Company Sites(wholly and Complexes Complexes

partially
(wholly owned) (partially
owned)*
(TPA)1 owned) (TPA)
1 Saudi Basic 15 13392245 10273759
Industries Corp.
(SABIC)
2 Dow Chemical 21 13044841 10529421
Co.
3 ExxonMobil 20 12515000 8550550
Chemical Co.
4 Royal Dutch 13 9358385 5946693
Shell PLC
5 Sinopec 13 7895000 7275000
6 Total AS 11 5933000 3471750
7 Chevron Philips 8 5607000 5352000
Chemical Co.
8 LyondellBasell 8 5200000 5200000
9 National 7 4734000 4734000
Petrochemical
Co.
10 Ineos 6 4656000 4286000

*As of January 1, 2013[15]

1= Tons per annum

43
11.2 Ethylene producing industries in India (17)

Sr. no Ethylene producer Capacity of ethylene No. of

produced (KTPA)** complexes
1 Reliance Industries 3620 5
2 GAIL 1120 3
3 OPAL 1200 1
4 IOCL 800 1
5 HPL 800 1
** As of 2017[17]
11.3 Licensors
Sr. Licensing company Percent share of technology[17]
no.
1 TechnipFMC 40% (Technip and Stone & Webster)
2 Lummus 35%
3 Linde 15%
4 KBR 10%

11.4 Choice of licensor technology

Following factors influence the choice of technology for the design of plant by chemical companies:-
1) Capacity
2) Flexibility in operation
3) Low specific energy
4) Overall energy consumption
5) Capital expenditure (CAPEX)
6) Operating expenditure (OPEX)
7) Net present value (NPV)
8) Payback period
9) Relation with the licensor

44
Following factors influence the choice of technology for a furnace design in an ethylene plant:-
1) Capacity
2) Feed flexibility
3) Conversion and yield
4) Thermal efficiency
5) Run length of the coils
6) Steam to hydrocarbon ratio
7) Fuel gas consumed per feedstock (or ethane) cracked

45
12. Process Flow Diagram

46
 13. Energy balance

13.1 Compressors

Sample Calculation of Compressor 1

μ = 1.518 Molar Flowrate (kmol/s)

ϒ = 1.25 for Polytrophic Expansion
R = 8.314 kJ/kmol K
P1 = 0.34 kg/cm2
P2 = 2 kg/cm2
T1 = 315 K

Outlet Temperature is,

  1 
 
 P   
T2  T1  2   448
448.973
.97 K
 P1 

Work done is,

   1 
  
        
 1  8454.942 kW
P
W   
2
 RT 1  
   1    
P 1 
 

 c = Compressor Efficiency, taken as 0.8

 m = Motor Efficiency, taken as 0.9

Break-horse power is,

47
 W
Wb   11742.98 kW
cm

Compressor P1 (kg/cm2) P2 (kg/cm2) T1 (K) T2 (K) W(kW) Wb.(kW)

1 0.34 2 315 448.9735634 8454.942117 11742.97516

2 1.6 5.1 310 390.887455 5104.729114 7089.901547

3 4.9 12 311 372.0124052 3850.433932 5347.824906

4 11.3 25.9 314 370.6584559 3575.660397 4966.194995

13.2 Heat exchanger

Sample calculation of Transfer line exchanger (TLX) heat exchanger:

The exchanger is used to remove the heat from the cracking effluent. Boiler feed water is used as the
utility. The temperature of the cracked effluent decreases from 366o C to 230oC.

Cracking HEAT Cracking

effluent effluent
EXCHANGER

Boiler feed Boiler feed

water water

48
 Stream Temperature (oC)
INPUT
366
4 Cracking effluent

OUTPUT
230
4 Cracking effluent

STREAM TEMPERATURE(oC)
INPUT
Boiler feed water 116
OUTPUT
Boiler feed water 316

𝑄 = 𝑚×𝑐𝑝×𝜟𝒕
Heat to be removed to stream 4 (kJ/h) 29790794.97
Amount of boiler water required (kJ/h) 591087.2

49
 Other heat exchangers used in the plant
Sr no Equipment name Utility Q (kJ/h) M (kJ/h)
requirement
1 Ultra selective Boiler feed 35230125.52 24113.70672
exchanger (USX) water
2 TLX 1 Boiler feed 25723849.37 17607.01531
water
3 TLX 2 Boiler feed 16192468.61 17306
water
4 CG first stage Boiler feed 29790794.97 591087.2
aftercooler water

5 CG fourth stage Propylene 7740585.77 7740585.77

sub cooler reagent

13.3 Distillation Columns

Utilities used

Cooling
Water VHP steam HP steam LMP steam LP steam
T (inlet) (˚C) 33 500 370 250 210
P (kg/cm^2 g) 4.5 104 42 11.5 3.5
Cp (kJ/kg K) 4.18 - - - -
λ (kJ/kg) - 1289.2 1697.8 1991.3 2147.4

Sample calculation of distillation column

Assumption: The top and bottom output streams from distillation column are saturated vapor and
saturated liquid

50
13.3.1. Ethane/propane fractionator

Condenser

Feed inlet

Molar
ΔHvap (kJ/kmol)
Component Flowrates(kmol/h) Xi ΔHvapXi
Hydrogen 449.36 0.00 0.00 0.00
Methane 8190 23.44 0.02 125.52
Acetylene 16700 0.00 0.00 0.00
Ethylene 14100 0.00 0.00 0.00
Ethane 15300 1496.00 0.98 14967.73
C3 Acetylene 21900 0.00 0.00 0.00
Propylene 18500 0.00 0.00 0.00
Propane 19200 9.77 0.01 122.70
Butadiene 22600 0.00 0.00 0.00
Other C4's(n-
6655
Butane) 0.00 0.00 0.00
C5's(n-Pentane) 26200 0.00 0.00 0.00
Benzene 45158 0.00 0.00 0.00
1529.21 1.00 15215.95

ΔH = ∑HiXi = 15215.95 kJ/kg

Qh = mΔH = 23268389.49 kJ

Utility: Cooling water

Cp of cooling water = 4.18 kJ/kg K
ΔT = 10 K
Qh = Qc= mcCpΔT
mc=556660.04 kg/h

Reboiler

Feed Inlet

Component ΔHvap (kJ/kmol) Molar Flowrates(kmol/h) Xi ΔHvapXi

Hydrogen 449.36 0.00 0.00 0.00
Methane 8190 0.00 0.00 0.00
Acetylene 16700 0.00 0.00 0.00
Ethylene 14100 0.00 0.00 0.00

51
Ethane 15300 8.00 0.01 80.04
C3 Acetylene 21900 0.00 0.00 0.00
Propylene 18500 0.00 0.00 0.00
Propane 19200 610.64 0.40 7666.85
Butadiene 22600 0.00 0.00 0.00
Other C4's(n-
6655
Butane) 38.90 0.03 169.27
C5's(n-Pentane) 26200 2.10 0.00 35.93
Benzene 45158 0.00 0.00 0.00
659.63 0.43 7952.09

ΔH = ∑HiXi = 7952.09 kJ/kg

Qc = mΔH = 5245440.20 kJ

Utility: Low Pressure Steam

ΔHsat= 1289.2 kJ/kg
Qc = Qh= mhΔHsat
mc= 2442.69 kg/h

13.3.2. Demethanizer prestripper

Condenser

Feed Inlet

Component ΔHvap (kJ/kmol) Molar Flowrates(kmol/h) Xi ΔHvapXi

Hydrogen 449.36 11.10 0.02 11.19
Methane 8190 46.96 0.11 862.20
Acetylene 16700 2.23 0.00 83.50
Ethylene 14100 245.89 0.55 7771.84
Ethane 15300 108.50 0.24 3721.11
C3 Acetylene 21900 0.00 0.00 0.00
Propylene 18500 16.86 0.04 699.29
Propane 19200 12.98 0.03 558.81
Butadiene 22600 0.98 0.00 49.77
Other C4's(n-
6655
Butane) 0.39 0.00 5.78
C5's(n-Pentane) 26200 0.17 0.00 10.06
Benzene 45158 0.03 0.00 3.19
446.11 1.00 13776.74

52
ΔH = ∑HiXi = 13776.74 kJ/kg
Qh = mΔH = 6145957.26 kJ

Utility : Cooling Water

Cp of cooling water = 4.18 kJ/kg K
ΔT = 10 K
Qh = Qc= mcCpΔT
mc=147032.47 kg/h

Reboiler

Feed Inlet

Molar
ΔHvap (kJ/kmol)
Component Flowrates(kmol/h) Xi ΔHvapXi
Hydrogen 449.36 0.00 0.00 0.00
Methane 8190 0.00 0.00 0.00
Acetylene 16700 0.00 0.00 0.00
Ethylene 14100 344.36 0.77 10883.91
Ethane 15300 250.80 0.56 8601.50
C3 Acetylene 21900 2.89 0.01 142.00
Propylene 18500 134.76 0.30 5588.36
Propane 19200 122.72 0.28 5281.54
Butadiene 22600 28.33 0.06 1435.24
Other C4's(n-Butane) 6655 10.20 0.02 152.10
C5's(n-Pentane) 26200 13.84 0.03 812.71
Benzene 45158 8.65 0.02 875.92
916.54 2.05 33773.27

ΔH = ∑HiXi = 33773.27 kJ/kg

Qc = mΔH = 30954594.85 kJ

Utility: Low Pressure Steam

ΔHsat= 1289.2 kJ/kg
Qc = Qh= mhΔHsat
mc=14414.92 kg/h

53
13.3.3 Demethanizer

Condenser
Feed Inlet

Molar
ΔHvap (kJ/kmol)
Component Flowrates(kmol/h) Xi ΔHvapXi
Hydrogen 449.36 11.10 0.19 83.96
Methane 8190 46.96 0.79 6471.66
Acetylene 16700 0.00 0.00 0.00
Ethylene 14100 0.92 0.02 217.24
Ethane 15300 0.45 0.01 115.76
C3 Acetylene 21900 0.00 0.00 0.00
Propylene 18500 0.00 0.00 0.00
Propane 19200 0.00 0.00 0.00
Butadiene 22600 0.00 0.00 0.00
Other C4's(n-Butane) 6655 0.00 0.00 0.00
C5's(n-Pentane) 26200 0.00 0.00 0.00
Benzene 45158 0.00 0.00 0.00
59.43 1.00 6888.61

ΔH = ∑HiXi = 6888.61 kJ/kg

Qh = mΔH = 409419.62 kJ

Utility: Cooling Water

Cp of cooling water = 4.18 kJ/kg K
ΔT = 10 K
Qh = Qc= mcCpΔT
mc=9794.73 kg/h

Reboiler

Feed Inlet

Molar
ΔHvap (kJ/kmol)
Component Flowrates(kmol/h) Xi ΔHvapXi
Hydrogen 449.36 0.00 0.00 0.00
Methane 8190 0.00 0.00 0.00
Acetylene 16700 12.60 0.21 3540.17
Ethylene 14100 1597.09 26.87 378888.72

54
Ethane 15300 629.38 10.59 162018.82
C3 Acetylene 21900 0.00 0.00 0.00
Propylene 18500 72.35 1.22 22521.37
Propane 19200 55.60 0.94 17961.43
Butadiene 22600 3.23 0.05 1226.95
Other C4's(n-Butane) 6655 1.20 0.02 134.54
C5's(n-Pentane) 26200 0.48 0.01 213.37
Benzene 45158 0.09 0.00 67.89
2372.02 39.91 586573.26

ΔH = ∑HiXi = 586573.26 kJ/kg

Qc = mΔH = 1391364471.51 kJ

Utility: Low Pressure Steam

ΔHsat= 1289.2 kJ/kg
Qc = Qh= mhΔHsat
mc= 647929.81 kg/h

13.3.4 Deethanizer

Condenser

Feed Inlet

Component ΔHvap (kJ/kmol) Molar Flowrates(kmol/h) Xi ΔHvapXi

Hydrogen 449.36 0.00 0.00 0.00
Methane 8190 0.00 0.00 0.00
Acetylene 16700 17.15 0.01 101.63
Ethylene 14100 1921.29 0.68 9611.13
Ethane 15300 880.18 0.31 4777.78
C3 Acetylene 21900 0.00 0.00 0.00
Propylene 18500 0.00 0.00 0.00
Propane 19200 0.00 0.00 0.00
Butadiene 22600 0.00 0.00 0.00
Other C4's(n-
6655
Butane) 0.00 0.00 0.00
C5's(n-Pentane) 26200 0.00 0.00 0.00
Benzene 45158 0.00 0.00 0.00
2818.62 1.00 14490.55

55
ΔH = ∑HiXi = 14490.55 kJ/kg
Qh = mΔH = 40843346.70 kJ

Utility: Cooling Water

Cp of cooling water = 4.18 kJ/kg K
ΔT = 10 K
Qh = Qc= mcCpΔT
mc=977113.56 kg/h

Reboiler

Feed Inlet

Molar
ΔHvap (kJ/kmol)
Component Flowrates(kmol/h) Xi ΔHvapXi
Hydrogen 449.36 0.00 0.00 0.00
Methane 8190 0.00 0.00 0.00
Acetylene 16700 0.00 0.00 0.00
Ethylene 14100 0.00 0.00 0.00
Ethane 15300 0.00 0.00 0.00
C3 Acetylene 21900 8.69 0.00 67.53
Propylene 18500 207.07 0.07 1359.11
Propane 19200 177.96 0.06 1212.23
Butadiene 22600 35.32 0.01 283.19
Other C4's(n-Butane) 6655 11.66 0.00 27.52
C5's(n-Pentane) 26200 14.45 0.01 134.33
Benzene 45158 8.88 0.00 142.34
464.03 0.16 3226.24

ΔH = ∑HiXi = 3226.24 kJ/kg

Qc = mΔH = 1497076.05 kJ

Utility: Low Pressure Steam

ΔHsat= 1289.2 kJ/kg
Qc = Qh= mhΔHsat
mc= 697.16 kg/h

56
13.3.5 Depropanizer

Condenser
Feed Inlet
Component ΔHvap (kJ/kmol) Molar Flowrates(kmol/h) Xi ΔHvapXi
Hydrogen 449.36 0.00 0.00 0.00
Methane 8190 0.00 0.00 0.00
Acetylene 16700 0.00 0.00 0.00
Ethylene 14100 0.00 0.00 0.00
Ethane 15300 0.00 0.00 0.00
C3 Acetylene 21900 0.00 0.00 0.00
Propylene 18500 199.24 0.52 9661.02
Propane 19200 182.28 0.48 9173.43
Butadiene 22600 0.00 0.00 0.00
Other C4's(n-
6655
Butane) 0.00 0.00 0.00
C5's(n-Pentane) 26200 0.00 0.00 0.00
Benzene 45158 0.00 0.00 0.00
381.52 1.00 18834.45

ΔH = ∑HiXi = 18834.45 kJ/kg

Qh = mΔH = 7185759.18 kJ

Utility: Cooling Water

Cp of cooling water = 4.18 kJ/kg K
ΔT = 10 K
Qh = Qc= mcCpΔT
mc=171908.11 kg/h

Reboiler

Feed Inlet

Molar
ΔHvap (kJ/kmol)
Component Flowrates(kmol/h) Xi ΔHvapXi
Hydrogen 449.36 0.00 0.00 0.00
Methane 8190 0.00 0.00 0.00
Acetylene 16700 0.00 0.00 0.00
Ethylene 14100 0.00 0.00 0.00
Ethane 15300 0.00 0.00 0.00

57
C3 Acetylene 21900 0.00 0.00 0.00
Propylene 18500 0.00 0.00 0.00
Propane 19200 0.00 0.00 0.00
Butadiene 22600 35.33 0.09 2092.75
Other C4's(n-Butane) 6655 11.44 0.03 199.48
C5's(n-Pentane) 26200 15.80 0.04 1085.24
Benzene 45158 9.77 0.03 1155.93
72.33 0.19 4533.40

ΔH = ∑HiXi = 4533.40 kJ/kg

Qc = mΔH = 327918.93 kJ

Utility: Low Pressure Steam

ΔHsat= 1289.2 kJ/kg
Qc = Qh= mhΔHsat
mc=152.71 kg/h

13.3.6 Propylene Stripper

Condenser

Feed Inlet

Component ΔHvap (kJ/kmol) Molar Flowrates(kmol/h) Xi ΔHvapXi

Hydrogen 449.36 0.00 0.00 0.00
Methane 8190 0.00 0.00 0.00
Acetylene 16700 0.00 0.00 0.00
Ethylene 14100 0.00 0.00 0.00
Ethane 15300 0.00 0.00 0.00
C3 Acetylene 21900 0.00 0.00 0.00
Propylene 18500 13.67 0.06 1094.59
Propane 19200 217.32 0.94 18063.99
Butadiene 22600 0.00 0.00 0.00
Other C4's(n-
6655
Butane) 0.00 0.00 0.00
C5's(n-Pentane) 26200 0.00 0.00 0.00
Benzene 45158 0.00 0.00 0.00
230.98 1.00 19158.58

ΔH = ∑HiXi = 19158.58 kJ/kg

58
Qh = mΔH = 4425342.42 kJ

Utility: Cooling Water

Cp of cooling water = 4.18 kJ/kg K
ΔT = 10 K
Qh = Qc= mcCpΔT
mc= 105869.44 kg/h

Reboiler

Feed Inlet

Molar
ΔHvap (kJ/kmol)
Component Flowrates(kmol/h) Xi ΔHvapXi
Hydrogen 449.36 0.00 0.00 0.00
Methane 8190 0.00 0.00 0.00
Acetylene 16700 0.00 0.00 0.00
Ethylene 14100 0.00 0.00 0.00
Ethane 15300 0.00 0.00 0.00
C3 Acetylene 21900 0.00 0.00 0.00
Propylene 18500 157.00 0.68 12574.36
Propane 19200 2.27 0.01 188.91
Butadiene 22600 0.00 0.00 0.00
Other C4's(n-Butane) 6655 0.00 0.00 0.00
C5's(n-Pentane) 26200 0.00 0.00 0.00
Benzene 45158 0.00 0.00 0.00
159.27 0.69 12763.28

ΔH = ∑HiXi = 12763.28 kJ/kg

Qc = mΔH = 2032832.51 kJ

Utility: Low Pressure Steam

ΔHsat= 1289.2 kJ/kg
Qc = Qh= mhΔHsat
mc=946.65 kg/h

59
13.3.7 Ethylene tower

Condenser

Feed Inlet
Component ΔHvap (kJ/kmol) Molar Flowrates(kmol/h) Xi ΔHvapXi
Hydrogen 449.36 0.00 0.00 0.00
Methane 8190 0.00 0.00 0.00
Acetylene 16700 0.00 0.00 0.00
Ethylene 14100 1835.06 0.68 9564.53
Ethane 15300 870.18 0.32 4921.47
C3 Acetylene 21900 0.00 0.00 0.00
Propylene 18500 0.00 0.00 0.00
Propane 19200 0.00 0.00 0.00
Butadiene 22600 0.00 0.00 0.00
Other C4's(n-
6655
Butane) 0.00 0.00 0.00
C5's(n-Pentane) 26200 0.00 0.00 0.00
Benzene 45158 0.00 0.00 0.00
2705.24 1.00 14486.00

ΔH = ∑HiXi = 14486.00 kJ/kg

Qh = mΔH = 39188094.90 kJ

Utility: Cooling Water

Cp of cooling water = 4.18 kJ/kg K
ΔT = 10 K
Qh = Qc= mcCpΔT
mc=937514.23 kg/h

Reboiler

Feed Inlet

Molar
ΔHvap (kJ/kmol)
Component Flowrates(kmol/h) Xi ΔHvapXi
Hydrogen 449.36 0.00 0.00 0.00
Methane 8190 0.00 0.00 0.00

60
Acetylene 16700 17.00 0.01 104.94
Ethylene 14100 76.85 0.03 400.56
Ethane 15300 0.00 0.00 0.00
C3 Acetylene 21900 0.00 0.00 0.00
Propylene 18500 0.00 0.00 0.00
Propane 19200 0.00 0.00 0.00
Butadiene 22600 0.00 0.00 0.00
Other C4's(n-Butane) 6655 0.00 0.00 0.00
C5's(n-Pentane) 26200 0.00 0.00 0.00
Benzene 45158 0.00 0.00 0.00
93.85 0.03 505.50

ΔH = ∑HiXi = 505.50 kJ/kg

Qc = mΔH = 47442.12 kJ

Utility: Low Pressure Steam

ΔHsat= 1289.2 kJ/kg
Qc = Qh= mhΔHsat
mc= 22.09 kg/h

61
 14. Design of Equipments

14.1 Heat Exchanger

14.1.1. Sample calculation of a C.G first stage aftercooler

Kern’s method is used for the design

Tube Shell side

side
(organic Value Unit (chilled value Unit
mixture) water)
In T1 89.8 ˚C t1 33 ˚C
Out T2 38 ˚C t2 45 ˚C

1) q= 29790794.98 kJ/h (from energy balance)

2) Log mean temperature difference, LMTD. For counter-current:
(𝑇1 − 𝑡2) − (𝑇2 − 𝑡1)
∆𝑇𝑙𝑚 = (𝑇1−𝑡2)
ln⁡(𝑇2−𝑡1)

LMTD=18.15°𝐶

3) Temperature correction factor.

(𝑇1 − 𝑇2)
𝑅=
(𝑡1 − 𝑡2)

(𝑡2 − 𝑡1)
𝑆=
(𝑇1 − 𝑡1)
Where R & S are two dimensionless ratios

62
 R= 4.31
S= 0.211
For 1 shell side and 2 or more even no. of passes for tube side the following graph gives the
value of temperature correction factor Ft
Ft= 0.801
The mean temperature difference using D𝑇𝑚
D𝑇𝑚 = Ft* LMTD
D𝑇𝑚 =14.53o C

4) U= 4300 W/𝑚2 °𝐶
The provisional area
𝑞
𝐴=
𝑈. 𝐷𝑇𝑚
𝐴 = 380𝑚2

63
5) Choose the tube diameter, assuming tube length,
Outer diameter do= 1.224 m
Tube thickness t = 0.016 m
Length taken as 5.994 m

6) Number of tubes:

𝐴
𝑁𝑡 =
𝜋 ∗ do ∗ L

𝑁𝑡 = 17⁡𝑡𝑢𝑏𝑒𝑠
7) Tube pitch and the tube bundle diameter

𝑝𝑡 = 1.25 *do
𝑝𝑡 = 1.53𝑚
1⁄
𝑁𝑡 𝑛1
⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡𝐷𝑏 = 𝑑𝑜 ∗ ( )
𝑘𝑙

Where
⁡𝑁𝑡 =number of tubes.
⁡𝐷𝑏 = bundle diameter.
𝑑𝑜 = tube outside diameter.
Square pitch is selected

64
 Table
No. of 1 2 4 6 9
passes
Kl 0.215 0.156 0.158 0.0402 0.0331
Nl 2.207 2.291 2.263 2.617 2.643

Nl= 2.263
Kl= 0.158
Db=9.62 m

8) Providing the split-ring floating head, thus bundle diameter clearance, BDC. Using the chart
below

Graph
Shell inside diameterbundle diameter, mm

Fixed and U-tube

Split-ring floating head

Outside packed head

Fixed and U-tube

65
 9) Calculating the shell diameter.
𝐷𝑠 = 𝐷𝑠 + 𝐵𝐷𝐶
BDC=1.89 m
𝐷𝑠 = 11.567⁡𝑚
Tube side coefficient
10) Number of tubes per pass:
𝑁𝑡
𝑁𝑡𝑝𝑝 = ⁡ = 4.25
𝑛𝑢𝑚𝑏𝑒𝑟⁡𝑜𝑓⁡𝑝𝑎𝑠𝑠𝑒𝑠

11) Tube-side mass velocity

𝑘𝑔
𝑡𝑢𝑏𝑒−𝑠𝑖𝑑𝑒⁡𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒( )
𝐺𝑚 = 𝑠
=34.78 kg/m2s
𝑁𝑡𝑝𝑝 𝑑𝑖2 ∗𝜋 ⁄4

12) Tube-side velocity

𝐺
𝜈= 𝜌𝑚 =0.03495 m/s
𝑖

13) Prandtl and Reynolds number for fluids inside tubes

𝐶𝑝 ∗𝜇
𝑃𝑟 = = 5.7
𝑘
𝜌𝑖 ∗𝑑𝑖 ∗𝜈
𝑅𝑒 = = 68815.12
𝜇𝑖

14) Heat transfer coefficient hi,

𝑘𝑓 𝜇 0.14
ℎ𝑖 = 𝑗ℎ ∗ ∗ 𝑅𝑒 ∗ 𝑃𝑟 0.33 ∗ ( )
𝑑𝑖 𝜇𝑤
The value of 𝑗ℎ i.e. tube side heat transfer factor is obtained from graph below
Graph
2

1
L/D=24
9
48
3
8
120
7
2
240
6
10
2 500
5
9
4
8

7
3
6
66
5
2
4
Hi ==1826 𝑊 ⁄𝑚2 ℃

Shell side coefficient

15) The baffle spacing
𝐵𝑠 = 𝐷𝑠 ∗ 0.4 = 4.6268 m

16) The area for cross-flow,

(𝑃𝑡 −𝑑𝑜 )𝐷𝑠 𝐵𝑠

𝐴𝑠 = =10.70𝑚2
𝑃𝑡

17) The shell side mass velocity

𝑘𝑔
𝑠ℎ𝑒𝑙𝑙−𝑠𝑖𝑑𝑒⁡𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒( )
𝐺𝑠 = 𝑠
= 5.394 kg/𝑚2 s
𝐴𝑠

18) The shell equivalent diameter

a square pitch arrangement

2
𝑃 −𝜋𝑑𝑜 2
4∗( 𝑡 )
4
𝑑𝑒 = =1.208 m
𝑑𝑜 ∗𝜋

19) The shell-side Reynolds number

𝐺𝑠 ∗𝑑𝑒
𝑅𝑒 = = 275094
𝜇

67
 20) Prandtl number

𝜇∗𝐶𝑝
𝑃𝑟 = = 4.17
𝑘

21) Shell-side heat transfer coefficient

ℎ𝑠 ∗ 𝑑𝑒 1/3 𝜇 0.14
𝑁𝑢 = = 𝑗ℎ ∗ 𝑅𝑒 ∗ 𝑃𝑟 ∗ ( )
𝑘𝑓 𝜇𝑤

Hs = 2792 W/𝑚2 ℃

22) The overall heat transfers co-efficient

1
𝑈𝑂 = 1 1 𝑑𝑜 ∗𝑙𝑛(𝑑𝑜 ⁄𝑑𝑖 ) 𝑑 𝑑
+ℎ + + 𝑑 ℎ𝑜 + 𝑑 ℎ𝑜
ℎ𝑜 𝑑𝑜 𝑘𝑤 ∗2 𝑖 𝑜 𝑖 𝑑𝑖

Fouling resistance shell side=0.0004 m2K/W

Fouling resistance tube side=0.0006 m2K/W

⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡𝑈𝑂 = 4380W/m2oC

Pressure drop

23) The tube side pressure drop

8𝑗𝑓 𝐿 𝜇 −𝑚 𝜌𝑖 𝜈 2
Δ𝑃 = (1.5 + 𝑁𝑡 [2.5 + + (𝜇 ) ]) = 0.70 kg/cm2
𝑑𝑖 𝑤 2

24) The pressure drop in the shell

𝐷 𝐿 𝑢𝑠2 𝜌 𝜇 −0.14
Δ𝑃𝑠 = 8𝑗𝑓 ∗ (𝑑 𝑠 ) ∗ (𝑙 ) ∗ ( ) ∗ (𝜇 ) = 0.10 kg/cm2
𝑒 𝐵 2 𝑤

68
 Other heat exchangers

Sr no Heat Area quantity T1 T2 t1 t2

exchangers (m2) (oC) (oC) (oC) (oC)

1 USX 81.1 12 300 300 856 573

2 TLX 1 196 1 300 3000 599 366

3 TLX 2 245 1 116 316 366 230

4 C.G first stage 2280 6 89.8 38 33 45

aftercooler

5 C.G fourth 474 1 8.9 8.9 38 13

stage subcooler

14.2 Distillation Columns

14.2.1. Sample calculation of E/P fractionator using Fenske Underwood method

Sr. No. Component Flowrate(kg/h)

1 Methane 281
2 Ethane 33723
3 Propane 20402
4 Butane 1686
5 C5’s 113
Total 56205

69
Sr. No. Component Flowrate(kg/h)
1 Methane 95
2 Ethane 11398
3 Propane 6896
4 Butane 569
5 C5’s 40
Total 18998

Condenser

Assume Saturated Vapor

Mass flowrate Molar

Component (kg/hr) Molecular weight Flowrates(kmol/hr) Xi
Hydrogen 0 2 0 0
Methane 375 16 23.4375 0.01533
Acetylene 0 26 0 0
Ethylene 0 28 0 0
Ethane 44880 30 1496 0.97828
C3 Acetylene 0 40 0 0
Propylene 0 42 0 0
Propane 430 44 9.7727273 0.00639
Butadiene 0 54 0 0
Other C4's(n-
Butane) 0 58 0 0
C5's(n-Pentane) 0 72 0 0
Benzene 0 78 0 0
45685 1529.2102 1

70
Reboiler
Assume Saturated Liquid

Molar
Component Mass flr (kg/hr) MW Flowrates(kmol/hr) Xi
Hydrogen 0 2 0 0
Methane 16 0 0
Acetylene 0 26 0 0
Ethylene 0 28 0 0
Ethane 240 30 8 0.01213
C3 Acetylene 0 40 0 0
Propylene 0 42 0 0
Propane 26868 44 610.63636 0.92573
Butadiene 0 54 0 0
Other C4's(n-
Butane) 2256 58 38.896552 0.05897
C5's(n-Pentane) 151 72 2.0972222 0.00318
Benzene 0 78 0 0
29515 659.63014 1

1) Light key = ethane

Heavy key = propane

2) ξlk =0.9782
ξhk =0.074
βlk =0.9782
βhk =0.92575
αlk/hk= 1.850

3) number of trays
Ni=12.3/(( αi-1)^2/3*(1-βi)^1/6)
Nlk=0.188
Nhk=0.6330
Ntotal=0.541
Nactual =0.677

71
4) reflux ratio
Ri=1.38/(( αi-1)^0.9 *(1-βi)^0.1)
Rlk=1.088
Rhk=1.230
Rtotal=1.20

5) Number of stages:

By Fenske method, we calculate minimum no. of stages (Nm)

(𝑅_1∗(1−𝑅_2⁡))
𝑙𝑛 ((𝑅_2∗(1−𝑅_1⁡)⁡))
𝑁𝑚 =
𝑙𝑛 𝛼(𝑙𝑘⁄ℎ𝑘)

𝑁𝑚 = 10.28

Graph 1.3.vi

From gillands graph we get,

Number of stages (N) =13

72
6) Height of the column
Tray stack=(N-1)*0.6=7.225
Extra feed space =1.5m
Disengagement height=1.5m
Skirt height=1.5m
Total height =13.225m

7) Diameter of the column

Unf=Csb ((density of liquid -density of gas)/density of gas)^0.5 *(20/liquid surface tension)^0.2

Unf=3970ft/s
A=3.14*D^2/4= V’/0.8*Unf*e*density of gas
D=2.542 m

Other distillation tower equipment’s

Sr.no equipment No of trays Height(mm) Diameter(mm)
1 E/P fractionator 13 13225 2542
2 Demethanizerprestripper 64 27360 1647
3 Demethanizer 29 24135 2200
4 Deethanizer 79 55670 2524
5 Depropanizer 50 27490 1250
6 Propylene stripper 140 58850 3900
7 Ethylene tower 125 81670 4166

73
14.3 Tower

14.3.1 Sample calculation of water quench tower

Mechanical Data Given:

Data Value Unit

Shell ID 5800 mm

Shell Length, T to T 26000 mm

Design Pressure 3.5 kg/cm2(g)

Max. Allowable Stress 1230.372 kg/cm2(g)

Corrosion Allowance 2.5 mm

Density of Shell Material 7850 kg/m3

Joint Efficiency Factor 0.85 -

Tray Stack Height 610 mm

Depth of Liquid 1110 mm

Tray Loading 0.0102 kg/cm2

Wind Flow

k1 0.7 -

k2 1 -

P1 (from Brownell & Young) 0.0001835 kg/cm2

P2(from Brownell & Young) 0.0018660 kg/cm2

Modulus of Elasticity 2.039x106 kg/cm2

74
Stresses

1. Stresses due to Internal Pressure

Thickness of shell due to circumferential stress of shell,

pDi 3.5  5.8

ts  c   0.0025  0.012 m
2 fJ  p 2 1230.372  0.85  3.5

t  ts  c  0.0095

The shell thickness is considerably smaller than the diameter of shell. Therefore we consider

Do  Di  5.8 m

pDo 3.5 104  5.8

Axial Stress, fs    5342105.263 kg/m2
4t 4  0.0095

2. Stresses induced due to Dead Weights

Stress induced due to weight of shell, Fdwt shell  ρshell  x  7850x kg/m 2

Weight of Liquid detained,

 x 1   x 1 
n    1    1  1.639 x  0.639
 Tray Spacing   0.61 

WL  Area of Tray  n  water  Depth

WL  48.067 x  18.739 kg

Stress induced due to weight of liquid detained,

WL
Fdwt liq   277.68 x  108.254 kg/m 2
Dt

Weight of trays,

Wtray  n  Area of Tray  Tray Loading  (4.417 x  1.722) 105 kg

Stress induced due to weight of trays,

75
 Wdwt
Fdwt tray   (2.55 x  9.948) 104 kg/m 2
Dt

Resultant Stress induced due to dead weights,

Fdwt  Fdwt shell  Fdwt liq  Fdwt tray

Fdwt  8127.68 x  108.253 kg/m 2

3. Stresses induced due to Wind Flow

Since height of tall column is greater than 20 m,

Pbw  k1k2P1h1Do  7.45 x kg

Puw  k1k2P2h2Do  1515.192 kg

Stress due to bending moment,

Pbwh1 h2
Mw   Puw(h1  )  3.725 x 2  1515.192 x  4545.576 kgm
2 2

4Mw
Fbm   14.84 x 2  6036.68  18110.041 kg/m2
D t
2

Resultant Tensile Stress and Compressive Stress

f  J  Faxial  Fdwt  Fbm

x  84.63 m

fcomp max  0.125E(t / Do)  4174676.724 kg/cm2

fcomp max  Fdwt  Faxial  Fbm

x  105.085 m

Assumption: For each 5 m of height the shell thickness can be increased by 2 mm.

76
Therefore uniform thickness of 42 mm is sufficient through the given water quench tower height of
26 m

Caustic Tower Thickness

We calculated,

x  134.37 m

Assumption: For each 5 m of height the shell thickness can be increased by 2 mm.

Therefore uniform thickness of 54 mm is sufficient through the given water quench tower height of
34.3 m

77
 15. Cost Estimation

15.1 Sample Calculations:

15.1.1. Cost estimation of C.G. first stage after coolers
Quantity = 6
Area (S) = 380m2 =4090.286 ft2 (1 exchanger)

Shell Tube
Material of construction (MOC) Carbon steel Carbon steel
Design pressure (kg/cm2g) 5 7

We will take design pressure as 7 kg/cm2g for costing as it is greater

Cost Index (2017) =572.8
Cost Index (2012) =584.6
UF= Cost Index (2017)/ Cost Index (2012)=572.8/584.6=0.979815
So= 400ft2, α= 0.65
Base cost (BC) =Co (S/So)α
=5000*(4090.286/400)0.65
=22660.57 USD
MF=MF2=3.29
Fm=1 (Shell/tubeCS/CS)
Fp=0 (P=99.563 psig<=150 psig)
Fd=0.8 (fixed tube sheet exchanger)
MPF= Fm*(Fp + Fd) = 0.8
Base module cost (BMC) = BC*(MPF+MF-1)*UF=22660.57*(0.8 + 3.29 – 1)*0.979815
=68607.81 USD
Total BMC of 6 exchangers= 411616.9 USD= Rs. 26757047 (1 USD= Rs. 65)

78
15.1.2. Cost estimation of ethylene tower
Ethylene Tower (Vertical fabrication)
L=81670mm=267.945ft
D=4166mm=13.668ft
Tray parameters
Tray material of construction Tray spacing(mm) Tray type
(MOC)
Carbon steel 610 Valve
Cost Index (2017) =572.8
Cost Index (2012) =584.6
UF= Cost Index (2017)/ Cost Index (2012)=572.8/584.6=0.979815
Base cost (BC) =Co (L/Lo) α (D/Do) β
=690*(267.945/4)0.78 (4166/3)0.98
= 81008.11USD
MF=MF2=3.18
Fm=0
Ft=0.4
Fs=1
MPF= Fm + Ft + Fs=1.4
Base module cost (BMC) =BC*(MPF+MF-1)*UF=81008.11*(1.4 + 3.18 – 1)* 0.979815
= 284155.3USD
= Rs.18470093 (assuming 1 USD=Rs.65)

79
 15.2 Plant cost estimate and evaluation of payback period
Equipment Cost(approximate Quantity Method
estimate) in INR
(as of 2017)
A Distillation Columns and 44 crores 7 Guthrie’s/Data
towers
B Heat exchangers 26 crores - Guthrie’s/Data
C Pumps 27 crores 130 Data
D Compressors 300 crores 4 Data
E Furnace (54.83*4) crores 4 Data
F Reactor 1.915 crores 1 Data
G Other vessels 30 crores 85 drums Data
H Pipes and fittings 518.588 crores - Calculation[19]
I Instrumentation cost 155.5764 crores - Calculation[19]
J Start up and commissioning 8.038 crores - Calculation[19]
K Contracting and labour 105.792 crores - Calculation[19]

L Miscellaneous 132.24 crores - Calculation[19]

M Contigency 156.043 crores - Calculation[19]

Purchased equipment cost= Cost of all the major plant equipments (A+B+C+D+E+F+G) =Rs.
648.235 crores
Direct plant cost=Purchased equipment cost + Piping and instrumentation costs =1322.3994
CAPEX (Capital expenditure) = Direct plant cost + J + K + L + M=Rs.1724.5124 crores

Plant operating expenditure (OPEX)[17]

1) Feed cost (C2/C3) –Rs.15200/tonnes of ethylene and propylene produced
2) Conversion cost (conversion to ethylene)-Rs.2200/tonnes of ethylene produced
3) Byproduct credit (profit hence removed)- -Rs.3300/tonne produced

80
Variable cost of ethylene=15200+2200-3300=Rs.14100/tonne of ethylene
4) Polyethylene (PE) conversion cost=Rs.15000/tonne of PE produced
5) Selling price of PE=Rs. 55000/tonne of PE produced

Contribution (Profit) =Selling price of PE-(variable cost of ethylene + PE conversion cost) =55000-
14100-15000=Rs. 25900/tonne
Simple payback period=Total investment/contribution = (1724.5124*10^7)/ (326*24*25900*58.549)
=1.45
Therefore, we can conclude that an investment of Rs. 1724.5124 crores is recovered in a period of
1.45 years (~18 months)

81
16. Piping & Instrumentation Diagram (P&ID)

82
 17. Hazard and Operability Studies (HAZOP)

The Hazard and operability study is an activity performed to identify hazards in a chemical process
facility. The mind is set free within certain analyzing limitations to identify the particular event, its
possible causes and provide mitigative measures to prevent such process deviations from being
unchecked. [20]
Engineering companies carry out HAZOP to identify any potential operational and safety issues that
comes into play during the operation of the given equipment. This involves a systematic review of the
Piping & instrumentation diagrams. Using standard guidewords, a discussion is prompted to identify
the possible causes and consequences of deviation from normal operations.
Information required for HAZOP are:-
1. P&ID’s
2. PFD’s
3. Data sheets and drawings of equipments

Team
The full HAZOP study requires a committee composed of:-

1. Experienced plant, laboratory, technical, and safety professionals.

2. A trained HAZOP leader who serves as the committee chair. This person leads the discussion
and must be experienced with the HAZOP procedure and the chemical process under review.
3. One individual must also be assigned the task of recording the results, although a number of
vendors provide software to perform this function on a personal computer.

Procedure
The selected changes/installations in a plant are reviewed in P&IDs. The area that is of concern
around this change/installation is selected and marked as a node. Various guidewords such as
pressure, flow, etc. are observed and their possible scope of deviation from operating condition (for
example more flow) is analyzed and the mitigative action is stated. In absence of mitigation,
recommendations are made by the chairman and the events are noted down to make the necessary
changes in the future. [17]
In our project, we have broken the P&ID into various nodes and analyzed two nodes that are critical
for the feedstock cracking and its separation to obtain ethylene.

83
A list of the guidewords used in the study is given in the table below.

PARAMETER DEVIATION

FLOW More
Less/None
Reverse

PRESSURE More (High or Surging)

less (Vacuum)

TEMPERATURE Low
High

84
 Two nodes are selected from the P&ID
Node no. 1: Ethane feed (stream no. 2) to cracking and quenching (till quench tower T-1)
Duty:-
FLOW: - 75,202 kg/h of feedstock to furnace (From material balance)
PRESSURE: - 10 kg/cm2 dropping to approximately 1.5 kg/cm2 at quench tower by FV-1
TEMPERATURE: - 60˚C
COMPOSITION: -Ethane/Propane to the furnace and cracked gas to the quench tower

Parameter Deviati Cause Consequence Mitigation Proposed Action

on
FLOW More Failure of control a)Stream pressure greater PV-1 provides -
valve FV-3/4 than usual at quench tower pressure relief
b)Reduced conversion of
feedstock
FLOW Less/no Malfunctioning of Overheating of radiant coils Furnace trip & Maintenance of
the FV-3/4 leading to damage closing of fuel alarm systems
gas supply
FLOW Less/no Radiant coil failure High pressure in furnace Same as above Maintenance of
alarm systems
PRESSURE More Failure of FV-3/4 a)Stream pressure greater PV-1 provides -
than usual at quench tower pressure relief
b)Reduced conversion of
feedstock
PRESSURE Less Malfunctioning of Overheating of radiant coils Furnace trip & Maintenance of
the FV-3/4 leading to damage closing of fuel alarm systems
gas supply
PRESSURE Less Radiant coil failure High pressure in furnace Same as above Maintenance of
alarm systems
TEMPERA More More firing of fuel High outlet temperature Furnace trip -
TURE gas in furnace leading to reduction in
quench tower performance
TEMPERA More External fire Immediate plant shutdown - Preventive measures
TURE to be ensured
TEMPERA Less Less firing of fuel Reduced yield of product - Burners to be
TURE gas monitored regularly
for their
performance
COMPOSIT As well High CO2 and H2S a)Possible corrosion Daily analysis of -
ION as from feed b)Product quality affected stream at
laboratory

OTHER Startup Normal startup - - -

85
 Node no. 3: Top product of deethanizer (stream no. 13) to ethylene tower product (stream
no.15)
Duty:-
FLOW: - 80647.39 kg/h (From material balance)
PRESSURE: - 20 kg/cm2g pressure falling to 17.2 kg/cm2g at the ethylene tower top
TEMPERATURE: - (-14˚C - -25˚C)
COMPOSITION: -Ethylene, acetylene and ethane

Parameter Deviati Cause Consequence Mitigation Proposed Action

on
FLOW More Failure of FV-7 a)recovery of a)PV-4 prevents Analysis of acetylene in
acetylene reduces pressure buildup due product to be analyzed in
b)purity of ethylene to acetylene laboratory
affected b)FV-8 controls flow
to ethylene tower
FLOW More Failure of FV-8 a)fluctuations in Analyzer detects
product quality quantity of DMF in
b) DMF carried to stream
ethylene tower

FLOW Less/no Malfunction of Product supply to - Installation of flow indicator

FV-7 downstream plants alarm
affected
FLOW Less/no Malfunction of Same as above - Same as above
FV-8

FLOW Less/no Malfunctioning a)product supply to PV-5 controls pressure Flow indicator alarm to be
of the FV-9 downstream plants buildup at ethylene installed
affected tower
b)buildup of
pressure at ethylene
tower top
COMPOSITI As well Failure of a)ethylene product - Installation of alarm system
ON as absorption of quality affected
acetylene
PRESSURE More Failure of FV-7 Already discussed in Already discussed in Already discussed in more
more flow more flow flow
PRESSURE More Malfunction of Pressure fluctuations PV-5 removes excess -
PV-4 at ethylene tower pressure
PRESSURE More Malfunction of Pressure buildup at - a)Regular maintenance of
PV-5 ethylene tower PV-5
b)installation of alarm to
indicate pressure buildup

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PRESSURE Less Malfunction of Already discussed in - Already discussed in less/no
FV-7 less/no flow flow

PRESSURE Less Malfunction of Already discussed in - Already discussed in less/no

FV-8 less/no flow flow

PRESSURE Less Malfunctioning Already discussed in Already discussed in Already discussed in less/no
of the FV-9 less/no flow less/no flow flow

OTHER Startup Normal startup - - -

87
 18. Conclusion

A pre-preliminary feasibility report on a project involving the design and setting up of a plant to
produce 4,00,000 TPA Ethylene was prepared. The process involves cracking of ethane and propane
feed in a furnace. The cracked effluent is then passed through different heat exchangers where its
cooled and then with the help of different distillation columns 99.999% pure Ethylene is formed.

The estimated cost of the project was found to be Rs. 1724.51 crores. A payback period of 1.45 years
is expected, assuming 100 % capacity utilization. This appears to be attractive.

The present report is based on the following assumptions:

1) Ideal market scenario for product ethylene.

2) All the material produced gets sold.

3) Cost of raw materials and products does not change with time.

4) Very small amount of loss of material across each equipment and almost 100%
separations at each separation step.

A detailed market survey about the demand for ethylene and rigorous calculations need to be carried
out to ascertain the economic feasibility of the project.

88
 19. References

1. Appendix, VIII, pp. 474 ff., Experiments and observations relating to the various branches of
natural philosophy: with a continuation of the observations on air, Joseph Priestley, London:
printed for J. Johnson, 1779, vol. 1.
2. Roscoe &Schorlemmer 1878
3. Gregory, William (1857). Handbook of organic chemistry (4th American ed.). A.S. Barnes & Co.
p. 157.
4. Hofmann, A. W. "Hofmann's Proposal for Systematic Nomenclature of the Hydrocarbons".
5. Luckhardt, Arno; Carter, J. B. (1 Dec 1923). "Ethylene as a gas anesthetic". Current Researches
in Anesthesia & Analgesia. Pg. No. 221–229.

6. Johnstone, George A. Johnstone (1 Aug 1927). "Advantages of Ethylene-Oxygen as an

anesthetic". California and Western

7. "OECD SIDS Initial Assessment Profile — Ethylene"

8. Elschenbroich, C.; Salzer, A. (2006). Organometallics : A Concise Introduction (2nd ed.).
Weinheim: Wiley-VCH.
9. Kniel, Ludwig; Winter, Olaf; Stork, Karl (1980). Ethylene, keystone to the petrochemical
industry. New York: M. Dekker.
10. NaimKosaric, ZdravkoDuvnjak, Adalbert Farkas, Hermann Sahm, Stephanie Bringer-Meyer,
Otto Goebel and Dieter Mayer in "Ethanol" Ullmann's Encyclopedia of Industrial Chemistry,
2011, Wiley-VCH, Weinheim.
11. Trout, Hugh H. (1927). "Blood Changes Under Ethylene Anæsthesia". Annals of Surgery. 86
12. John Roach (2001-08-14). "Delphic Oracle's Lips May Have Been Loosened by Gas Vapors".
National Geographic
13. Roscoe, Henry Enfield; Schorlemmer, Carl (1878). A treatise on chemistry. 1. D. Appleton.
p. 611.

14. Brown, James Campbell (July 2006). A History of Chemistry: From the Earliest Times Till the

Present Day. Kessinger.

15. Data from Oil and Gas Journal Website

16. Data from Platts Website
17. Literature survey done at TechnipFMC during summer internship
18. Loyd E. Bronwnell, Edwin H. Young “Process Equipment Design”
19. Max. S. Peters,Klaus D. Timmerhaus ”Plant Design and Economics for Chemical Engineers”
20. Daniel A. Crowl, Joseph F. Louvar “Chemical Process Safety”

89
21. Petrochemicals Vision – 2025 – Challenges & Opportunities presented at 5th Indian oil
Petrochemical Conclave , Mumbai , 4th February 2016.
22. Marketing Chapter dated June 07, 1996 on India Marketing Analysis published by IPCL
23. Project Report submitted by task force constituted OM No : SC/2/49 dated May 19 , 1987
submitted to GOI

90