Badger Process Technology

Styrene technology
As a leader in styrene technology for more than 55 years,
energy efficiency, reliability and long on-stream times
have become synonymous with the Badger name. Together
with our operating partner TOTAL, we have developed a
technology that operates at an ultra-low steam-to-oil ratio in
the reactors with the longest operating runs between catalyst
changes in the industry.

Styrene process Reaction

Low steam-to-oil, combined with our patented A two-stage dehydrogenation reaction system
Multi-Effect Distillation and Catalyst Stabilization converts ethylbenzene to styrene.
technologies, results in a low variable operating
cost. Deep vacuum in the reactor section together Purification
with low distillation temperatures result in high raw A distillation train recovers a benzene/toluene
material yields. Licensed units using our styrene byproduct, a styrene product, a recycle
technology represent approximately half of the ethylbenzene stream, and a residue stream.
styrene monomer produced via ethylbenzene
dehydrogenation. TechnipFMC Badger Process
Technology’s continued innovation in styrene
unit design, such as Direct Heating Unit (DHU)
technology, is second to none.

Styrene process scheme

Steam

Fresh First stage Second stage

dehydrogenation dehydrogenation
ethylbenzene
Aromatics

Vent gas
Effluent Aromatics
compression Fuel
cooling recovery
and cooling

Settler
Process condensate
stripper

B/T byproduct Styrene product

Benzene/ Styrene
Ethylbenzene
Toluene recovery
recovery
recovery

Residue
Recycled ethylbenzene

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Styrene Technology Highlights Catalyst Stabilization technology
Low variable operating cost Licensed exclusively by TechnipFMC Badger Process
XX Low steam-to-oil reaction operation Technology, Catalyst Stabilization technology
(CST) significantly extends the useful life of the
XX Low pressure results in high yields
dehydrogenation catalyst by replenishing the
XX Catalyst stabilization extends run life
potassium promoter. Having been licensed to
Commercial experience 27 styrene units, CST has proven to be a cost-effective
XX As of early 2019, TechnipFMC Badger Process solution by reducing the frequency that catalyst is
Technology has licensed plants representing almost replaced. CST is now licensed to 40% of the world’s
half of the world’s styrene manufactured by dehydrogenation capacity.
ethylbenzene dehydrogenation.
Benefits of CST include:
XX Single train operating experience as high
as 770 KTA XX Extended catalyst run times by 30-50%
XX Extensive feedback from operating plants XX Fewer turnarounds, which means less lost
production
Superior technology
XX Demonstrated superior mechanical integrity Our Partner: TOTAL
XX External reactor reheat exchanger for easy access Total’s research facilities and five operating units
and maintenance are invaluable resources to the development
XX Vertical feed/effluent exchanger provides constant and commercialization of styrene process
pressure drop and compact design improvements. Access to the operating
XX Low steam superheater outlet temperatures plants also allows for demonstration of new
or innovative concepts such as DHU.
XX Low polymerization inhibitor consumption
XX Equipment layout facilitates capacity expansion
XX Multi-Effect Distillation (MED) significantly reduces
the energy consumption

Direct Heating Unit technology

Direct Heating Unit (DHU) Technology is a
groundbreaking improvement to the styrene industry.

Benefits of DHU technology:

XX Combines the functions of a steam superheater cell

and a reheat exchanger
XX Fewer high temperature pipes
XX Reduces steam consumption
XX Less plot space
XX Less pressure drop for both steam and the process
XX Replaces a fired heater with a heat exchanger
–– Fewer interlocks
–– Less complex controls
–– Easier to operate
PetroChina Dushanzi Petrochemical Company’s
–– Inherently safer 320 KTA EB/SM Plant

TechnipFMC Badger Process Technology

Dana Johnson Grant Donahoe
Dana.johnson@technipfmc.com grant.donahoe@technipfmc.com
+1 617 748 7220 +1 617 748 7202
Discover more. TechnipFMC.com

© Copyright TechnipFMC plc 2019. All rights reserved.