R T 0024

J.O./W.O. NO.: 140704 DOC. NO.
: 140704-R-T-0024
CLIENT: GAIL (India) Limited
PROCESS DOCUMENT PROJECT: GAIL Petrochemical Complex II Project
LOCATION: Pata, Uttar Pradesh, India
TABLE OF CONTENTS
Section Page
1.0 PROCESS DESCRIPTION ........................................................................................................................... 3
1.1 FEED PREPARATION ................................................................................................................................... 3
1.2 FURNACE SECTION ..................................................................................................................................... 4
1.3 QUENCH WATER TOWER SYSTEM .......................................................................................................... 6
1.4 DISPOSITION OF PYROLYSIS TARS ......................................................................................................... 8
1.5 PROCESS WATER CLEANUP ...................................................................................................................... 8
1.6 WATER STRIPPER / FEED SATURATOR SYSTEMS ................................................................................ 9
1.7 CRACKED GAS COMPRESSION ............................................................................................................... 10
1.8 CAUSTIC WASH SYSTEM ......................................................................................................................... 11
1.9 FINAL COMPRESSION, DEHYDRATION, AND PSA UNIT ................................................................... 12
1.10 HP DEETHANIZER AND LP C2 STRIPPER SYSTEM ............................................................................. 12
1.11 ACETYLENE HYDROGENATION ............................................................................................................. 13
1.12 DEMETHANIZATION SYSTEM ................................................................................................................. 13
1.13 C2 SPLITTER AND HEAT PUMP SYSTEM .............................................................................................. 15
1.14 DEPROPANIZER .......................................................................................................................................... 16
1.15 C3 HYDROGENATION SYSTEM ............................................................................................................... 16
1.16 PROPYLENE FRACTIONATION (INTEGRATED WITH COMPLEX I) ................................................. 17
1.17 DEBUTANIZER ............................................................................................................................................ 18
1.18 ETHYLENE REFRIGERATION .................................................................................................................. 18
1.19 PROPYLENE REFRIGERATION ................................................................................................................ 19
1.20 SPENT CAUSTIC TREATMENT (WET AIR OXIDATION UNIT) .......................................................... 20
1.21 GASOLINE HYDROGENATION UNIT ...................................................................................................... 21
1.22 C4 HYDROGENATION UNIT ..................................................................................................................... 21
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1.0 PROCESS DESCRIPTION
The process description should be read in conjunction with the Process flow diagrams.
GAIL (India) Limited has contracted SHAW to provide a Basic Engineering Design Package (BEDP) for a
Gas Cracking Unit (GCU). This GCU is to be built as part of the new Gail Petrochemical Complex II,
which is near the existing Petrochemical Complex I, in Pata, District of Auraiya in the State of Uttar
Pradesh, India. The GCU nameplate capacity is 450,000 MTA (metric tonnes per annum or 450 KTA) of
polymer grade ethylene and corresponding quantity of polymer grade propylene. The GCU is also designed
to produce by-products, which include hydrogen, fuel gas, partially hydrogenated C5’s, hydrogenated
pyrolysis gasoline, and pyrolysis fuel oil.
The fresh feedstocks to the GCU of the new Gail Petrochemical Complex II are liquid C2+ and liquid
propane. Recycle feeds that are cracked in the furnaces of Complex II GCU include recycle ethane, recycle
propane, and recycle C4’s. Additional recycles that will be sent to the Complex II GCU are recycle gas
from the new Complex II LLDPE/HDPE Swing Units, recycle gas from the existing Complex I
LLDPE/HDPE Swing Units, and the raw pyrolysis gasoline from the existing Complex I GCU. Also, the
propylene fractionation system of the new Complex II GCU will be integrated with the propylene
fractionation system of the existing Complex I.
The following general sections are included in the process description:
1. Feed Preparation
2. Furnace Section
3. Quench Water Tower System
4. Disposition of Pyrolysis Tars
5. Process Water Cleanup
6. Water Stripper / Feed Saturator Systems
7. Cracked Gas Compression
8. Caustic Wash System
9. Final Compression, Dehydration, and PSA Unit
10. HP Deethanizer and LP C2 Stripper
11. Acetylene Hydrogenation
12. Demethanization System
13. C2 Splitter and Heat Pump System
14. Depropanizer
15. C3 Hydrogenation System
16. Propylene Fractionation (Integrated with Complex I)
17. Debutanizer
18. Ethylene Refrigeration
19. Propylene Refrigeration
20. Spent Caustic Treatment (Wet Air Oxidation Unit)
21. Gasoline Hydrogenation Unit (GHU)
22. C4 Hydrogenation Unit (C4HU)
1.1 FEED PREPARATION
(PFD Dwg Nos. 140704-110-0311, and -0312)
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Fresh C2+ liquid feed from storage or C2/C3 Unit is fed to Ethane Feed Flash Drum (110-VV-111) on flow
control, reset by the liquid level in the drum. Liquid from the Ethane Feed Flash Drum is vaporized in
Ethane Feed Vaporizer No. 1 (110-EE-101) and No. 2 (110-EE-103), using C3 Refrigeration (C3R), with
duty credited to the C3 Refrigeration system. The vaporized stream is then mixed with the vapor flashed
from the Ethane Feed Flash Drum and is superheated in the Ethane Feed Heater (110-EE-102) using C3R,
with duty credited to the C3 Refrigeration system. Ethane Feed Auxiliary Vaporizer (110-EE-104) is
located parallel to Ethane Feed Vaporizer No. 1 and No. 2 and is designed for 40% of their total duty. It
uses LP steam to vaporize C2+ feed and is normally no flow but is available for vaporization of C2+ if the
C3R system is not in operation or cannot provide sufficient vaporization.
There are two normally no flow streams that combine with the C2+ feed prior to the Ethane Feed Flash
Drum. One of these is a liquid recycle ethane stream which is used during startup when the C2 Refrigerant
/ Heat Pump Compressor (110-KA-600) is not running or is running at reduced speed. The other normally
no flow line is boil off gas from OSBL ethane storage on back pressure control.
Fresh propane from OSBL storage on flow control and recycle propane from the C3 Splitter (110-CC-540)
are mixed and then vaporized in the Propane Vaporizer (110-EE-107), using quench water (QW). Recycle
hydrogenated C4s from the C4 Hydrogenation Unit are vaporized in Recycle C4 Vaporizer (110-EE-105)
using LP steam. Vaporized propane and C4’s combine with vaporized C2+ feed from 110-EE-102 and
vaporized recycle ethane from the bottoms of the C2 Splitter (110-CC-450). The combined feed is then
superheated using QW in the Feed Superheater (110-EE-106) before feeding the furnaces. The pressure
controller located downstream of the Feed Superheater controls furnace feed header pressure by first
adjusting the control valve on the inlet to Ethane Feed Vaporizer No. 2, then the control valve on the inlet to
Ethane Feed Vaporizer No. 1, and finally the control valve on the inlet to the Ethane Feed Auxiliary
Vaporizer.
Any unvaporized heavy ends from the Propane Vaporizer or the Recycle C4 Vaporizer are sent to the
Cracked Gas 3rd Stage Suction Drum (110-VV-330). A normally no flow line is available to send
propylene liquid from OSBL to use the Propane Vaporizer to provide propylene vapor to the C3 Splitter
and the C3 refrigeration system during startup.
1.2 FURNACE SECTION
(PFD Dwg No. 140704-110-0313)
The USC® Cracking Furnaces (110-FF-110/120/130) consist of three (3) SHAW proprietary Ultra
Selective Conversion (USC)® 48W-T furnaces (6 cells). The normal furnace capacity is based on 2.5
furnaces (5 cells) operating with one cell available for decoking and hot steam standby (HSSB).
The W coil offered in the pyrolysis USC® furnace design provides a medium residence time coil ideally
suited for optimum cracking of the light gas feedstock. The W coil provides increased selectivity and
reduction in fresh feed requirements, in combination with high coil capacities and long run lengths.
The USC®48W-T furnaces are designed for Independent Cell Decoking. Each radiant cell can be decoked
individually if desired. This concept is successfully used on modern designs to increase overall furnace
availability. Decoking cell fired duty is approximately 30-40 percent of the normal duty.
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With the twin cell concept employed in the 48W-T furnace, each furnace has two (2) separate fireboxes,
and each firebox contains one (1) row of twenty-four (24) W-coils each. The convection section is mounted
above and between the two (2) radiant boxes.
The preheated mixture of hydrocarbon feed and dilution steam is fed via external crossover piping to the
radiant section. Each radiant coil is provided with a critical flow venturi at the inlet to ensure uniform flow
to each coil through the run period. When the absolute ratio of the downstream pressure to the upstream
pressure exceeds 0.9 across the venturi, then uniform flow to each coil is not ensured and it then becomes
necessary to decoke the furnace.
The radiant coils are suspended vertically and supported by constant tension spring supports at the inlets.
Roof penetrations are through a shadow box which has removable covers.
Cracking effluent from the radiant coils is rapidly quenched in proprietary Ultra Selective Exchangers
(USX’s). Short transfer lines connect each pair of radiant coil outlets to one USX quench exchanger gas
(process) inlet. The transfer line has a very low adiabatic volume which minimizes yield degradation from
secondary reactions. The USX’s provide effective and rapid cooling of the products from the pyrolysis
reaction while recovering heat in the form of very high pressure (VHP) steam.
The cracking effluent from the USX’s is then further quenched in a pair of Transfer Line Exchangers (TLX-
1’s and TLX-2’s). Each radiant cell has a dedicated pair of TLX-1 and TLX-2 heat exchangers. The TLX-1
exchangers generate additional VHP steam. The TLX-2 exchangers preheat hydrocarbon feed mixed with
dilution steam leaving the saturator.
The heat recovery convection section recovers heat from the flue gases leaving the radiant fireboxes. The
recovered heat is used for various service duties, thereby increasing the overall thermal efficiency of the
furnace.
The convection section preheats hydrocarbon feed and boiler feed water (BFW), and superheats VHP
steam. These convection coils are described, from the top bank of the furnace down, as:
5. (Top of Furnace) Dry Hydrocarbon Feed Preheat
4. VHPBFW Economizer
3. VHP Steam First Superheater (before attemperation)
2. VHP Steam Final Superheater (after attemperation)
1. (Bottom of Furnace) Hydrocarbon Feed and Dilution Steam Heater
Dry hydrocarbon feed flows from the top convection bank to the saturator, where dilution steam is added,
then the saturated gas is routed back to the convection section and heated in bank 1 (bottom of furnace).
VHPBFW is preheated in bank 4 and then flows to the steam drum. VHP steam from the steam drum is
superheated in a series of VHP steam superheat coils. VHP steam from the steam drum enters bank 3 for
initial superheating. The VHP steam superheat coils have an intermediate external attemperator
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(desuperheating station) between banks 2 and 3 which controls the VHP steam superheat outlet
temperature. VHP steam exits bank 2 and is piped to the VHP steam header.
The Decoke Drum (110-VV-100) collects solids from the decoking process and exhausts steam and air to
the atmosphere.
DMDS is injected to passivate the furnace coils, thus reducing coke formation, CO production, and
corrosion in the furnace coils.
1.3 QUENCH WATER TOWER SYSTEM
(PFD Dwg Nos. 140704-110-0321, and -0324)
The Quench Water Tower (110-CC-220) receives the cracking furnace effluent, condenses the dilution
steam from the cracked gas, rejects the heavy components, and recovers the process waste heat against
other suitable process streams.
Gas cracking has traditionally resulted in highly contaminated Quench Water. This contamination by tars,
polymer oils, and coke fines has resulted in costly dilution steam generation feed water clean-up and high
effluent treating costs. Cracking of gas feeds produces heavy hydrocarbons and pyrolysis tar, which have
densities similar to that of water. The continuous injection of sulfur into furnace feeds as coking and
carbon monoxide control methods complicates the control of pH in the bottoms of the Quench Water Tower
and the resulting oil-water separation. Once the water and hydrocarbon has emulsified, separation becomes
difficult. SHAW has addressed this issue by designing the Quench Water Tower System with two discrete
circulation loops: a Presaturation section and a condensation or Quench Water circulation section.
The cracked gas from the furnace TLX exchangers feeds the Quench Water (QW) Tower via a dry transfer
line. In the QW Tower, the upward flowing cracked gas is cooled by direct contact with the two circulation
loops. The temperature is reduced by this quenching and results in condensation of the tar and heavy
hydrocarbons. Gas from the QW Tower overhead goes to the Cracked Gas Compression at 41 °C.
Within the Presaturator section of the QW Tower, angle iron decks are chosen for their high fouling
resistance. The upper section of the QW Tower employs SHAW proprietary Ripple TraysTM.
In the Presaturator section, the furnace effluent is brought to saturation point by circulating water. As well
as saturating the furnace effluent, this water also washes down the coke fines and the majority of the tars.
The saturated furnace effluent passes from the Presaturator section into the upper tower (condensation)
section via chimney trays. In this section the dilution steam is condensed from the cracked gas by the
circulating QW. The hydrocarbon that condenses in this section is pyrolysis gasoline, which has a
significantly lower density than water and is easily separated in Oil/Water Separator No. 2 (110-VV-222).
The saturation water in the cracked gas leaving the QW Tower is recovered in the cracked gas compression
system knock out drums and returned to the QW Tower system. Process water condensed in the cracked
gas compression circuit, along with wash water injected into the compressor stages, is anticipated to return
to the QW system via the Cracked Gas First Stage Suction Drum Condensate Pump (110-PA-310A/B).
Process water condensed from drier regeneration gas is captured in the Regeneration Gas Separator (110-
VV-390) and also flows on level control to the QW Tower chimney tray section.
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Another source of water, condensed within the QW system, is the overhead flow of stripping steam and
stripped hydrocarbon vapors from the Low Pressure Water Stripper (110-CC-260).
The water/hydrocarbon mixture, from the bottom of the QW Tower, flows by gravity to the Oil/Water
Separator No. 1 (110-VV-221). The purpose of this vessel is to effect a three-phase separation of the
process water stream. The vessel separates the heavy phase, which contains tar and coke particles, from the
bulk stream. A water/hydrocarbon interface is established which allows separation of the remaining two
liquid phases.
The Oil/Water Separator No. 1 is a long horizontal vessel, in which the feed from the QW Tower enters at
one end of the vessel. There are two vertical baffles located near the end of the separator. The first baffle,
the tar baffle, rises to a height of about 50% of the vessel diameter. All of the heavy material has settled to
the bottom of this compartment, so there should not be any tar compounds in the next compartment. There
are no pump suction lines on the “tar” side of this baffle. The aim of this system is to produce a lower QW
circulation loop which cools the cracked gas condensing the heavy hydrocarbon compounds and removing
coke fines and tar from the cracked gas. This lower loop is not used to provide QW heat to the plant since it
contains naphthenic, asphaltic, and polymerizable compounds which foul heat exchanger surfaces with tar
and heavy oils.
An automated timed cycle is used to blow down from multiple locations along the Oil/Water Separator No.
1 into the Tar Disposal Separator No. 1 (110-VV-250). The blowdown cycle for the pyrolysis tar products
in the tar hold-up section of the Oil/Water Separator No. 1 can be done using a programmed controls
routine or manually activated. The pyrolysis tars are drawn from the Oil/Water Separator No. 1 through the
tar drain nozzles located on the bottom of the vessel and spaced across the length of the tar hold-up
compartment. The tar and coke fines removal is accomplished by the pressure differential between the
Oil/Water Separator No. 1 and the Tar Disposal Separator No. 1, with flow through a sloping, electrically
heat traced line. Each of the pyrolysis tar blow down valves are identical on/off valves, which are sized to
induce tar flow by generating a large rush of water flow from the separator when the valve is fully opened.
Should one or more of the tar blow down valves have a restricted flow due to pyrolysis tar and solids
deposition within the valve inlet and/or valve body, the Operator is provided a connection (not shown on
PFD; refer to P&ID) from the discharge of the Presaturator Circulation Pump (110-PA-220 A/B) to utilize
the hot Presaturator water and back flow through the restricted valve and line.
Throughout the length of the Oil/Water Separator No. 1, there is a water/hydrocarbon interface. The
hydrocarbon layer overflows the second baffle in the separator. The Pyrolysis Gasoline Pump (110-PA-
221A/B) takes the suction from the last compartment and delivers it to the Oil Slop Drum (OSBL), along
with the tar products from the Tar Disposal Separator No. 2 (110-VV-251).
Suction for the Presaturator Circulation Pump is taken from in between the baffles in the Oil/Water
Separator No. 1 and returned to the QW Tower via a distributor located above the top row of angle iron. To
maintain adequate inventory in the Presaturator section, the total level controller of the water side of the
Oil/Water Separator No. 1 will reset the Presaturator make-up water flow controller set point to reduce, or
increase, the make-up as needed. Thus, any of the water that had originated from the vaporization in the
Presaturator section that is not needed to maintain level in the Oil/Water Separator No. 1 would be
eliminated as part of the net process water flow.
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In the condensation section of the QW Tower, the total water flow is collected at the chimney trays. This
water flow rate is split three ways: net process water draw off, Presaturation water make-up, and the
circulating QW. The Presaturator water make-up is as described above. The net process water make drawn
off consists of the cracking furnace dilution and purge steam and cracked gas compression water injection.
The remaining portion of the total Quench Water Pump (110-PA-222 A/B/C) flow is the circulating Quench
Water. The QW circulation is flow controlled back to the top tray of the QW Tower. The QW heat is first
recovered by the different process users throughout the plant and the balance of the heat is cooled by the
Quench Water Cooler (110-EE-226). The process users are shown on PFD 140704-110-0324.
1.4 DISPOSITION OF PYROLYSIS TARS
(PFD Dwg No. 140704-110-0321)
The pyrolysis tars and water that are periodically blown down to the Tar Disposal Separator No. 1 are
allowed to stand in the vessel for a period of time. After settling, the vessel is pumped by the Oily Water
Return Pump (110-PA-224) to return a portion of the aqueous phase to the bottom of the Presaturator
section of the QW Tower. When a maximum tar level is obtained in the vessel or the level in Tar Disposal
Separator No. 2 is low, liquid pyrolysis tars and water will be transferred to Tar Disposal Separator No. 2.
This transfer of liquids is also accomplished by pressurizing the Tar Disposal Separator No. 1 with nitrogen
until a sufficient pressure differential is established between the two tar separators.
Tar Disposal Separator No. 2 serves as a tar surge volume. It is a continuously stirred drum with the Tar
Drum Mixer (110-RM-251) maintaining a fairly evenly mixed liquid inventory of pyrolysis tars, coke fines,
and process waste waters and oils. The liquid mixture in the Tar Disposal Separator No. 2 is pumped by the
Tar Transfer Pump (110-PA-225A/B) through an electrically heat traced line to the Oil Slop Drum (OSBL).
The bottom section of both Tar Disposal Separator No. 1 and No. 2 are electrically heat traced up to the
possible maximum tar level. The heat tracing is set to maintain a nominal vessel skin temperature of about
87 °C, in order to keep the process material against the inside vessel wall fluid, while preventing thermal
degradation of the pyrolysis tars. Over the course of the operation, a deviation in outside vessel wall
temperature is acceptable, but the wall temperature should always be maintained at greater than 65 °C and
should not exceed 99 °C.
Note that wash oil is also piped to the Tar Disposal Separators and transfer piping to provide the Operator
the capability of tar viscosity control and soak, if necessary, the equipment and piping and dissolve
pyrolysis tar deposits. When using any of the wash oil connections, the flow used is to be limited to prevent
disturbances in the process water wash loop of the Oil/Water Separator No. 2.
1.5 PROCESS WATER CLEANUP
(PFD Dwg Nos. 140704-110-0321, and -0322)
The net process water make draw from the discharge of the Quench Water Pump (110-PA-222A/B/C) is
created by a level controlled pathway. The flow of process water to the Low Pressure Water Stripper is
dictated by level control of the chimney tray at the bottom of the QW Tower condensation section. The
chimney tray level control adjusts the opening of the control valve in the LP Water Stripper feed water line
to balance the required out flow of process water from the QW circuit.
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Prior to LP Water Stripper, the process water flows through the Oil/Water Separator No. 2. This vessel
operates liquid full and allows the gasoline and water sufficient residence time to achieve separation. The
aqueous phase flows from the bottom of the Oil/Water Separator No. 2 and is fed forward, after a Process
Water Filter (110-GN-240A/B) to the Dispersed Oil Extraction (DOX) Unit (110-XX-242) and then to the
LP Water Stripper.
The DOX Unit efficiently removes any solids and coalesces and separates the hydrocarbons. Specifics
regarding equipment and equipment operation shall be provided by the vendor.
1.6 WATER STRIPPER / FEED SATURATOR SYSTEMS
(PFD Dwg No. 140704-110-0323)
Process Water from the DOX unit feeds onto the top tray of the LP Water Stripper. The purpose of the
stripper is to preheat the water and to strip dissolved hydrocarbons and acid gases such as H2S and CO2.
The stripper floats on the pressure of the QW Tower, with the overhead vapor returned to the QW Tower.
The stripping medium is provided by way of the Water Stripper Reboiler (110-EE-260). The overhead flow
rate is based on the total process water feed to the stripper and is maintained by adjusting the LP steam
condensate of the reboiler controlling the reboiling duty. The system is designed to reduce the amount of
styrene, and other polymer precursors, in the feed to the Feed Saturator (110-CC-270), by stripping it and
recycling it to the QW Tower. If the styrene content is not reduced in the feed to the Feed Saturator, the
Saturator system exchangers foul rapidly with a resulting loss in energy efficiency and the creation of large
quantities of blow down water that overwhelms the water treatment system.
The water from the bottom of the LP Water Stripper is pumped then split to the Dilution Steam Generator
exchanger (110-EE-271) and to the Feed Saturator. There is also a normally no flow line that sends excess
process water to Complex I GCU, which is to be used when Complex II GCU is receiving cracked gas from
the Complex I GCU sixth furnace. The Dilution Steam Generator exchanger supplies the dilution steam to
Furnace cells that are on Hot Steam Standby (HSSB), up to a maximum of two cells. The water that feeds
the Feed Saturator is circulated through the tower to saturate the preheated hydrocarbon furnace feed to the
desired steam to hydrocarbon ratio. A Feed Saturator Circulation Heater (110-EE-270) heats the circulating
water to a temperature of 140 °C. A flow controller, cascaded from a temperature controller, controls the
returning circulation flow until an overhead temperature setpoint has been reached; the setpoint corresponds
to a set steam to hydrocarbon ratio. Angle iron decks are utilized in the Feed Saturator tower due to the
high fouling resistance.
A minimum 5-10 wt% of the feed to the Feed Saturator is removed from the system as blow down to
prevent accumulation of non-volatile compounds. The flow, stripped free of Benzene, is discharged from
the Saturator through the Feed Saturator Blowdown Cooler (110-EE-272) and to the waste water treatment
system.
A steam to hydrocarbon balance calculator is provided and reads input from the hydrocarbon feed flow
instruments and from the various water flow instruments in the Feed Saturator system. The circulation flow
rate will be adjusted, based on water balance around the Feed Saturator, the Feed Saturator overhead
temperature, and the total hydrocarbon feed, to reach the desired ratio.
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If the Feed Saturator system is down for any reason, the preheated hydrocarbon feed bypasses the Feed
Saturator and is re-routed to the overhead line. At this time, the steam supplied for the ratio is in the form
of live steam injection, desuperheated High Pressure steam.
1.7 CRACKED GAS COMPRESSION
(PFD Dwg No. 140704-110-0331)
The cracked gas compression system utilizes a five-stage compressor. The overhead from the QW Tower is
mixed with the methane recycle and GHU vent and is fed to the Cracked Gas (CG) 1st Stage Suction Drum
(110-VV-310) to remove liquid droplets that are entrained in the cracked gas. The cracked gas is then fed
to the first stage of the Cracked Gas Compressor (110-KA-300). The first-stage discharge is cooled by
cooling water in CG 1st Stage Aftercooler (110-EE-310), mixed with the Complex II LLDPE/HDPE Unit
ethylene purge and fed to the CG 2nd Stage Suction Drum (110-VV-320). This drum separates the liquid
into a water stream which is returned to the first stage suction drum, where it is then pumped to the QW
Tower, and a hydrocarbon stream that is normally no flow which is pumped to the QW Tower or to the
Debutanizer bottoms, with on/off level control. The vapor proceeds to the second stage of the Cracked Gas
(CG) Compressor.
The second-stage compressor discharge is cooled against cooling water in CG 2nd Stage Aftercooler (110-
EE-320) and fed to the CG 3rd Stage Suction Drum (110-VV-330). The condensed liquid is returned to the
second stage suction drum and the vapor proceeds to the third stage of the Cracked Gas Compressor.
The third-stage compressor discharge is mixed with the LP C2 Stripper overhead vent, cooled against
cooling water in CG 3rd Stage Aftercooler (110-EE-330), mixed with C4HU vent and Complex I LLDPE/
HDPE Unit ethylene purge, and fed to the CG 4th Stage Suction Drum (110-VV-335). The condensed
liquid is returned to the CG 3rd Stage Suction Drum and the vapor proceeds to the fourth stage of the
Cracked Gas Compressor.
The fourth-stage compressor discharge is cooled against cooling water in CG 4th Stage Aftercooler (110-
EE-335) and fed to the CG 4th Stage Discharge Drum (110-VV-340). The liquid is returned to the 4th Stage
Suction Drum and the vapor proceeds to the Caustic Tower Preheater (110-EE-339).
The discharge pressure from each of the compressor stages has been set such that the discharge
temperature, with BFW injection, from each stage is less than 90°C based on compressor efficiency of 77
percent. Cooled HP BFW injection system is provided to reduce the compressor discharge temperature by
injecting cooled HP BFW into the suction line and the casing of each stage of the compressor. If
continuous water injection is practiced, and the system is designed for 90°C operating temperatures, fouling
on the blades of the compressor will be significantly minimized. Additionally, the compressor casings have
been provided with nozzles for wash oil injection. The wash oil injection will be part of a scheduled
program to further reduce fouling and enable longer cycle between turnarounds.
The Cracked Gas Compressor is driven by a VHP steam turbine, operating on speed control, reset by the
first stage suction pressure of the compressor. There are minimum flow circuits in the CGC system to
protect the compressor from going into surge. There are two circuit recycles for the Cracked Gas
Compression system; the first recycles cracked gas from upstream of the CGC fourth stage back to the first
stage suction, while the second recycles cracked gas from the discharge of the CGC fifth stage back to the
fourth stage suction. The minimum flow circuits are flow controlled by an advanced control system.
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1.8 CAUSTIC WASH SYSTEM
(PFD Dwg Nos. 140704-110-0332, and -0336)
The acid gases must be removed from the CG to meet ethylene product specifications, and to protect the
Acetylene Hydrogenation catalyst from H2S poisoning. Compressed vapor from the CG 4th Stage
Discharge Drum (110-VV-340) feeds the caustic wash system. Feed superheat temperature is controlled to
50 °C by varying the QW flow to the Caustic Tower Preheater (110-EE-339). Heating the Caustic Tower
feed minimizes hydrocarbon condensation in the caustic wash system and maximizes caustic utilization as
well as prevents the formation of popcorn polymer fouling in the Caustic Tower.
The Caustic Tower (110-CC-340) consists of four sections. The three lower sections are used for caustic
scrubbing and the top section is used for washing the treated gas with cooled, phosphate-free HP BFW to
avoid caustic carryover into the downstream equipment. The gas enters the Caustic Tower below the
bottom tray. As the gas flows upwards, it comes in contact with circulating weak, medium, and strong
caustic solutions. The treated gas is cooled by wash water from the Caustic Tower Wash Water Cooler
(110-EE-341) and the caustic is washed out from the gases. The wash water leaves the tower to wash spent
wash oil.
A three stage caustic treatment system is normally provided to insure that the low CO2 specification of the
ethylene product is met. The weak caustic is circulated by the Weak Caustic Circulation Pump (110-PA-
341 A/B). The medium strength caustic is circulated by the Middle Caustic Circulation Pump (110-PA-342
A/B). The strong caustic is circulated by the Strong Caustic Circulation Pump (110-PA-343 A/B). The
wash section needs to be operated at 48 °C which is ~ 5 °C above the dew point of the CG.
20 wt% caustic from offsite is stored in the Fresh Caustic Day Tank (110-TT-341). The caustic from the
tank is pumped by the 20% Caustic Makeup Pump (110-PA-340 A/B) and diluted to 10 wt% with cooled
phosphate-free HP BFW from the HP BFW Cooler before being injected into the tower. BFW is also added
to the wash water loop to account for vaporization within the tower and makeup water. Wash oil injection
is provided for in the weak, medium and strong caustic circulation loops to dissolve any polymer formation.
A continuous gasoline injection is not necessary, but with gasoline injection points and the use of SHAW
proprietary Ripple TraysTM, SHAW has been able to meet the acid gas specification in the ethylene product
in all of its plants.
The spent caustic withdrawn from the bottom of the tower is deoiled in the Spent Caustic Deoiling Drum
(110-VV-342) and degassed in the Spent Caustic Degassing Drum (110-VV-343) to flash dissolved light
hydrocarbon as much as possible. The Deoiling Drum consists of four compartments that act as two
separate drums within one shell. The first two compartments act as a spent caustic / oil wash drum, and the
last two compartments act as a spent wash oil / water washing drum. It is required to water wash the spent
wash oil to remove carryover caustic before sending it to Tar Disposal Separator No 2.
Degassed spent caustic is sent to the Spent Caustic Tank (110-TT-344). From the tank, the spent caustic is
pumped by the Spent Caustic Pump (110-PA-349) to the Wet Air Oxidation spent caustic treatment unit.
Caustic and spent caustic drips flow to the Spent Caustic Drain Drum (110-VV-344) by gravity or nitrogen
pressure. Oil is skimmed from the liquid surface of the tank and sent to the Skim Oil Drum (110-VV-348)
to be pumped by the Skim Oil Pump (110-PA-348) to the Tar Disposal Separator No. 2.
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1.9 FINAL COMPRESSION, DEHYDRATION, AND PSA UNIT
(PFD Dwg Nos. 140704-110-0332, and -0333)
The overhead vapor from the Caustic Tower goes to the CG 5th Stage Suction Drum (110-VV-345). The
liquid from the drum is sent to the Spent Caustic Deoiling Drum (110-VV-342) and the vapor proceeds to
the fifth stage of the Cracked Gas Compressor. The fifth-stage compressor discharge is cooled against
cooling water in CG 5th Stage Aftercooler (110-EE-340) and is further cooled against C3R in the Drier Feed
Chiller (110-EE-345). It is then fed to the Drier Feed Knock-Out Drum (110-VV-349). Condensed water
is recycled to the CG 4th Stage Discharge Drum (110-VV-340). The hydrocarbon drips are pumped to the
HC Drips Coalescer (110-XX-360) to remove any entrained water, treated in the Liquid Driers (110-VV-
360A/B), and fed to the LP C2 Stripper (110-CC-370). The vapor from the Drier Feed Knock-Out Drum is
dried in the Cracked Gas Primary Drier (110-VV-350A/B) and fed to the HP Deethanizer (110-CC-360).
The cracked gas and liquid dehydrator systems each have two vessels containing 3A molecular sieves, with
one in operation, one on regeneration / standby. The cracked gas driers operate in a downward flow
direction, while the liquid driers operate in an upward flow direction. Vessels are sized to allow at least a
48 hour on-line cycle at end of desiccant life. Each dehydrator consists of a main bed and guard bed. Cycle
times are based on the main bed only. A moisture analyzer is located between the main and guard beds to
monitor water breakthrough.
The molecular sieves are regenerated by heating the bed with warm tail gas, which is heated against
regeneration effluent in the Regeneration Gas Cross Exchanger (110-EE-392) and against high pressure
steam in the Regeneration Gas Feed Heater (110-EE-390). The warm tail gas flows counter-currently to the
main process stream, desorbing water from the sieves. The temperature for various steps of heating is set
by blending heated gas with unheated. The effluent is cooled against regeneration feed in the Regeneration
Gas Cross Exchanger and against cooling water in the Regeneration Gas Effluent Cooler (110-EE-395) and
then goes to the Regeneration Gas Separator (110-VV-390) to separate the condensed water from the gas.
The condensed water is sent to the QW Tower. The vapor proceeds to the fuel gas system. After heating,
the drier is cooled and kept in a standby mode. The tail gas is used to regenerate the Cracked Gas Primary
Driers, the Liquid Driers, and the Secondary Drier.
Raw hydrogen product is purified in the PSA Unit (110-XX-450) and then used in C3 Hydrogenation, C4
Hydrogenation, the GHU, and in the polyethylene units. A Hydrogen Booster Compressor (110-XX-
415A/B) is provided to compress the hydrogen product to the required battery limit conditions. The PSA
unit purge is sent to fuel gas.
1.10 HP DEETHANIZER AND LP C2 STRIPPER SYSTEM
(PFD Dwg No. 140704-110-0334)
The dried cracked gas vapor is fed to the HP Deethanizer (110-CC-360). The HP Deethanizer is reboiled
against LP Steam in the HP Deethanizer Reboiler (110-EE-360). The tower bottoms are cooled against
cooling water in the LP C2 Stripper Feed Cooler (110-EE-368) and against propylene refrigeration in the
LP C2 Stripper Feed Chiller (110-EE-369) and sent to the LP C2 Stripper (110-CC-370). The overheads
stream is partially condensed against propylene refrigeration in the HP Deethanizer Condenser (110-EE-
365) and then goes to the HP Deethanizer Reflux Drum (110-VV-366). The uncondensed vapor, consisting
of C2s and lighter components passes to the Acetylene Hydrogenation system.
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The HP Deethanizer is operated to minimize C3s in the overhead product from the tower. The bottom of
the tower is operated with enough C2 leakage to maintain the bottoms temperature at a point where fouling
is minimized (65 - 70°C).
The LP C2 Stripper is fed by the HP Deethanizer bottoms and the hydrocarbon drips from the CG
compressor. The C2s in the bottoms of the HP Deethanizer are easily recovered in the LP C2 Stripper. The
LP C2 Stripper is run at a much lower pressure than the HP Deethanizer Tower. This ensures that the C2s
vaporize and can be easily stripped from the feed and that the bottoms temperature is low (below 65°C).
These C2s in the LP C2 Stripper overheads vent are recycled to the cracked gas compressor 3rd stage
discharge. The amount of C2s recycled in this manner is very small and has little impact on the size and the
power of the CG Compressor. The LP C2 Stripper is reboiled against quench water. The LP C2 Stripper
Reboiler (110-EE-370) is a small exchanger since the heat input required to recover the C2s is small. The
bottoms from the LP C2 Stripper are sent to the Depropanizer (110-CC-510).
SHAW's experience indicates that to avoid excessive fouling, and ensure that the desired run lengths can be
achieved, the temperatures at the bottoms of both towers must be limited. The operating pressure of the LP
C2 Stripper is selected to ensure that its bottoms temperature is less than 65°C. The HP Deethanizer
bottoms run at 65-70°C.
1.11 ACETYLENE HYDROGENATION
(PFD Dwg No. 140704-110-0335)
The HP Deethanizer overhead is heated against secondary drier effluent in the Acetylene Reactor
Feed/Effluent Exchanger (110-EE-380) and against LP steam in the Acetylene Reactor Feed Heater (110-
EE-381) before passing to the Acetylene Reactors (110-RB-380A/B). There are two reactors operating in
series. These reactors convert acetylene to ethylene/ethane. The effluent of the first reactor is cooled with
cooling water in the Acetylene Reactor Intercooler (110-EE-384) before entering the second reactor. The
effluent of the second reactor is cooled by cooling water in the Acetylene Reactor Aftercooler (110-EE-
386). The gas is then dried using 3A molecular sieve in the Secondary Drier (110-VV-385) before passing
through the Acetylene Reactor Feed/Effluent Exchanger and going to the Demethanization system. There
is only a small amount of water made in the Acetylene Reactors (mainly the reaction: CO + 3H2 Æ CH4 +
H2O) so the Secondary Drier is on-stream two weeks before being regenerated and is not spared.
The Acetylene Reactor Feed Heater is provided to control the inlet temperature of the feed to the reactors
which varies as the catalyst ages or when there is a variation in the CO content in the feed.
The Acetylene Reactor system is designed with the option to select from Chevron Phillips, Sud-Chemie, or
CRI licensor-approved catalysts. When the catalyst has to be changed in one reactor, the valving / piping
arrangement allows operation with only one reactor while the catalyst is replaced in the other reactor.
Typical operating conditions at start-of-run and end-of-run will vary depending on the catalyst selected.
Refer to the Acetylene Reactor process data sheet for catalyst types and typical operating conditions for
each catalyst.
1.12 DEMETHANIZATION SYSTEM
(PFD Dwg Nos. 140704-110-0341, and -0342)
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In the Demethanization system, condensing and separation of the C2 and heavier components from the
cracked gas is done in the chilling train, by the use of progressively colder levels of ethylene, propylene and
process refrigeration in plate fin exchangers. The liquid condensates thus formed are already partially
fractionated via the chilling train and are fed forward to the Demethanizer (110-CC-420).
The dry cracked gas entering the chilling train passes through the Dry Cracked Gas Filter (110-GN-
401A/B) to remove 3A mol sieve fines, is cooled and partially condensed against a portion of the
Demethanizer bottoms stream in the Demethanizer Feed Chiller (110-EP-401), then goes to the
Demethanizer Feed Separator 1 (110-VV-401).
The vapor from the 1st drum is chilled in the third pass of the Demethanizer Core Exchanger (110-EP-
405C) against the warm level of ethylene refrigerant, the methane recycle stream, off gas, and raw
hydrogen stream and then sent to the Demethanizer Feed Separator 2 (110-VV-402).
The vapor from the 2nd drum is chilled in the fourth and fifth passes of the Demethanizer Core Exchanger
(110-EP-405D, E) by the two coldest levels of ethylene refrigerant, the methane recycle stream, off gas, and
raw hydrogen stream before going to the Demethanizer Feed Separator 3 (110-VV-403).
The vapor from the 3rd drum is chilled in the sixth pass of the Demethanizer Core Exchanger (110-EP-
405F) against the liquid and vapor from the Demethanizer Feed Separator 4 (110-VV-404), methane
recycle, off gas, and raw hydrogen stream before passing to Demethanizer Feed Separator 4.
The vapor from the 4th drum either mixes directly with Demethanizer overheads before being fed to
Expander 1, is partially heated in the cold box and sent to Expander 1, or is sent through the cold box as raw
hydrogen en route to the PSA unit. A flow controller is used on the stream that is partially heated in the
cold box prior to Expander 1 to control the temperature to Expander 1.
The liquid streams from the four Demethanizer feed separators flow into the Demethanizer based on a
pressure difference between the chilling train and the Demethanizer Tower. A tail gas pressure controller
letdown valve, located upstream of the expander provides the differential pressure required for liquid
movement from the feed drums into the Demethanizer. The Demethanizer Condenser (110-EP-425) is a
downflow condenser, using -101°C ethylene refrigerant level, to separate methane and hydrogen from
ethylene and heavier materials. By using a downflow condenser, a cold pump is not needed, which is
desirable because cryogenic pumps are high cost items that are a major operational hazard and one of the
main sources of unreliability in a conventional ethylene plant.
The Demethanizer overheads are mixed with off gas and then pass to the Expander 1 Suction Drum (110-
VV-430), before going to the Residue Gas Expander 1 (110-KA-400A). The effluent from Expander 1 is
fed to the Expander 1 Discharge Drum (110-VV-435). The vapor stream goes to the Residue Gas Expander
2 (110-KA-400B), while the liquid stream flows to Expander 2 Discharge Drum (110-VV-434). The
effluent from Expander 2 is fed to the Expander 2 Discharge Drum. The vapor off gas from the Expander 2
Discharge Drum is heated in the Demethanizer Core Exchanger (110-EP-405A-F). The off gas is then
recompressed in the Residue Gas Compressor 2 (110-KA-400B) and Residue Gas Compressor 1 (110-KA-
400A), to use as regeneration gas or fuel gas.
The methane rich liquid from the Expander 2 Discharge Drum is recycled to the CG 1st Stage Suction Drum
after being vaporized and heated in the Demethanizer core exchanger.
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The feeds to the Demethanizer are essentially ethane and lighter material. Thus, the bottoms from this
column do not need deethanization and can feed the C2 Splitter directly. The Demethanizer is reboiled with
propylene refrigerant vapor in the Demethanizer Reboiler (110-EE-420). Part of the Demethanizer bottoms
product is vaporized in the Demethanizer Feed Chiller before being sent to the C2 Splitter. The remainder
feeds the C2 Splitter directly.
1.13 C2 SPLITTER AND HEAT PUMP SYSTEM
(PFD Dwg No. 140704-110-0343)
The C2 Splitter (110-CC-450) is a low-pressure ethylene-ethane superfractionator and is part of an open-

loop heat pump system that is integrated with the ethylene refrigeration system. The fractionation in the C2
Splitter separates the ethylene/ethane feed into a high purity ethylene overhead vapor and an ethane bottoms
stream for recycle cracking. The heat-pump provides both the reboiling heat input and the refluxing
refrigeration. The system operates at relatively low pressure, thereby increasing the relative volatility,
decreasing the required reflux ratio and the number of trays required. This system reduces energy
consumption significantly compared to a corresponding high pressure, indirectly refrigerated system.
The C2 Splitter receives two feeds: a liquid stream from the Demethanizer bottoms which serves as the top
feed and a vapor stream (via the Demethanizer Feed Chiller) also from the bottoms of the Demethanizer
which serves as the lower feed to the tower. These feeds are introduced at separate trays to match the tower
vapor liquid concentration profile.
The compression stage for the heat pump is stage 3 of the C2 Refrigerant/Heat Pump Compressor (110-KA-
600). The tower overhead is reheated in the C2 Heat Pump Suction Heater (110-EP-453A/B) and fed
together with the vapor from the 2nd stage discharge to the 3rd stage of the C2 Refrigerant/Heat Pump
Compressor. The heat pump discharge is desuperheated against cooling water in the C2 Heat Pump
Desuperheater (110-EE-456) and further desuperheated against ethylene product, ethane recycle and tower
overheads in the C2 Heat Pump Suction Heater, before being condensed against C2 Splitter bottoms in the
C2 Splitter Reboiler (110-EP-450), against recycle ethane in the Ethane Recycle Vaporizer (110-EP-454),
and against propylene refrigeration in the C2 Heat Pump Trim Condenser (110-EP-455). The discharge
pressure of the heat pump (3rd stage of the C2 Refrigerant / Heat Pump Compressor) is set by a temperature
approach to the reboiler temperature. The condensed effluents from the 3 exchangers are then sent to the
C2 Splitter Reflux Drum (110-VV-455).
The liquid from the reflux drum splits four ways. Part of the liquid from the drum (up to a maximum of
100% of design ethylene capacity less the reflux and refrigeration requirements) is pumped by the Ethylene
Product Pump (110-PA-455A/B) through the Ethylene Product Subcooler (110-EP-452), to the C2 Heat
Pump Suction Heater, where it is vaporized against heat pump discharge, and then sent to battery limit as
ethylene product vapor, with split range pressure control adjusting the flow from the Ethylene Product
Subcooler and from storage sphere.
Another portion of liquid from the reflux drum is an optional cryogenic liquid ethylene product rundown
which is subcooled in the Ethylene Product Cooler (110-EP-601A/B/C) and routed to ethylene liquid
product atmospheric storage tanks. The C2 Splitter heat pump and ethylene refrigeration systems have been
designed for two rundown scenarios: a normal rundown mode with the plant operating at design capacity,
with 35% of the ethylene product to rundown, and the balance as vapor product; and a maximum rundown
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mode with the plant operating at 50% capacity and all of the ethylene product to rundown and no ethylene
product vaporized.
The third liquid stream from the reflux drum is the C2 Splitter reflux, which is subcooled against C2
Splitter overhead in the C2 Heat Pump Suction Heater and returned to the top tray of the C2 Splitter as
reflux.
The balance of liquid ethylene from the reflux drum is subcooled in the second pass of the Demethanizer
Core Exchanger (110-EP-405B) and sent to the ethylene refrigeration circuit.
Temperature control of the heat pump discharge line is achieved by adjusting the bypass of C2 Splitter
overhead around the second pass of the C2 Heat Pump Suction Heater (110-EP-453B). In addition, a
normally no flow line from the Ethylene Product Subcooler is available for heat pump discharge
temperature control when the plant is operating at reduced capacity with all ethylene product rundown to
atmospheric storage and no ethylene product being vaporized in the C2 Heat Pump Suction Heater.
The C2 Splitter bottoms recycle ethane is vaporized in the Ethane Recycle Vaporizer and superheated in the
C2 Heat Pump Suction Heater, before being recycled to the furnace feed for cracking.
Note that the C2 Splitter does not contain a pasteurization section since the upstream demethanizer system
is designed to meet the methane specification for the ethylene product and also eliminates hydrogen and
carbon monoxide after hydrogenation. Thus, there is no recycle vent from the C2 Splitter to the cracked gas
system, thereby reducing cracked gas compressor power.
1.14 DEPROPANIZER
(PFD Dwg No. 140704-110-0351)
The LP C2 Stripper Bottoms is sent to the Depropanizer (110-CC-510) to recover a C3 stream which is
pumped to the C3 Hydrogenation system followed by propylene recovery, and a C4+ stream that is sent to
the Debutanizer (110-CC-550).
The Depropanizer reboil heat is supplied by using desuperheated low pressure steam in the Depropanizer
Reboiler (110-EE-510 A/B). The gross overhead is totally condensed using C3 refrigerant in the
Depropanizer Condenser (110-EE-515). Any non-condensables (normally no flow) are separated in the
Depropanizer Reflux Drum (110-VV-515) and are vented to the Cracked Gas Compressor 1st stage
discharge.
Liquid from the Depropanizer Reflux Drum is transferred to the C3 Hydrogenation system by Depropanizer
Reflux/Product Pump (110-PA-515A/B). The net bottoms from the Depropanizer pass to the Debutanizer.
1.15 C3 HYDROGENATION SYSTEM
(PFD Dwg No. 140704-110-0352)
The C3 hydrogenation unit is a liquid-phase single-stage reactor system. The feed to the system is the
Depropanizer overhead liquid. The system is designed to selectively hydrogenate the methyl acetylene
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(MA) and propadiene (PD) in the feed to favor the production of propylene and is then sent to the propylene
recovery section.
The MAPD in the C3 Hydrogenation Reactor (110-RB-520) is converted to propylene, propane, and a small
amount of green oil. The maximum MAPD content in the effluent of the C3 Hydrogenation Reactor is
1000 ppm vol.
The scheme is a once-through system, with no recycle and recycle drum required. Hydrogen from the PSA
Unit feeds the reactor on flow ratio control. A normally no flow stream from the propylene product line is
recycled to the inlet of the reactor and used for reactor loading at turndown.
Complex II will have a single C3 hydrogenation reactor. The C3 hydrogenation system of Complex II will
be integrated with Complex I so that when the Complex II reactor is under regeneration, the spare reactor
from Complex I (10-RB-620 A or B) will serve as spare for Complex II.
1.16 PROPYLENE FRACTIONATION (INTEGRATED WITH COMPLEX I)
(Complex II PFD Dwg No. 140704-110-0352 and Complex I PFD Dwg No. 75D-09)
The propylene fractionation area of new petrochemical Complex II Gas Cracking Unit (GCU-II) is to be
integrated with the propylene fractionation area of existing petrochemical Complex I Gas Cracking Unit
(GCU-I) by combining the GCU-II and GCU-I hydrogenated C3-streams at the inlet to GCU-I Propylene
Stripper (10-CC-602). The side draw propylene rich stream and bottoms propane rich stream from GCU-I
Propylene Stripper will feed the new GCU-II C3 Splitter tower (110-CC-540), which will produce polymer
grade propylene and recycle propane.
Hydrogenated C3’s from GCU-II C3 Hydrogenation Reactor are combined with the existing hydrogenated
C3’s from GCU-I and fed to the existing GCU-I Propylene Stripper. The overhead from the GCU-I
Propylene Stripper will be condensed against cooling water in the existing GCU-I Propylene Rectifier
Condenser (10-EE-605) and then pass to the existing GCU-I Propylene Tower Reflux Drum (10-VV-604).
The vent from the drum is recycled back to the GCU-I CGC area, while liquid reflux from the drum is
pumped to GCU-I Propylene Stripper via existing GCU-I Propylene Tower Reflux Pumps (10-PA-
603A/B). The GCU-I Propylene Stripper will be reboiled using QW in the existing GCU-I Propylene
Stripper Reboiler (10-EE-604). The existing product draw from the GCU-I Propylene Stripper will be used
to drawoff a propylene rich stream that will be pumped to new GCU-II C3 Splitter tower by modified or
new GCU-I Propylene Product Pumps (10-PA-604A/B). The propane rich bottoms from the GCU-I
Propylene Stripper will be pumped by new GCU-I Propylene Stripper Transfer Pump (10-PA-606A/B) to
new GCU-II C3 Splitter tower.
The GCU-II C3 Splitter overhead is condensed against cooling water in C3 Splitter Condenser (110-EE-
535) and then goes to the C3 Splitter Reflux Drum (110-VV-555). Reflux is pumped to the C3 Splitter by
the C3 Splitter Reflux Pump (110-PA-555A/B). The tower has a pasteurizing section to remove a small
vapor stream containing hydrogen. The tower is reboiled using quench water in the C3 Splitter Reboiler
(110-EE-540). The polymer grade product is taken off as a side draw from the C3 Splitter and pumped to
OSBL by Polymer Grade Propylene Product Pump (110-PA-552A/B). The flow rate of polymer grade
propylene product is regulated by flow control that is reset by the level in the C3 Splitter Reflux Drum. The
propylene product is cooled to 40 °C in the Propylene Product Cooler (110-EE-541) by cooling water.
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The propylene and MAPD content of the C3 Splitter bottoms stream is monitored by the on-stream
analyzer. Some of the C3 Splitter bottoms product is recycled back as propane recycle to the GCU-II
furnaces to be cracked to extinction, while the remainder is sent to the GCU-I furnaces. Both destinations
are on flow control, with the GCU-II propane recycle on low level override from the C3 Splitter. The
propane can also be pumped by the C3 Recovery Pump (110-PA-540) to storage.
1.17 DEBUTANIZER
(PFD Dwg No. 140704-110-0353)
The Depropanizer bottoms stream is fed to the Debutanizer (110-CC-550). The Debutanizer separates C4’s
from higher boiling material. The C4 components exit overhead as a mixed C4’s stream which are then
sent to the C4 hydrogenation unit. The bottoms pyrolysis gasoline is cooled against cooling water in the
Raw Pyrolysis Gasoline Cooler (110-EE-551) before being sent to the GHU. The Debutanizer is reboiled
with de-superheated low pressure steam in the Debutanizer Reboiler (110-EE-550) and condensed against
propylene refrigeration in the Debutanizer Condenser (110-EE-555).
SHAW's experience indicates that to avoid excessive fouling, and ensure that the desired run lengths can be
achieved, the temperature at the bottom of the Debutanizer must be limited. The operating pressure of the
Debutanizer is selected to ensure that its bottoms temperature is less than 100°C and the heat flux is limited
in the reboiler.
1.18 ETHYLENE REFRIGERATION
(PFD Dwg Nos. 140704-110-0343, and -0361)
The ethylene refrigeration (C2R) system supplies process chilling at three levels:
x 1st level: -60 °C (6.7 kg/cm2 g)

x 2nd level: -85 °C (1.7 kg/cm2 g)
x 3rd level: -101 °C (0.19 kg/cm2 g)
In addition, the system provides process heating by subcooling liquid C2R in the Demethanizer Core
Exchanger (110-EP-405B), prior to the ethylene refrigeration circuit.
The C2 Refrigerant/Heat Pump Compressor is a three stage centrifugal machine, the third stage providing
the heat pump for the C2 Splitter. Liquid from the C2 Splitter Reflux Drum is subcooled against off gas,
raw hydrogen, and methane recycle in the second pass of the Demethanizer Core Exchanger and feeds the
refrigeration circuit.
The subcooled C2R feeds the C2R 3rd Stage Suction Drum (110-VV-630) under level control of that drum.
When ethylene product is rundown to atmospheric storage, C2R is supplied to the Ethylene Product Cooler
(110-EP-601A). The third pass of the Demethanizer Core Exchanger (110-EP-405C) operates by
thermosyphon off the C2R 3rd Stage Suction Drum. Vapor from the drum feeds the third stage suction of
the C2 Refrigerant/Heat Pump Compressor.
The C2R 3rd Stage Suction Drum supplies liquid to the Ethylene Product Cooler (110-EP-601B) on
condensate pot level control and the C2R 2nd Stage Suction Drum (110-VV-620) to maintain its level. The
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fourth pass of the Demethanizer Core Exchanger (110-EP-405D) operates by thermosyphon off the C2R 2nd
Stage Suction Drum. The C2R vapor from the refrigerant drum flows to the second stage suction of the
compressor.
Liquid C2R from the C2R 2nd Stage Suction Drum flows to the C2R 1st Stage Suction Drum (110-VV-610),
Ethylene Product Cooler (110-EP-601C) and the Demethanizer Condenser (110-EP-425), all under their
level control. The fifth pass of the Demethanizer Core Exchanger (110-EP-405E) operates by
thermosyphon off the C2R 1st Stage Suction Drum. The vapor from the drum flows to the first stage
suction of the compressor.
The C2 Refrigerant/Heat Pump Compressor is driven by a VHP-steam turbine. The turbine operates on
speed control, reset by the third stage suction pressure of the compressor.
There are three minimum flow circuits in the C2 Splitter Heat Pump / C2R systems to protect the
compressor from going into surge. The first circuit detects first stage suction flow and recycles C2R from
downstream of the C2 Heat Pump Desuperheater to the C2R 1st Stage Suction Drum. The gas passes
through a liquid loop seal in the drum inlet line, desuperheating as it vaporizes the liquid C2R. The second
circuit detects the inlet flow to the second stage compressor inlet and recycles desuperheated C2R vapor to
the C2R 2nd Stage Suction Drum via a liquid loop seal. The third circuit detects flow from the third stage
discharge and recycles the desuperheated C2R vapor to the 3rd Stage suction, upstream of the C2 Heat
Pump Suction Heater. The minimum flow circuits are flow controlled by an advanced control system.
1.19 PROPYLENE REFRIGERATION
(PFD Dwg No. 140704-110-0362)
The propylene refrigeration (C3R) system supplies process cooling at two levels:
x 1st level: varies based on user

x 2nd level: -37 °C (0.62 kg/cm2 g)
In addition, the system provides process heating by subcooling liquid C3R or condensing vapor C3R.
The vapor from the single stage centrifugal C3R Compressor (110-KA-650) discharge is condensed against
cooling water in the C3R Condenser (110-EE-695) and goes to the C3R Receiver (110-VV-665). The
Compressor discharge pressure is controlled by a vapor vent from the C3R Receiver to the fourth stage
cracked gas compressor suction and a hot vapor bypass around the condenser. The liquid refrigerant from
the C3R Receiver flows in parallel to the first stage of the Demethanizer Core Exchanger (110-EP-4005A),
the Ethane Feed Vaporizer No. 1 (110-EE-101), and the Ethane Feed Heater (110-EE-102), where the
refrigerant is sub-cooled.
The first level of refrigeration supplies the LP C2 Stripper Feed Chiller (110-EE-369), the Depropanizer
Condenser (110-EE-515), the Drier Feed Chiller (110-EE-345), and the Debutanizer Condenser (110-EE-
555). The flow of C3R to the LP C2 Stripper Feed Chiller and the Depropanizer Condenser is on level
control. The flow of C3R to the Drier Feed Chiller is back pressure controlled by the cracked gas outlet
temperature to maintain the outlet temperature above the hydrate formation temperature. Flow of C3R to
the Debutanizer Condenser is level controlled to achieve the required tower operating pressure.
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J.O./W.O. NO.: 140704 DOC. NO.: 140704-R-T-0024
The vapor C3R streams from the LP C2 Stripper Feed Chiller and the Depropanizer Condenser are mixed
and fed to the C3R 2nd Stage Drum (110-VV-670). The vapor streams from the Drier Feed Chiller and the
Debutanizer Condenser are mixed with a vapor stream from the compressor discharge and fed to the
Demethanizer Reboiler (110-EE-420), where the vapor is condensed, and then sent to the C3R 2nd Stage
Drum.
The vapor from the C3R 2nd Stage Drum is mixed with a vapor stream from the compressor discharge and
fed to the Ethane Feed Vaporizer No. 2 (110-EE-103), where the vapor is condensed, and then sent to the
C3R 1st Stage Suction Drum (110-VV-660).
The second level C3R liquid from the C3R 2nd Stage Drum flows to the HP Deethanizer Condenser (110-
EE-365) and the Ethylene Product Subcooler (110-EP-452) on level control. The vapor from these users is
combined and fed to the C3R 1st Stage Suction Drum. The liquid in the C3R 1st Stage Suction Drum
circulates by thermosyphon through the C2 Heat Pump Trim Condenser (110-EP-455), where it is partially
vaporized.
The C3R Compressor is driven by an HP-steam turbine which operates on speed control, reset by the
suction pressure of the compressor. There is one minimum flow circuit in the C3R system to protect the
compressor from going into surge. The circuit detects suction flow and recycles C3R effluent from the
compressor discharge
1.20 SPENT CAUSTIC TREATMENT (WET AIR OXIDATION UNIT)
(PFD Dwg No. 140704-110-0371, -0372, and -0373)
Pumped spent caustic from the Spent Caustic Tank (110-TT-344) is filtered and heated against de-
superheated low pressure steam (LPS) before flowing into the top tray of the Hydrocarbon Stripper (110-
CC-701), where it is stripped of the light hydrocarbon components with de-superheated LPS. The stripper
is operated at a bottom temperature of 130-140°C to allow polymerization to occur in the stripper and
maximize the volatile organic compounds (VOCs) removal, thus allowing the WAO Reactors to run with
minimum polymer formation and maximum oxidation conversion efficiency.
The pressure of the stripper is sufficient for recycling the overhead vapor (steam and hydrocarbons) back to
the Quench Water Tower (110-CC-220) after separating any condensate from these vapors in the Overhead
Separator (110-VV-701). The separated condensate is sent back to the stripper by gravity flow. The stripped
spent caustic from the bottom of the Hydrocarbon Stripper is pumped by the WAO Feed Pump (110-PA-
701 A/B) through a filter to the WAO system. The filter removes polymers that are formed during the
stripping process.
The Wet Air Oxidation Area consists of a single Wet Air Oxidation (WAO) Reactor (110-RB-701), WAO
Spent Caustic Flash Drum (110-VV-702), and Oxidate Cooler (110-EE-703). Compressed air is injected
into each reaction zone of the WAO reactor and is bubbled into the spent caustic solution, where it reacts
with the oxidizable contaminants in the spent caustic. The WAO reactor contains three (3) bubble zones
where air and spent caustic are co-currently contacted.
The plant air is compressed using the Air Compressor (110-XX-701) and passed on flow control through
sparger elements into each reaction zone. The required reactor temperatures are reached through the
addition of filtered high pressure steam (HS) to the air entering the bottom of each of the two reactor
Page 20 of 22
J.O./W.O. NO.: 140704 DOC. NO.: 140704-R-T-0024
vessels. HS from the steam header is desuperheated with boiler feed water from the header and then
filtered before being added to the air in order to maintain the reactor operating temperature. The oxidation
reaction releases more heat in the first reaction zone than in the second, and so on, through the reactor
system due to a higher concentration of the sulfur compounds in the first zone than in the second.
Therefore, steam is not normally required in the first (bottom) reaction zone of the WAO Reactor.
The spent caustic flows to the bottom of the WAO Reactor, where it is contacted co-currently with air and
steam. The spent caustic stream (liquid) flows slowly upward and is oxidized by the stream of fine air
bubbles passing through the liquid. The rising air causes a high degree of mixing within each zone. Each
reactor is provided with horizontal baffles that enhance liquid/gas mixing and create turbulence, which
enhances mass transfer. The liquid and the gas both flow upward together to the top of the first reaction
zone, where they encounter additional air from the distributor of the second reaction zone. They continue to
flow upwards into the third (top) reaction zone. The oxidized spent caustic from the top draw of the WAO
reactor is flashed in WAO Spent Caustic Flash Drum (110-VV-702) and cooled against cooling water in the
Oxidate Cooler (110-EE-703) before being introduced to the Neutralization system.
The vent gas from the top of the reactor is mixed with circulating water from WAO Wash Circulating
Cooler (110-EE-702) in the Depleted Air-Water Contactor (110-RM-701) then mixes with vapor from the
B flash drum (110-VV-702) and flows to WAO Water Wash Contactor (110-VV-703) to knock out water
droplets entrained in the vent gases. The wash water is re-circulated and cooled against cooling water.
Lower concentrations of dissolved sodium salts are maintained in the wash water re-circulation loop by
purging water from the loop. The purge water is sent to the WAO Spent Caustic Flash Drum (110-VV-
702).
The spent caustic from the WAO Spent Caustic Flash Drum is cooled in the Oxidate Cooler (110-EE-703)
and is fed to the Neutralization Package Unit, where it is mixed and reacted with sulfuric acid. The unit
contains several tanks, pumps, and mixers for diluting acid and reacting the acid with spent caustic. The
polished oxidate, after being neutralized, is sent to waste water treatment.
1.21 GASOLINE HYDROGENATION UNIT
The purpose of this first stage hydrogenation unit is to deeply hydrogenate the diolefins and alkenyl
aromatic compounds, in order to meet product specifications. One reaction section is required in which
mainly diolefins and styrenics are hydrogenated, and where the reaction takes place mostly in liquid phase.
Downstream of the reaction section, light components are removed, and the hydrogenated gasoline is
separated into the required product cuts.
Raw pyrolysis gasoline from the Debutanizer bottoms is mixed with raw pyrolysis gasoline from Complex
I, and fed to the GHU. When the GHU is down or during reactor regeneration, the raw pyrolysis gasoline
can bypass the GHU, and go to OSBL storage.
For detailed description, refer to the GHU Sub-Licensor package.
1.22 C4 HYDROGENATION UNIT
The purpose of the C4 Hydrogenation Unit (C4HU) is to greatly reduce the amount of diolefins and olefins
present in the C4 feed, before returning the hydrogenated C4 product to the steam cracker furnaces. The
required specification is reached in a single stage reaction section, using a high liquid recycle rate that
Page 21 of 22
J.O./W.O. NO.: 140704 DOC. NO.: 140704-R-T-0024
allows to smoothly control the reaction exotherm, and to ensure long cycles by limiting green oils
formation.
Mixed C4’s are pumped by the Debutanizer Reflux Pump (110-PA-556) to the C4HU. When the C4HU is
down or during reactor regeneration, the mixed C4’s can bypass the C4HU, and go to OSBL storage. When
hydrogenated C4 product is off-spec it can be routed to OSBL storage.
For detailed description, refer to the C4HU Sub-Licensor package.
Page 22 of 22

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J.O./W.O. NO.: 140704 DOC. NO.

1.0 PROCESS DESCRIPTION

The following general sections are included in the process description:

1.1 FEED PREPARATION

(PFD Dwg Nos. 140704-110-0311, and -0312)

1.2 FURNACE SECTION

(PFD Dwg No. 140704-110-0313)

5. (Top of Furnace) Dry Hydrocarbon Feed Preheat

3. VHP Steam First Superheater (before attemperation)

2. VHP Steam Final Superheater (after attemperation)

1. (Bottom of Furnace) Hydrocarbon Feed and Dilution Steam Heater

1.3 QUENCH WATER TOWER SYSTEM

(PFD Dwg Nos. 140704-110-0321, and -0324)

1.4 DISPOSITION OF PYROLYSIS TARS

(PFD Dwg No. 140704-110-0321)

1.5 PROCESS WATER CLEANUP

(PFD Dwg Nos. 140704-110-0321, and -0322)

1.6 WATER STRIPPER / FEED SATURATOR SYSTEMS

(PFD Dwg No. 140704-110-0323)

1.7 CRACKED GAS COMPRESSION

(PFD Dwg No. 140704-110-0331)

1.8 CAUSTIC WASH SYSTEM

(PFD Dwg Nos. 140704-110-0332, and -0336)

1.9 FINAL COMPRESSION, DEHYDRATION, AND PSA UNIT

(PFD Dwg Nos. 140704-110-0332, and -0333)

1.10 HP DEETHANIZER AND LP C2 STRIPPER SYSTEM

(PFD Dwg No. 140704-110-0334)

1.11 ACETYLENE HYDROGENATION

(PFD Dwg No. 140704-110-0335)

1.12 DEMETHANIZATION SYSTEM

(PFD Dwg Nos. 140704-110-0341, and -0342)

1.13 C2 SPLITTER AND HEAT PUMP SYSTEM

(PFD Dwg No. 140704-110-0343)

The C2 Splitter (110-CC-450) is a low-pressure ethylene-ethane superfractionator and is part of an open-

(PFD Dwg No. 140704-110-0351)

1.15 C3 HYDROGENATION SYSTEM

(PFD Dwg No. 140704-110-0352)

1.16 PROPYLENE FRACTIONATION (INTEGRATED WITH COMPLEX I)

(PFD Dwg No. 140704-110-0353)

1.18 ETHYLENE REFRIGERATION

(PFD Dwg Nos. 140704-110-0343, and -0361)

x 1st level: -60 °C (6.7 kg/cm2 g)

1.19 PROPYLENE REFRIGERATION

(PFD Dwg No. 140704-110-0362)

x 1st level: varies based on user

1.20 SPENT CAUSTIC TREATMENT (WET AIR OXIDATION UNIT)

(PFD Dwg No. 140704-110-0371, -0372, and -0373)

1.21 GASOLINE HYDROGENATION UNIT

For detailed description, refer to the GHU Sub-Licensor package.

1.22 C4 HYDROGENATION UNIT

For detailed description, refer to the C4HU Sub-Licensor package.

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