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2584 Ind. Eng. C h e m . Res.

1994,33, 2584-2590

Coke Formation in the Thermal Cracking of Hydrocarbons. 4.


Modeling of Coke Formation in Naphtha Cracking
Geert C. Reynierst and Gilbert F. Fromenti
Laboratorium uoor Petrochemische Techniek, Universiteit Gent, Krggslaan 281, S 5, B9000 Gent, Belgium

Frank-Dieter Kopinke and Gerhard Zimmermann


Abteilung Hochtemperaturreaktionen a m Institut fur Technische Chernie der Universitat Leipzig,
0-04303 Leipzig, Permoserstrasse 15, Germany

An extensive experimental program has been carried out in a pilot unit for the thermal cracking
of hydrocarbons. On the basis of the experimental information and the insight in the mechanisms
for coke formation in pyrolysis reactors, a mathematical model describing the coke formation
has been derived. This model has been incorporated in the existing simulation tools at the
Laboratorium voor Petrochemische Techniek, and the run length of a n industrial naphtha
cracking furnace has been accurately simulated. In this way the coking model has been validated.

Introduction 2. Next, the coil was heated, still under a flow of


steam, to the desired temperature profile.
One of the main problems in the thermal cracking of 3. Next the hydrocarbon feed was introduced. This
hydrocarbons for olefin production is the formation of a caused a disturbance of the temperature profile, due to
coke layer on the inner wall of the coils. This leads in the endothermic reactions. This transient period was
the first place to a decrease of the heat flux to the kept as short as possible. Within 15 min the reactor
reacting gas mixture and second also to an increase of was again in steady state.
the pressure drop over the reactor. Periodically the 4. The operating conditions were kept constant for a
furnace operation has to be stopped and the coke has period of 6 h. During this period, several analyses of
to be burnt off by means of a mixture of steam and air. the reactor effluent were carried out. The pressure and
In the previous papers in this series (Kopinke et al., temperature profiles in the reactor were continuously
1988, 1993a,b) relative rates of coke formation from monitored.
various types of carbon atoms (aliphatic, aromatic, ...I 5 . After 6 h the hydrocarbon feed was stopped. This,
were determined. The relative rates were determined again caused an upset in the temperature profile.
by adding a small but precisely defined amount of a I4C- Hence, a stabilization period of 15 min was required.
labeled component to a naphtha feed. 6. Finally, the coke formed during the experiment
The present paper provides a mechanistic interpreta- was burnt off by means of a mixture of steam and air.
tion of the experiments performed by Kopinke et al. and The carbon monoxide and carbon dioxide concentrations
of additional experimental information obtained in the in the reactor effluent were measured continuously by
pilot plant for thermal cracking of the Laboratorium infrared analyzers, together with the total volumetric
voor Petrochemische Techniek. effluent flow. Decoking mainly took place in a reaction
Experimental information and mechanistic interpre- front wandering through the reactor. The temperature
tation were combined to develop a model describing in the reaction front amounted to about 1000 "C.
quantitatively the coking process in thermal cracking Forty-five experiments were carried out, with widely
coils. The coking model was combined with a kinetic different feedstocks and operating conditions. Feed-
model for the pyrolysis of liquid feedstocks, a reactor stocks ranged from CH4 to n- and i-Cs, C2H4, benzene,
model and a furnace model. The combination of these and mixtures thereof, naphtha and kerosene. The coil
models allows the accurate prediction of the run length outlet temperature ranged from 820 to 960 "C, the coil
of a furnace for the thermal cracking of naphtha. outlet pressure ranged from 1.5 t o 3.6 bar absolute and
the diluent was either H2O or N2.
Experimental Procedure and Results From the set of experiments a number of industrially
important conclusions can be drawn:
The pilot plant for thermal cracking at the Labora- 1. Under identical conditions ethane yields more coke
torium voor Petrochemische Techniek has been de- than propane or n-butane. From the discussion of the
scribed elsewhere (Van Damme and Froment, 1982). mechanism of coke formation, it will become clear that
The unit is very flexible as to feedstock and operating this is linked to the type of radicals produced with the
conditions. A rigorous procedure was followed in the different feedstocks. In ethane cracking, hydrogen,
coking experimentation reported in the present paper: methyl, vinyl, and ethyl radicals are important. All
1. An oxidative pretreatment of the reactor walls was these are small and active radicals. In cracking longer
applied prior to each experiment. Twice-distilled water chain paraffins allyl radicals are also formed. Allyl
was fed at a rate of 1k g h to the coil which was kept at radicals are more stable and less reactive.
600 "C. 2. Isoparaffinic feedstocks yield more coke than the
corresponding normal paraffinic feedstocks.
* Author to whom correspondence should be addressed. 3. Steam, used as a diluent, is not inert toward coke.
E-mail: gf@elptes3.rug.ac.be. Experiments were carried out under exactly the same
' Present address: ENSIM N.V., Noorderlaan 127, B2030 conditions except that in one case steam dilution was
Antwerp, Belgium. used and in the other case nitrogen, for the same molar
0888-5885/94/2633-2584$04.50/~ 0 1994 American Chemical Society
CxHy
C

*+ -
- *
Ind. Eng. Chem. Res., Vol. 33,No. 11, 1994 2585
A,
--.-

Figure 1. Mechanism of filament growth.


t
flow rate. In all cases the experiment with nitrogen
dilution yielded more coke than the one with steam
dilution. The difference in coke yield is strongly de-
pendent on the type of feedstock used and on the
operating conditions. It is clear, however that steam is Figure 2. Growth of carbon layer.
able to remove part of the coke formed at temperatures
exceeding 850 “C. ticles on the coke formation decreases steadily as the
4. The rate of coke formation increases with pressure. metal surface becomes covered by a carbon layer. A
This indicates that bimolecular reactions are important. remanent catalytic activity is always present, however.
In free radical reaction schemes, the main bimolecular Heterogeneous Noncatalytic Mechanism. This
reactions are hydrogen abstractions and addition reac- mechanism is the most important one in the coke
tions. formation. The overall structure of the filament coke
is graphitic. This implies the degradation of the hy-
Development of a Coking Model drocarbons to an aromatic structure by condensation
and dehydrogenation.
The experimental observations and a detailed litera- At the gadcoke interface the polyaromatic layer is not
ture survey point to a complex mechanism of coke yet completely dehydrogenated. At this surface hydro-
formation in thermal cracking. Three mechanisms gen abstraction reactions by free radicals from the gas
contribute to the deposition of a coke layer. phase can occur. Hydrogen, methyl, and ethyl radicals
Heterogeneous Catalytic Mechanism. During the are the most active species. As a consequence, the
startup of a furnace, the reacting gas mixture is in concentration of the “active sites” a t the coke surface
contact with the bare reactor walls. Incoloy 800H, becomes a function of the gas phase composition. This
frequently used as the material of construction, contains explains the experimental observation according t o
31 wt % nickel. By chemisorption, species from the gas which feedstocks generating more active radicals also
phase form a metal-hydrocarbon complex on the nickel yield more coke.
crystallites at the inner tube wall. This complex At the free radical positions on the coke surface,
decomposes and yields carbonaceous material on the certain gas phase molecules (coke precursors) react via
metal surface. The carbon migrates through the metal an addition mechanism. All unsaturated molecules
particle by diffusion and precipitates a t the grain from the gas phase are potential precursors. In Figure
boundaries. The driving force for the diffusion is a 2, an example of the reaction sequence is shown with
difference in thermodynamic activity between the car- l-hexene as a precursor.
bon at the metal surface and the carbon at the grain The long aliphatic side chain of these molecules is
boundaries (Bianchini and Lund, 1989). Diffusion is the subject to decomposition. The remaining part of the
rate-determining step of the process. The precipitated molecule reacts in a few steps to a ring structure, in
carbon causes stress in the metal structure. Eventually, which the dehydrogenation reactions proceed very rap-
the stress becomes so large that the nickel crystallite idly. In this way the aromatic structure continues to
is removed from the metal structure. As more carbon grow further and the free radical site at the coke surface
is deposited, a carbon filament, carrying a metal particle is regenerated by further hydrogen abstraction.
on top of it, is formed. This is shown in Figure 1. In This mechanism explains the formation of a deposit
the coke layer from an industrial reactor for the thermal consisting of graphitic layers containing carbon atoms
cracking of naphtha, a dense network of filaments has in sp2 hybridization. The hydrogen content of such a
been observed with filaments having a diameter be- deposit is very low, in agreement with industrial
tween 2 and 5 pm and a length between 20 pm and l observations. Several other reaction sequences, an
mm. example of which is shown in Figure 3, yield cross-
The rate of carbon deposition in this initial phase is linked graphitic structures. The cross-linking of aro-
very high. In an electrobalance type of reactor, also matic layers explains why samples of coke layers from
available at the Laboratorium voor Petrochemische industrial coils are extremely hard and can hardly be
Techniek, initial coking rates of more than 50 g/m2h drilled.
have been observed in the thermal cracking of ethane It is clear that the number of possible reaction paths
at 810 “ C . After 15 min, however, the coking rate is extremely large. Every molecule from the gas phase
decreases, to reach a n asymptotic value of less than 10 is in principle a potential coke precursor. Since the
g/(m2h). number of species in the reaction mixture is very large,
The filament network forms a porous structure. especially when cracking liquid feedstocks, it is impos-
Deficiencies in the graphitic structure act as active sites sible to take into account all those reactions in develop-
on the outer walls of the filaments. On these active sites ing a model for the coke formation.
coke deposition continues via the heterogeneous non- Free radicals contribute to coke formation via termi-
catalytic mechanism. The influence of the metal par- nation reactions with the coke macroradical. This
*
2586 Ind. Eng. Chem. Res., Vol. 33, No. 11, 1994

+ H -
In this section the paraffin content in the reacting
mixture has decreased to a large extent.
For the same reasons, naphthenes can also be ne-
glected as direct precursors t o coke.
Unsaturates are a very important class of coke
precursors. They are reaction products of the pyrolysis
reactions so that their concentration in the high-
temperature zone of the reactor is high. Furthermore,
unsaturates are reactive and are good candidates for
radical addition. C4 components, which are present in
high concentration, are important coke precursors.
Longer chain unsaturated components decompose rap-
idly to smaller components.
Aromatics form a second class of important coke
precursors. The aromatic ring structure is close to the
structure of the coke matrix. Further, (branched)
A aromatics are reactive components, especially at the
high temperatures prevailing in thermal cracking coils.

b&+a-. The basis of the modeling is the presence of “active


sites” at the coke surface. These are in reality radical
positions. The coke is mainly graphitic in structure. The
free radical sites at the surface are all phenylic or
benzylic sites. As an approximation, the activity of
these sites is considered to be equal.
Addition reactions occurring at these sites regenerate
the free radical position, so that the total number of
Figure 3. (a) Cross-linking with sp3 active sites is constant. What follows then is a sequence
linking with sp2 carbon atom. of dehydrogenationand cyclization reactions causing the
incorporation of the carbon atoms of the coke precursor
contribution is relatively unimportant, however, as is into the coke layer.
clear from a comparison of the concentration of the free The essential elements of the reaction of a precursor
radicals in the reaction mixture (typically 10-6-10-3 wt with an active site at the coke surface are (a) the growth
%) with the coke yield, which is of the order of 0.1 wt of the coke layer with a number of carbon atoms equal
%. Free radicals mainly act in hydrogen abstraction t o the carbon number of the precursor and (b) the
reactions. regeneration of the “active site” at the coke surface.
Homogeneous Noncatalytic Mechanism. This An example of such a reaction with ethylene as a
third mechanism implies the formation of polynuclear precursor can be written
aromatics in the gas phase via free radical reactions.
These large molecules grow in the gas phase to tar P’+ C,H4-2C + P’+ 2H,
droplets that can be liquid or even solid at the conditions
prevailing in a thermal cracking reactor. Part of the and the corresponding rate equation for carbon forma-
droplets impinge on the tube wall. Some rebound into tion:
the gas phase, but it is more likely that they adhere to
the surface and are incorporated in the coke layer, since
the outer surface of the droplets is not completely
dehydrogenated. Hence, hydrogen abstraction reactions
by gas phase radicals are possible and the coke layer The concentration of the free radicals at the coke
can grow further. surface is unknown. The coke has a macroradical
This mechanism is considered important only in the character, mainly due to hydrogen abstraction by the
cracking of heavy liquid feedstocks, such as atmospheric radicals from the gas phase. The influence of free
or vacuum gas oil, or else when the temperature exceeds radicals as abstracting species in the coke formation can
900 “C. be accounted for by introducing a multiplication factor
containing the concentration of the main reaction
products of the two most active radicals. The most
Quantitative Formulation of the Rate of Coking abundant and reactive of these are H’ and CH3’. The
In what follows the modeling of the coking in thermal concentration of hydrogen and methane are taken to be
cracking reactors will concentrate on the main mecha- proportional to that of H’and CHf, respectively. The
nism, the heterogeneous noncatalytic mechanism. Tak- following expression can then be written for the rate of
ing into account all the possible reaction pathways coke formation out of an ethylene precursor:
would Iead t o an unrealistically high number of kinetic
parameters, and their estimation would not be possible
or at least inaccurate.
The number of reactions can be decreased by restrict- A similar approach for the other precursors leads to
ing the number of coke precursors. a coke model containing 12 reactions in parallel. The
Paraffins are the main components in a naphtha rate of coke formation may then be expressed as
feedstock. These components do not disappear through
addition reactions, so that their direct contribution to
coke formation is low. Moreover, the coking rate is
highest in the high-temperature section of the reactor.
Ind. Eng. Chem. Res., Vol. 33, No. 11,1994 2687
The precursors are classified into groups depending Table 1. Basic Information for the Run Length
upon their characteristic function (double bond, triple Simulation
bond, aromatic ring, ...). Furnace Data
The reactions of coke radicals with precursors belong- height (mm) 9090
ing to the same group are considered t o have the same length (mm) 14400
activation energy. A reference component is chosen in width (mm) 2500
number of burners 160
each group. The reference factors for the coke formation thickness of refractory (mm) 230
out of the other members of the group are related to thickness of insulation (mm) 50
that of the reference component through the relative
reactivities for coke formation derived by Kopinke et al. Fuel Conditions
fuel composition (~01%)
(1988, 19931, thus reducing the number of independent methane 95
parameters to be estimated from the experimental data. hydrogen 5
initial fuel gas flow rate (kmoyh) 198.4
air excess (%I 10
Simulation of the Run Length of a Furnace for uniform side wall firing
the Thermal Cracking of Naphtha
Reactor Configuration
The coking model is combined with the kinetic model 8 coils, split coil design
for the pyrolysis of liquid feedstocks which generates total length (mm) 53890
the local concentrations of Hz, CHI, and the coke number of passes 6
passes 1-4: split section
precursors along the coil. The structure of this model total length (mm) 35920
has been described by Clymans and Froment (1984)and internal diameter (mm) 80.0
Hillewaert et al. (1988). The rigorous kinetic model external diameter (mm) 95.6
enter in the plug flow continuity and energy equations passes 5,6: single tube section
for the reactor simulation. The heat flux to the reactor total length (mm) 17970
is generated by a detailed furnace model (Plehiers and internal diameter (mm) 114.3
Froment, 1988; Rao et al., 1988). This combination of external diameter (mm) 129.9
models allows an accurate and detailed simulation of a Operating Conditions
thermal cracking unit. hydrocarbon flow rate per coil (kgh) 2785
Table 1 presents the basic information about the steam dilution (kg/kg) 0.7
industrial furnace, the split coil reactors, and the coil inlet temperature ("C) 620
coil outlet pressure (bar abs) 1.45
operating conditions. No further data are required to
set up the simulation model for the radiation section, Material Properties
except the location of the burners in the walls and the emissivity of furnace wall 0.60
location of the reactor coils in the furnace. This emissivity of tubes 0.95
information is provided in Figure 4. thermal conductivity (W/(m K))
refractory 0.0193 + 118.0 x 10-6T (K)
The furnace geometry is complex. Because of sym- insulation 0.0452 + 111.1x 10-6T(K)
metry only half of the furnace and four reactor coils need tubes -1.257 + 0.04327T(K)
to be simulated. The approach followed for run length coke 6.46
simulations has been described in detail elsewhere specific gravity of coke (kg/m3) 1600
(Plehiers et al., 1990). The continuity equation for Feedstock Characterization
carbon is integrated by incrementing the time in specific gravity d(15/15) 0.7057
discrete steps. The coking rate is considered to be PNA analysis (wt %)
constant in each time interval. For this simulation, n-paraffins 33.0
time intervals of 200-300 h were appropriate. In total, isoparafhs 37.0
280 h of CPU time was required on a Data General naphthenes 18.0
Eclipse MV15000/8 computer to carry out the complete aromatics 12.0
boiling range ("C)
run length simulation. IBP 36.0
The operating policy of the furnace consisted of 50% 94.5
keeping the ethylene production constant in time. FBP 161.0
Figure 5 shows the ethylene yield averaged over the four
reactors. It is constant over the whole run length within Figure 7 shows the heat consumption of the furnace.
0.1 wt % absolute or 0.3%relative. The feed rates were To keep the ethylene production constant, in spite of
also kept constant over the run length. the growing coke layer and its increasing heat transfer
Significant differences were found, however, among resistance, requires an increase of the heat input. The
the individual coils. The ethylene yields from the four ethylene production cost, therefore, rises with time.
coils are shown in Figure 6. The initial differences are Figure 8 gives the evolution of the coil inlet pressures
due to a distinct location of each coil with respect to the for the individual reactors. To keep the coil outlet
burners. This results in differences in the radiative heat pressure constant, the inlet pressure has to be raised.
transfer fluxes to each reactor and, hence, in different This leads t o a higher pressure level in the reactor,
naphtha conversions and ethylene yields. The evolution favoring the secondary (ethylene-consuming) reactions
with time of the ethylene yield from each reactor is not over the primary (ethylene-producing) reactions. Sec-
identical. The growth of the coke layer is not the same ondary reactions are mostly bimolecular, while primary
for each coil, and as a consequence the amount of heat reactions proceed via a monomolecular mechanism.
transferred to the reacting process gas and the pressure The most pronounced increase in coil inlet pressure
level in the reactors evolve in a different way. These is found in coil 2, in which it amounts to 0.35 bar, a
are factors which affect the ethylene yield and selectiv- 23%relative increase with respect to the initial pressure
ity. drop of 1.51 bar.
2688 Ind. Eng. Chem. Res., Vol. 33, No. 11,1994

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I I I I I 1 Figure 6. Evolution with time of ethylene yield in the various
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Figure 7. Evolution with time of the total energy input to the
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Figure 8. Evolution with time of inlet pressures.
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Figure 4. (a) Front view of furnace. (b) Top view of furnace


showing burners and coils.
w (n+l

14t Figure 9. Initial heat flux profiles.


to a higher temperature level in these reactors and in
a higher feedstock conversion.
7.
0
1
Ka
I
(.ooo 1- 2,000
Figure 10 shows the evolution of the heat flux profiles
Ik.(hl as a function of time for reactor 4. The heat flux
Figure 5. Evolution with time of average ethylene yield. increases in the split tube section of the reactors,
whereas in the single tube section the heat flux de-
The initial heat flux profiles are shown in Figure 9. creases with time.
The heat input is highest for reactors 2 and 4, leading The rise of the heat fluxes in the first part of the
Ind. Eng. Chem. Res., Vol. 33,No. 11, 1994 2689
F - 0
ST

10

2s

16

10

0
0 10 W W a W
-I*

Figure 10. Evolution with time of heat flux profile for coil 4. Figure 12. Evolution of profiles of thickness of coke layer in coil
4.
wmi.*ohi

I I I
L B T B T
0 10 Io W
rnDn In)
m 50
100 , 1 , I ,
0 10 W W m so
Figure 11. Evolution with time of profiles of coking rate in coil
4. Figure 13. Profiles of external tube skin temperature, coil 4.
T-lV
reactor results from the requirement of achieving a 1.1oo ,
higher conversion, so as to keep the ethylene yield
constant, in spite of the increase in pressure. It
compensates for the decrease of the heat fluxes in the
second part of the reactor caused by the coke formation.
The coke layer reaches its maximum thickness in the
second part of the coil.
It should be stressed that these results can only be
obtained from a detailed furnace and reactor simulation.
Assuming a translation of the heat flux profile with
time, as is normally done when performing only reactor
mo 1
m
simulation, leads to an overestimate of the coking rates 0 1Lo
Iu*in)
2,m

and to predicted run lengths which are too short. Figure 14. Evolution with time of external tube skin tempera-
The evolution of the coking rates with time is shown ture.
in Figure 11 (reactor 4). The coke formation takes place The evolution with time of the coke layer is reflected
at the temperature of the gadcoke interface. The coking in the external wall temperatures. These are shown for
rates are high in the second part of the reactor. As a reactor 4 in Figure 13. The temperature rises with time
consequence, the coke layer grows fast there and creates to meet the heat flux requirements, in spite of the
an additional resistance to heat transfer. Further, the additional resistance to the heat transfer resulting from
coke layer also causes a decrease of the tube cross- the coke deposition. Initially, the temperatures are
sectional area and this leads to higher linear gas highest in the high-temperature section of the reactor,
velocities in this section, causing an improved convective where the coking rates are highest and the coke layer
heat transfer from the interface to the reacting gases. reaches its maximum thickness. The largest increase
These two effects lead to a decrease with time of the in the external wall temperatures is observed in this
interface temperatures in the single tube section of the section. The maximum value is reached at a reactor
reactor. Together with the interface temperatures, the length of 47 m. Initially the maximum value is ap-
coking rate also decreases with time. proximately 1000 "C.
In the split part of the reactor the coke layer is less Figure 14 shows the evolution with time of the
important. Increasing the heat fluxes with time in- maximum external wall temperature for the four simu-
creases the gadcoke interface temperatures and the lated reactors. This value should be watched carefully
coking rates. The coke layer tends to become more during operation, since there is a limitation imposed by
uniform along the tube with time. the metallurgy. In the present case the limiting value
The simulated thickness of the coke layer is given in is 1090 "Cand it is reached on reactor 4 after 1900h or
Figure 12 for reactor 4. The coke reaches its maximum about 80 days of operation, after which decoking is
thickness on the last pass, immediately after the last necessary. The simulated value is in excellent agree-
lower U-bend in the reactor. At the end of the run the ment with the observed plant value, which was 85 days.
coke thickness is 8.7 mm, corresponding to a reduction The temperature limit is reached on one reactor only.
in diameter of more than 15%. For the other reactors there still is a margin of some 10
2590 Ind. Eng. Chem. Res., Vol. 33, No. 11, 1994

"C,meaning that their run length could have been Literature Cited
extended for 5-7 days. In commercial operation, it
might be worthwhile to decrease the cracking severity Bianchini, E. C.; Lund, C. R. F. Kinetic Implications of Mecha-
on reactor 4,so as to prolong the production cycle. nisms Proposed for Catalytic Carbon Filament Growth. J . Catal.
1989,177, 455-466.
Clymans, P. J.; Froment G. F. Computer Generation of Reaction
Conclusions Paths and Rate Equations in the Thermal Cracking of Normal
and Branched Paraffins. Comput. Chem. Eng. 1984,8(2), 137-
Literature data and experimental observations were 142.
combined to obtain mechanistic insight into coke forma- Figueiredo, J. L.; Orfao, J. J. M. Carbon Deposits on Metal
tion in thermal cracking. Three mechanisms contribute. Catalysts-Mechanisms of Formation and Gasification. Catal.
Initially a filament layer is formed by interaction of gas Today 1989,5,385-393
phase species with metal particles from the reactor wall. Hillewaert, L. P.; Dierickx, J. L.; Froment, G. F. Computer
The main mechanism is the interaction between active Generation of Reaction Schemes and Rate Equations for
sites on the coke layer with gas phase species. The Thermal Cracking. AIChE J . 1988,34(11, 17-24.
active sites are free radicals and originate from hydro- Kopinke, F. D.; Zimmermann, G.; Nowak, S. On the Mechanism
gen abstraction by small active gas phase radicals, such of Coke Formation in Steam Cracking-Conclusions from Re-
sults obtained by Tracer Experiments. Carbon 1988,26 (21,
as hydrogen and methyl radicals. At the free radical 117-124.
sites unsaturated precursors from the gas phase react Kopinke, F. D.; Zimmermann, G.; Reyniers, G.; Froment, G. F.
via addition, followed by a set of dehydrogenation and Relative Rates of Coke Formation from Hydrocarbons in Steam
cyclization reactions finally yielding a graphitic coke Cracking of Naphtha. 2. Paraffins, Naphthenes, Mono-, Di-, and
layer. A third mechanism involves the formation of Cycloolefins, and Acetylenes. Ind. Eng. Chem. Res. 1993a,32
droplets in the gas phase which then impinge and (11,56-60.
adhere t o the surface and are incorporated in the coke Kopinke, F.-D.; Zimmermann, G.; Reyniers, G.; Froment, G. F.
layer. This last contribution is thought to be important Relative Rates of Coke Formation from Hydrocarbons in Steam
only in the cracking of very heavy liquid feedstocks. Cracking of Naphtha. 3. Aromatic Hydrocarbons. Ind. Eng.
Chem. Res. 1993b,32(ll), 2620-2625.
The mechanistic considerations and the experimental Plehiers, P. M.; Froment, G. F. Firebox Simulation of Olefin Units.
information were used to develop a kinetic model in Presented at the AIChE Spring National Meeting, March 6-10,
which a set of 12 coke precursors form coke via a set of 1988.
parallel reactions. Plehiers, P. M.; Reyniers, G. C.; Froment, G . F. Simulation of the
This coking model was combined with a kinetic model Run Length of an Ethane Cracking Furnace. Ind. Eng. Chem.
for the cracking, a reactor model and a furnace model Res. 1990,29 (41, 636-641.
to simulate the run length of a furnace for the thermal Rao, M. V.; Plehiers, P. M.; Froment, G. F. The Coupled Simulation
cracking of naphtha. Detailed and accurate information of Heat Transfer and Reaction in a Pyrolysis Furnace. Chem.
can be obtained from this simulation. The growth of a Eng. Sci. 1988,43(6), 1223-1229.
coke layer is accurately simulated, and so is the evolu- Van Damme, P. S.; Froment, G. F. Thermal Cracking Computer
tion of the external tube skin temperatures. The Control in Pilot Plants. Chem. Eng. Prog. 1982,78 (91, 77-82.
simulated and experimental run lengths agree within
5%. Received for review December 9, 1993
Simulations of this kind can be used to optimize Revised manuscript received March 9, 1994
furnace operation for various feedstocks and operating Accepted July 6 , 1994@
conditions. They can be used as a guide for the
adaptation of the operating variables aiming at prolong- @ Abstract published in Advance A C S Abstracts, September
ing the run length of the furnace. 15, 1994.

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