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J. Anal. Appl. Pyrolysis 81 (2008) 106–112


www.elsevier.com/locate/jaap

Study on the technology of thermal cracking of paraffin


to alpha olefins
a,b, a
XinDe Chen *, YongJie Yan
b
a College of Resource and Environmental Engineering, East China University of Science and Technology, Shanghai 200237, China Guangzhou
Institute of Energy Conversion, Chinese Academy of Science, Guangzhou 510640, China
Received 8 March 2007; accepted 14 September 2007
Available online 29 September 2007

Abstract

Alpha olefins are mainly produced from paraffin cracking in China, but their quality is not good because of bad quality of cracking feed and
outdated technology. The technology of paraffin once-through cracking, paraffin recycle cracking of removing the heavy fraction after wax
vaporizing and that of removing the heavy fraction before wax vaporizing were investigated in this paper. It was found that the technology of
paraffin recycle cracking of removing the heavy fraction before wax vaporizing is new and better under the same operating conditions. Using
hard paraffin (mp 54–56 8C) as feed, the high-quality alpha olefins products (C 5–C21) containing more than 97 wt% of olefins and more than 88
wt% of alpha olefins are produced under optimum process conditions, which are a steam to paraffin ratio of 15 wt%, process temperature of
600 8C, low hydrocarbon partial pressure and residence time of 2 s. In addition, with the technology of the second injecting steam in ethylene
cracking used in paraffin cracking, producing coke in paraffin cracking furnace has been markedly reduced.
# 2007 Elsevier B.V. All rights reserved.

Keywords: Alpha olefins; Paraffin cracking; Hard paraffin; Ethylene cracking

1. Introduction recovery (EOR) [9]. Therefore, the technology of making


alpha olefins has attracted great attention.
Alpha olefins and their derivatives are important chemical A conventional route to produce alpha olefins is
feedstocks and value-added products. The butylenes-1, oligomerization of ethylene, in which naphtha is thermally
hexene-1 and octylene-1 are mainly used as comonomer of cracked to mainly low-molecular weight paraffin gases, and
polyethylene and have great influence on the density of resin they are dehydrogenated to produce low-molecular olefins
[1]. Alpha olefins in the C9–C16 range are normally used as that are subsequently converted to larger alpha olefin
chemical feedstocks for lubricants, surfactants, alcohols and molecules by oligomerization. Alpha olefins produced by this
other valuable commodities. Synthetic lubricants can reduce process are of high quality, but their production cost is also
frictional losses enough to cut the energy consumption by 2– very high.
8% [2,3]. Synthetic detergents produced from straight chain
Another process to produce alpha olefins from wax cracking
olefins have biodegradation characteristics superior to those of
has been widely used over world since 1960s [10,12] because the
detergents from other sources [4,5]. C16–C18 alpha olefins can paraffin is very plentiful and cheap. The main units in China are
be used to synthesize lubricant of oil field artesian well slurry located in Petrochemical Industry Factory in Lanzhou, No. 3
[6,7]. C9–C20 alpha olefins can be used to produce pour-point Chemical Factory in YanSan and No. 1 Petrochemical Industry
depressant [8]. C14–C19 alpha olefins can be used to Factory in Fushun. However, the quality of the alpha olefins
synthesize alkylbenzene sulfonates applied to enhanced oil produced by this process is unsatisfying and the liquid olefin
yield is lower due to the deficiency of the wax cracking
technology and the high oil content of cracking material. In
* Corresponding author at: Guangzhou Institute of Energy Conversion,
Chinese Academy of Science, Guangzhou 510640, China. addition, the trouble in producing coke in the cracking furnace
Tel.: +86 13724081125. pipe is so serious that the units should be stopped every 90 days
E-mail address: cxd_cxd@hotmail.com (X.D. Chen). of operation, resulting in a high run cost.

0165-2370/$ – see front matter # 2007 Elsevier B.V. All rights reserved.
doi:10.1016/j.jaap.2007.09.009
X.D. Chen, Y.J. Yan / J. Anal. Appl. Pyrolysis 81 (2008) 106–112

Mittal reported thermal cracking of paraffin (C 23–C34) of fresh paraffin (C22–C34). Another is the heavy fraction (HF,
from a refinery under a so-called optimum process conditions C35) formed via oligomerization of olefinic gases at high
[13]. The process temperature was 560 8C, pressure 0.4 MPa, temperature whose carbon numbers are greater than those of
1
and a steam to wax ratio of 1.56 mol mol . Conversions to fresh paraffin. As the HF easily produces coke in the pipe of
gas and liquids were, respectively, 24.8 wt% and 28.4 wt%. cracking furnace, it should be removed from the cracking
The cracked liquid product (C 9–C17) contained 87.6 wt% of output before cracking reaction. The third is unreacted wax
olefins, 72.6 wt% of alpha olefins, 6.0 wt% of paraffin, and (C22–C34), which can be repeatedly cracked with fresh
6.4 wt% of aromatics. However, 24.8 wt% of gas yield is very paraffin. Both wax and alpha olefins are analyzed by gas
high just to obtain 28.4 wt% of liquid yield. chromato-graphy (GC).
Ikura reported the thermal cracking of hard paraffin wax
(mp 53–57 8C) to alpha olefins at 503 8C [14], with 2.3. Once-through cracking experiment
conversions to gas and liquid product being 8.9 wt% and 89.1
wt%, respectively. The liquid product contained 68.5 wt% of The unit of once-through cracking experiment was
alpha olefins, 10.4 wt% of paraffin, 1 wt% of benzene, 1
designed to convert approximately 1–3 kg h of paraffin to an
toluene and xylene and 20.1 wt% of others.
alpha olefins rich liquid, which is capable of operating with a
Compared with the process of oligomerization of ethylene, gas phase residence time as short as 1.5 s and a reaction
it is evident from the above-mentioned literature that these temperature up to 650 8C. The once-through wax cracking
alpha olefins from wax cracking are difficult to meet the need flow chart was shown in Fig. 1. The reactor body is practically
of fine chemical industry because of their bad quality. a tube. Three kinds of Incolly 800 H tubes with i.d. of 8, 6, 4
Therefore, it is urgent that a new technology for producing mm and length of 20 m were used according to the process
high-quality alpha olefins from wax cracking should be condition.
developed. In this paper, the hard paraffin (mp 54–56 8C) Soft water pumped into a electric heater is heated to 200
which contains very little oil was used as cracking feed. The 8C and mixed with fresh wax. The mixture is pumped into a
best operating conditions for producing alpha olefins with vaporizer to be vaporized and into the cracking reactor to be
high-quality and high-yield are determined by once-through cracked. The whole gaseous product enters a high-temperature
wax cracking experiments in lab, and then the industrial condenser where the HF and unreacted wax are condensed.
experiment was conducted in conven-tional industrial units of The HF and unreacted wax are collected in a glass bottle and
paraffin recycle cracking of removing the heavy fraction after separated via distillation of decompression. The alpha olefin
wax vaporizing, with the determined best operating conditions rich liquids, water steam and non-condensibles slip through
and the technology of the second injecting steam in ethylene. the high-temperature condenser and enter the low-temperature
The problem and reasons about conventional technology of condenser where the alpha olefins and water are condensed.
paraffin recycle cracking of removing the heavy fraction after The alpha olefins and water are collected and separated in the
wax vaporizing in the industrial experiment were also oil and water separator. Only non-condensible gases slip
analyzed. Consequently, the better new technology of paraffin through the low-temperature condenser. The gases are
recycle cracking of removing the heavy fraction before wax measured with a gas meter.
vaporizing was proposed and studied with the same operating Experiments were done with fresh wax. After the steady
conditions in order to obtain the alpha olefins with high target reaction temperature was reached, a sample period
quality and reduce the coke in the paraffin cracking furnace. began and the unit continued to run for 24 h before the run
was completed. Process gases were sampled and collected in
2. Experimentation gas bags and analyzed for hydrocarbons up to C 5 and H2. Both
alpha olefins and paraffins were analyzed by gas chromato-
2.1. Materials graphy.

The hard paraffin (mp 54–56 8C) with oil content of 0.8 wt 2.4. Industrial recycle cracking of removing the HF after
% was used and the specification is shown in Table 1. wax vaporizing

2.2. The method of analysis The flow chart of industrial recycle cracking of removing the
HF after wax vaporizing is shown in Fig. 2. The industrial
There are three parts in the paraffin cracking output. One is experiment was done in the 50 ktonnes/annum paraffin cracking
the cracked gas (C1–C4) and the alpha olefins rich liquid product unit modified. The fresh wax feed is pumped into a distillation
(C5–C21) whose carbon numbers are smaller than those tower, and the gases and C5–13, C14–18 alpha olefins

Table 1
Hard paraffin (mp 54–56 8C)
1
Oil content (wt%) Specific gravity (D15.6) Melting point (8C) v(sulfur) (mg g ) Remnant charcoal (wt%) Molecular weight
0.8 0.8045 54.5 8.4 0.02 339
108 X.D. Chen, Y.J. Yan / J. Anal. Appl. Pyrolysis 81 (2008) 106–112

Fig. 1. The once-through wax cracking flow chart.

with the second high-temperature steam in the mixture device.


The vaporized wax and steam enter cracking section of
furnace 1 and furnace 2 by three routes to crack, and then the
three gaseous products enter the distillation tower after fast
cooling in the rapid cooler.

2.5. Industrial recycle cracking of removing the HF before


wax vaporizing

The flow chart of industrial recycle cracking of removing the


HF before wax vaporizing is shown in Fig. 3. The industrial
experiment was conducted in the 35 ktonnes/annum wax cracking
unit modified. The fresh wax feed is pumped into a distillation
tower. The gas and C5–13, C14–18 alpha olefins are, respectively,
Fig. 2. The recycle cracking of removing the HF after wax vaporizing.
cut from the top and the middle of distillation tower. The
material, composed of unreacted wax, fresh wax and the HF, at
are, respectively, drawn off from the top and the middle of the bottom of distillation tower is pumped into decompression
distillation tower. The material at the bottom of distillation tower, furnace 1 to be heated and enters fractionating tower of
which is composed of fresh wax, unreacted wax and the HF, is decompression to be cut into three fractions: the C 21 alpha
taken out from the bottom of distillation tower with a pump and olefins, HF and mixed wax, composed of unreacted wax and
enters warm-up heating section together with the first steam. The fresh wax, all of which are, respectively, drawn out from the top,
mixture is heated to be vaporized in the vaporizing section of the middle and the bottom of fractionating tower. The mixed wax
furnace 1, and then enter the flash tower to be flash-vaporized. enters warm-up heating section together with the first steam. The
The HF is drawn off the bottom of flash tower. Vaporized wax is mixtures are heated to vaporize to 70% in vaporizing section of
exited from the top of flash tower and mixed furnace 1, and then enter mixer together with the second high-
temperature steam to be fully flash-vaporized. The fully
vaporized wax and steam enter cracking section of furnace 2 by
two routes to be cracked, and then the two gaseous products enter
the distillation tower after fast cooling in the rapid cooler.

3. Results and discussion

3.1. Once-through cracking experiment

The suitable temperature of wax cracking is normally 550–


600 8C, and there is optimal residence time at a reaction
temperature. In addition, reducing the hydrocarbon partial
pressure of reaction system is helpful to improving the quality
and yield of product. By keeping the same ratio of wax
Fig. 3. The recycle cracking of removing the HF before wax vaporizing. conversion and the same feed, the reaction at a lower
X.D. Chen, Y.J. Yan / J. Anal. Appl. Pyrolysis 81 (2008) 106–112 109

Table 2
The operating conditions and quality and yield of product for once-through paraffin cracking
Item 1 2 3
The operating conditions of paraffin cracking The steam to wax ratio (wt%) 15 10 5
Temperature at the inlet of cracking reactor (8C) 500 500 460
Temperature at the outlet of cracking reactor (8C) 600 580 570
Equivalent temperature (8C) 575 565 545
The residence time (s) 2.28 4.0 8.0
Pressure at the outlet of furnace (MPa) 0.10 0.10 0.20
The yield of cracked product (wt% of feed) Unreacted paraffin 67.31 74.95 78.03
Liquid olefin 20.46 15.53 13.56
Gas 9.62 6.93 5.47
The HF 2.61 2.59 2.94
Once-through conversion ratio 30.08 22.46 19.03
The quality of cracked product (wt% of liquid olefin) Alkane 2.56 3.63 3.45
Aromatics 0.58 0.89 0.93
Alpha olefin 86.76 82.31 81.56
Olefin 96.86 95.48 95.62

temperature needs much more reaction time than that at a remove the HF before wax vaporizing, which is a new one
higher temperature, that is to say, the reaction at a lower and is not used by forefathers.
temperature needs less steam than that at a higher
temperature. According to the literature and experience, the 3.2.1. The operating conditions of industrial recycle
three series of representative operating conditions of wax cracking experiment
cracking were selected in our work. According to the operating conditions of better olefins
In addition, the less the oil content in the cracking paraffin yield and high quality of once-through cracking, the designing
is, the higher the quality and yield of liquid olefins are [11], conditions of recycle cracking in industrial experiment units
the hard paraffin (mp 54–56 8C) with of 0.8 wt% oil content mean a temperature of 600 8C at the outlet of cracking
being used. reactor, an equivalent temperature of 575 8C, the residence
Table 2 shows the effects of the operating conditions on the time of 2 s, the steam to wax ratio of 15 wt%, and the once-
quality and yield of the liquid product (C 5–C21) and the ratio through cracking ratio of 30 wt%. The operating conditions
are shown in Table 3.
of once-through conversion, which was based on the averaged
values of the variables in 24 h. Cracking at a high temperature In order to reduce producing coke, the technology of the
clearly accelerates conversions. It is evident that, cracking at a second injecting steam in ethylene cracking is applied to the
high temperature, the high steam to wax ratio and the short wax cracking technology. It is said that the pipe of furnace
reaction residence time greatly improve the product quality will not produce coke if the ratio of wax vaporization is lower
and raise the product yield. At a temperature of 600 8C at the than 70%, but will easily produce coke if the ratio of wax
outlet of cracking reactor, an equivalent temperature of 575 vaporization is between 70% and 100%. When large
8C, the residence time of 2 s, the steam to wax ratio of 15 wt quantities of high-temperature steam is injected into the pipe
% and once-through conversion ratio of 30 wt%, the yield and at the point of the ratio of 70% of wax vaporization in order to
quality of olefin product cracked from hard paraffin (mp 54– make wax instantly vaporize in a high-effective mixing unit,
56 8C) are found satisfactory, and the product (C5–C21) the ratio of vaporization will instantly reach 100%, but will
contains 96.86% of olefin, 86.7% of alpha olefins, 2.56% of not pass through the process at the ratios of vaporization of
alkanes and 0.58% of aromatics. 70–100%, which can avoid the pipe producing coke. Besides,
using the technology of the second injecting steam is
3.2. Industrial recycle cracking experiment beneficial to shortening wax high-temperature residence time,
reducing the hydrocarbon partial pressure and improving the
During the practical production, there is only 30% of wax olefin product quality.
cracked in once-through cracking. In order to raise the product
yield, the unreacted wax should be repeatedly cracked, which is 3.2.2. The industrial recycle cracking of removing the HF
not easy to achieve in laboratory experiment but can easily be after wax vaporizing
done in industrial production. The olefins product, unreacted wax By using soft wax, soap wax and hard wax (mp 54–56 8C)
and the HF of the cracking output should be separated during the as feed, the quality and yield of practical industrial product are
recycle cracking. There are two ways to separate them according shown in Table 3, reveals that, compared with industrial
to the type of the HF separation. One is to remove the HF after production results of soft and soap wax cracking, the yield and
wax vaporizing, which is an conventional process and has been quality of the liquid product (C5–C21) by using hard paraffin
used for 35 years in China. The other is to (mp 54–56 8C) as feed have been greatly improved in the new
110 X.D. Chen, Y.J. Yan / J. Anal. Appl. Pyrolysis 81 (2008) 106–112

Table 3
The industrial experimental results and operating conditions
Item Once-through Removing the HF after wax Removing the HF
cracking vaporizing before wax vaporizing
Hard wax Soft wax Soap wax Hard wax Hard wax
The operating conditions The first steam to wax ratio (wt%) 15 1.5 1.5 3 3
of paraffin cracking The second steam to wax ratio (wt%) – 3 3 12 12
Temperature at the inlet of cracking furnace (8C) 500 460 460 500 500
Temperature at the outlet of cracking furnace (8C) 600 570 570 600 600
Equivalent temperature (8C) 575 575 575
The residence time (s) 2.28 8 8 2.1 2.1
Pressure at the outlet of cracking furnace (MPa) 0.10 0.25 0.10 0.10 0.10
The yield of cracked Liquid olefin 63 41 56 60 65
product (wt% of feed) Gas 29 19 32 33 31
The HF 8 38 12 7 4
Once-through cracking ratio 30.08 17 22.35 30.2 30.15
The quality of cracked Alkane 2.56 10.38 10.36 5.12 2.48
olefin (wt% of Aromatics 0.58 1.25 0.85 0.61 0.46
liquid olefin) Alpha olefin 86.76 44.66 60.75 82.13 88.65
Olefin 96.86 88.37 88.79 94.27 97.06
Color Colorless Yellow Yellow Buff Colorless

operating conditions. By operating in these conditions, the olefins content of product. In addition, the diolefins and
cracked product with buff color contains 82.13% of alpha aromatics have influence on the product color.
olefins and 94.27% of olefin. The product yield reaches 60%. Secondly, the residence time of vaporizing wax in the flash
Besides, the coke produced in the pipe of furnace, the plate tower even reaches 430 s and temperature of vaporizing wax
and wall of flash tower and the outlet pipe of flash tower have in flash tower is high. Vaporizing wax in flash tower has
been greatly reduced, resulting in a long period of the unit cracking reaction to produce olefins. Similarly, the olefins
running and the reduction of the cost of run. This illustration have the second cracking or aromatization reaction to produce
can be seen from the pressure at outlet pipe of flash tower and diolefins, aromatics and gas in cracking furnace to raise the
the thickness of coke produced in furnace pipe and outlet pipe gas yield and reduce the liquid olefin yield and the alpha
of flash tower. The pressure at outlet pipe of flash tower was olefin content of product. The diolefins and aromatics also
0.14 MPa at the beginning of starting the unit. After having have influence on the product color.
been run for 180 days, the pressure only rise to 0.17 MPa, Thirdly, there are some olefins and little HF in mixed wax,
which was far from the controlling data. During the former resulting in the fact that the ratio of mixed wax straight chain of
practical production, when there was much coke in above 81.45% is obviously lower than that of fresh wax of 90.35%, and
place, the pressure in the outlet pipe of flash tower rapidly the alpha olefins content of liquid product drops down. If
went up and the unit was stopped. Coke production was
measured and the situation of coke produced was observed
after industrial experiment. The thickness of coke produced in
furnace pipe and outlet pipe of flash tower was, respectively,
0–1 mm and 2– 3 mm, and was 20–30 mm and 50–100 mm
after running for a period of 90 days during the above-
mentioned practical production.
However, compared with the laboratory result of once-
through wax cracking, some troubles in this industrial
experiment are found, that is, the color of liquid olefin is buff,
the gas and the HF yield are higher, and the liquid olefin yield
and the alpha olefin content are lower. The main reasons are
as following.
Firstly, the olefins ( C 21) are not fully separated from mixed
wax. Fig. 4 shows the carbon number distribution of fresh wax,
mixed wax and vaporizing wax. Fig. 4 also shows that there are
some olefins ( C21) in mixed wax and vaporized wax, which has
the second cracking or aromatization reaction to produce
diolefins, aromatics and gas in cracking furnace, thus raising the Fig. 4. The carbon number distribution of fresh wax, mixed wax and
gas yield and reducing the liquid olefin yield and the alpha vaporizing wax.
X.D. Chen, Y.J. Yan / J. Anal. Appl. Pyrolysis 81 (2008) 106–112

Table 4
The straight chain alkane distribution of fresh wax and mixed wax
The straight chain alkane Fresh wax Mixed wax
distribution (wt% of feed)

C
20 0.14 0.06
C
21 0.61 0.30
C
22 2.38 1.57
C
23 9.11 7.54
C
24 14.96 12.35
C
25 17.63 15.54
C
26 13.40 13.01
C
27 10.73 10.93
C
28 6.32 6.61
C
Fig. 5. The carbon number distribution of fresh wax and the HF. 29 3.53 3.74
C
30 1.91 2.26
C
31 2.00 2.80
the C22–34 in mixed wax is 100%, the straight chain ratio will C
32 2.28 3.68
be 87.1%, which approaches that of fresh wax. C
33 2.10 3.55
C
Finally, there is large quantities of wax fraction (the C 22–34) in C
34 2.10 2.68
HF, which makes the HF yield raise. Fig. 5 shows the carbon 35 1.54 1.98
C
number distribution of fresh wax and HF. The distillation of HF 36 0.70 1.24
C
in laboratory indicates that the C 35 is only 30 wt%, so the true HF 37 0.40 1.11
Total 91.84 90.95
yield is about 2 wt%, but in fact it is 7 wt%.

3.2.3. The industrial recycle cracking of removing the HF about 70%, and makes the mixed wax fast fully vaporize, thus
before wax vaporizing shortening the high-temperature residence time of mixed wax,
The industrial experimental results of recycle cracking of improving the olefin quality and avoiding producing coke. In
removing the HF before wax vaporizing are shown in Table 3 addition, the flash tower is cancelled to shorten the high-
which shows that, compared with the technology of recycle temperature mixed wax residence time.
cracking of removing the HF after wax vaporizing, the new
technology can greatly raise the liquid olefin yield to 65%, 4. Conclusions
improve the olefin product quality by 97% of olefin, 88 wt%
of alpha olefin, 2% of normal paraffin and makes the product The better operating conditions of better olefin yield and
colorless. Also, the product quality is better than that of once- quality mean a temperature of 600 8C at the outlet of cracking
through experiment and approaches that of ethylene oligamer- reactor, an equivalent temperature of 575 8C, the residence time
ization. of 2 s, the steam to wax ratio of 15 wt%, once-through cracking
According to the problems existing in industrial recycle ratio of 30 wt% by the once-through cracking experiment, and the
cracking of removing HF after wax vaporizing, the new use of hard paraffin (mp 54–56 8C) as feed.
technology of industrial recycle cracking of removing the HF New wax recycle cracking technology of removing the HF
before wax vaporizing is modified from that of removing the HF before wax vaporizing is adopted to obviously reduce the second
after wax vaporizing. The fractionating tower of decompression olefin cracking and aromatization reaction to produce diolefins,
appears in the new technology. The material at the bottom of aromatics and gas in cracking furnace, to rapidly raise the content
distillation tower is cut by the fractionating tower of decom- of alpha olefins, to reduce the content of paraffin, to improve the
pression into three fractions, such as the C 21 liquid olefins, mixed product appearance, to increase greatly the liquid olefin yield and
wax and the HF. Table 4 shows the straight chain alkane carbon to reduce the gas and the HF yield.
number distribution of fresh and mixed wax. It is evident that the Under the operating conditions with a steam to wax ration of
straight chain alkane carbon number distribution of the mixed 15 wt%, a high temperature of 600 8C, a low hydrocarbon
wax is similar to that of fresh wax. Also, there is very little partial pressure and a short residence time of 2 s, by using
olefins fraction ( C21) in the mixed wax, so it reduces the second hard paraffin (mp 54–56 8C) as feed, the new wax recycle
cracking or aromatization reaction, thus producing diolefins, cracking technology of removing the HF before wax
aromatics and gas in cracking furnace. As a result, the alpha vaporizing can obtain high-quality colorless alpha olefin
olefins content of product and the liquid olefin yield increase, the product with 97 wt% of olefin, 88 wt% of alpha olefin and 2
gas yield decreases, and the total straight chain alkane to mixed wt% of normal paraffin, which approaches that of ethylene
wax ratio of 90.95 wt% is almost the same as the total straight oligamerization and meets the need of fine chemical industry.
chain alkane to fresh wax ratio of 91.84 wt%. Moreover, there is The technology of the second injecting steam in ethylene
also very little wax fraction in HF, and the HF yield reduces. In cracking used in wax cracking not only can obviously reduce
the process of the new technology, a large amount of the second producing coke in furnace pipe, prolong unit running period
high-temperature steam is injected between vaporized section and and slow down the running cost, but also can shorten the
radiation section where the vaporizing ratio of mixed wax is residence time of high-temperature mixed wax, reduce
112 X.D. Chen, Y.J. Yan / J. Anal. Appl. Pyrolysis 81 (2008) 106–112

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