23rd Ethylene Producers’

Conference 2011

Topical Conference at the 2011 AIChE Spring Meeting and
7th Global Congress on Process Safety

Chicago, Illinois, USA
13-17 March 2011

ISBN: 978-1-61782-892-8

NY 10016-5991 Phone: (203) 702-7660 Fax: (203) 775-5177 www. Copyright© (2011) by AIChE All rights reserved. Printed by Curran Associates.com Web: www. please contact AIChE at the address below.com .aiche. (2011) For permission requests. AIChE 3 Park Avenue New York. Inc. 57 Morehouse Lane Red Hook. NY 12571 Some format issues inherent in the e-media version may also appear in this print version.org Additional copies of this publication are available from: Curran Associates. Inc. NY 12571 USA Phone: 845-758-0400 Fax: 845-758-2634 Email: curran@proceedings. 57 Morehouse Lane Red Hook. Inc.Printed from e-media with permission by: Curran Associates.proceedings.

......... 140 Satoshi Hata... 270 Terryl Matthews................................... Steven Pyl.. Pritchett................................ Pinakin Mistry The Impact of Ethylene and Propylene Impurities Upon Polyolefins Units ............................. 165 Brian Ames Feed Contamination with Sodium and Its Impact on Ethylene Furnaces................................... Gampa Bhat........................... Jonathan D..................................... Bill Valerioti Energy Reduction Through Utilities Advanced Control ... Simmons Train Performance ........................ Daniel Frye........ Marin Design........................................... 2 Steven Ramsey Green House Gas Reporting In the Ethylene Manufacturing Sector........................... 1 Darrell Dolmage Confusion and Anxiety: The Very Latest on the Re-Revised Ozone Standard .........Risks & Impacts............................. 13 Valerie Barth.. 340 David Hokanson A Novel Approach to Design and Implementation of Multivariable Process Controllers for C3 Fractionation Columns............................................. Guy B.......... 289 Hubert Koepf....... Tim Song ....................... 220 Mark Brayden.. Van Geem.......... 327 Clay Thiele............................................................... 215 Scott Smith......................... 221 André Bernard...................................................................................................................................................... 271 John Penton. 38 Colman De Jong Steam Turbine Fundamentals with an Emphasis on Blade Design ........................... Boyd Start up Issues of Ethylene Plants .........................The Basics of Performance and Rerate ............................................................... 178 Dave Purvis Mitigation of Fouling from Vinyl Acetate Recycle to Ethylene Plant........... 28 Keith Wade Impact of New Industrial Boiler and Process Heater Air Regulations on the Chemical Industry............................................... 155 Stephen Plaisance The Energy Challenge: Providing Sustainable Supplies to Meet Growing Demand ............................................................. Marie-Françoise Reyniers................................................................ 236 Kevin M............................... Takuro Koda Utilization of Equipment Health Management in an Ethylene Plant ......................................... 29 Amy Marshall Centrifugal Process Compressors . 164 F.............................................................................. Installation......................... Bryan Vick Life Cycle of Aluminum Plate Fin Exchangers ...................................................................................... Eli Gronowski Sulfur Myths ......... 86 Sandra J......... 269 Thomas Callahan Optimum Maintenance Interval Considerations for Major Ethylene Plant Compressors and Steam Turbines ............................................................................................. Schietekat.................................................................................................................................................................................................................................................... and Monitoring of ID Fans for Ethylene Furnaces .................................................................................. 166 Bala Devakottai.Evaluation and Monitoring by Torque Meter Applications.... Junichi Horiba.......... Allen C..... 298 Rick Swain...... Thomas Dijkmans..... Vijay Srinivas Flux Oil Stream Import to Quench System .............................. Reinhold Hoelzl Aluminum Plate-Fin Heat Exchanger Thermal Fatigue Study............................. Thomas Pickett............................ Robert M.............. Cardell Process and Equipment Considerations In the Art of Cold Box Design ...................................................................TABLE OF CONTENTS Use of IR Camera During Ethylene Unit Startup .................................................................................................................................................................................. Carl M...................................................... Emil Jacobs Global Olefins Outlook........... 353 James Wu................................................. Miller Field Repair of Brazed Aluminum Plate-Fin Heat Exchangers................... Beata Manek Steam Cracking of Heavy Oil Fractions Revisited................ 318 Sam Willard Investigative Process Uncovers Cause of Surface Tearing In Cold Box Aluminum Alloy Pipe Components......................... Cheri Kwast New Flare System VOC Regulations & Reduction Control Options...............................What We Know and What We Do Not Know ....................................................................................... Kevin Yates........................ 253 Neal D.....................................................................................................................................

.............................. 679 Kuyen Li............. Vincenzo Sangiorgio Introductory Remarks................................. Harry Wang................................... Conny Petersson Large Scale Ethylene Unit APC Using Shell Multivariable Optimizing Controller (SMOCPro) ................................................................ AspenPlus and Aspen Online .......................................................... 570 Bernd Heida................ 643 Michael J....................... 533 Michael J... Soichi Iwamoto.............................. De Bruyn Industry Standards for Composite Repair of Process Piping ............. Brian Piercy Severe Erosion in a Charge Gas Compressor.. Ravi Nath European Ethylene Producers Committee (EEPC) Corrosion Under Insulaton (CUI) Prevention of CUI: “Roadmap to Managing CUI” ......... Hendrik J............. 611 P......... 645 David Leung Catofin Propane Dehydrogenation Project .. Jordan Enhance Cracked Gas Compressor Reliability with Novel Antifoulant Technology............... Curtis Eng......................................... Carl G... 461 Simon Frost............................. David Banks.............. Catharina Winberg............. 502 Dave Oulton........................................................................................................................... Qiang Xu ........How Hard Can It Be?"................................................... Eric Romers Advanced Catalytic Olefins (ACO) : First Commercial Demonstration Unit Begins Operations ... Takeshi Seki.................... Tomoo Niikura......................... 605 Mark A..................... Matherne Furnace Penetration Sealing Systems ............ Julian Price..........................................Engineered Solutions for Cracking Furnaces.... Tallman World Light Olefins Markets Outlook: Impact of Changing Energy and Feedstock Market Dynamics on Regional Olefins Markets ...... Stanley...................................... 432 Klaus Bormuth...... Chris Alexander Composite Repairs for the Rehabilitation of Corroded or Damaged Pipework.................................... Robert J............... Maximo (Max) Salazar................................ W...................................................................... Jong-Ho Park..................... Tomas Tejder................................................................................. Zygula........ Jae Ho Lee.............................. N.......................... Dalla Francesca Alessandro............... Dilip Dharia.......................................... 369 Bengt-Ove Andersson............................... Mahesh Subramaniyam Improving Ethylene Charge Gas Compressor Performance ....................... "Bill" Napier........ 644 Mark Eramo Improve Plant Flexibility for the Changing Feedstocks and Technologies................................................................................ 624 Giorgio Greco. 662 Timothy M................... Ayumu Fujita.............................. Matherne Scale-up of Advanced MTO Technology and Integrated OCP Technology ......................... 488 Malcolm A.................. Ramaswamy....... Bernd Metzen............................Cause and Solutions to Microbiologically Induced Corrosion........... 559 Stephen J...................... Bruce Evans Design Considerations for Propylene Splitters.................................... J........ Jong-Nam Kim...................................................................... Jang Jae Lee Cracked Gas Compressor Control Tutorial .............................................. Gartside Beyond "Classics": New Technologies to Boost Capacity In a Butadiene Unit. Nick Moore Cooling Water Issues ..................... Paul Yap........................... Conny Petersson Use of Process Simulation In Ethylene Plant APC and Dynamic Optimization......................................................................................Design and Operational Considerations ... Dalby........................................ 402 Akitoshi Takinami... Deuk Soo Park Catalytic Cracking of FT Products for Light Olefins Production ............... Werner Peschel Recover Ethylene from Refinery Off-Gas Via the Ole-SIVTM Process.......... Youichi Takeuchi........................ Karl Kolmetz Flare Minimization Via Dynamic Simulation........................... 593 Nauman Islam Objectives of Anti-Surge Control .............................................................. Hak Kim C5 Metathesis for Increased Propylene Production .............. 380 Donald Frank..Experiences Migrating a Process Control System: "Legacy to Bleeding Edge ........ Sun Choi............................................. Vinh Nguyen New Approach for Furnace Severity/Conversion and TMT Inferentials Using SPYRO.......................... 476 Carl G.. 584 Seong Jun Lee.................................................... Randolf Hugo......................................... Peirson Best Practices for Inlet Cone Refractory of Transfer Line Exchangers.. James M.......... 545 Angeline Moodley................................... 394 Bengt-Ove Andersson....... Catharina Winberg..................... Tallman......................................................................... Tomas Tejder......................................... Marcus Hedlund............... Eddy Fontenot................................... 651 Marco Van Goethem.......................................................... Olof Gahne............... 442 Julian Bedoya....... 594 W......... 650 Randy Miller Co-Cracking Vs.. Matthew Knight....... Segregated "Hybrid" Cracking In Individual Furnaces ...... Marcus Hedlund................ Olof Gahne............................... 517 John Senetar........

.... Niara Eckhard.......................................... Sobczyk................................................. 765 Claire J..................... 824 Roger Metzler................................................................................................................................ 782 Jennifer L........................... Ramaswamy........................................................................................ Michael Moran.....Thoughts about Safety.... Raymond Tucker Fouling Mitigation Program Recovers Operating Efficiency and Extends Run Length for Ethylene Plant Oil Quench Tower .......... Staying at Zero....... Matthew Knight............................................................................. 791 Emerentino B........................ 751 Joan Del Castillo Consequences of High-Pressure Tube Ruptures In Low-Pressure Liquid-Filled Shell Heat Exchangers .............................. Jeeranum Jintana..................................... 832 Peter J... Niara Eckhard Trip & Throttle Valve Reliability. 808 Laurence J............................ 789 Michael R.................................. Chandresh Patel Practices to Mitigate NOx Risk In Cryogenic Section of Ethylene Plants ......................................................................... N.. Eliana Vidal................................... Mahesh Subramaniyam Loss of Downcomer Seal on a Depropanizer During a Plant Start Up..................................... Li Feng Acetylene Converters Troubleshooting............................................ Ennis.......... Zych Fouling/Viscosity Control Mitigation Strategy Overcomes Problems In Quench Oil System...... Kamal K............................................. Patrick Lucas...... Traynor A New Class of Polymer Inhibitors .... Botros.................... Bancroft......................... 790 Mike Hong............................. 842 André Bernard Author Index ....................................................................... Zhenning Gu Improved Ethylene Cracking Furnace Control with Modern Process Mass Spectrometers.............. Quadro.. 833 P............................................................ Sivakumar Nayarajan Enhanced Heat Transfer Technology Proves Beneficial In Cooling Water Driven Condensers ................. Richard Zoldak Loss of Flow In a Process Water Pump .................................................................... Jaildes Britto.... 691 Rendell Newton Ethylene Boil-off Puzzle ............... 737 Eliana Vidal.................

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