Ethedco

Classroom Training
for Ethylene & Butadiene Technology
‫الشركة المصرية إلنتاج اإليثيلين ومشتقاته‬

The Egyptian Ethylene & Derivatives Co.
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Ethylene Process Overview
» After this session you will understand……..

» What “Ethylene Process” comprises of
» Flow from “feed” to “products”
» The function of each unit
» Major equipment and their functions
» Overview about Ethylene Plant Utilities
» Overview about Butadiene Plant
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Training Content
Purpose of the session

General Design Values
General Process Overview Drawing
HOT SECTION
 MRU and Amine
 Feed Handling
 Cracking Heater
 Quench Water and Process Water
 Process Water Stripper and DS
COLD SECTION
 Charge Gas Compression
 Caustic Tower
 CG Dryer
 Dryer Effluent Wash Tower
-3-
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Training Content
 Chilling Train
 Demethanizer
 Deethanizer
 Acetylene Hydrogenation
 C2 Green Oil KO Drum and Ethylene Dryer
 Ethylene Fractionator
 Ethylene and Ethane Storage
REFRIGERATION
 Propane Refrigeration
 Ethylene Refrigeration
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Training Content
UTILITIES
 Steam Generation
 Cooling Water
 Fuel Gas & Nitrogen
 Utility Water & Portable Water
 Waste Water & Waste Oil
 Instrument Air & Plant Air
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Training Content
BUTADIENE PLANT
 Depropanizer
 Debutanizer
 Feed Vaporization
 Main Washer and Rectifier/Afterwasher Column System
 Degassing, Compression and C4 Acetylenes Removal System
 Distillation (Product Purification)
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General Design Values
 Plant Capacity
 Designed to produce 460,000 MT/Y polymer grade ethylene
 OPERATING HOURS
 8000 operating hours per year
 FEED
 Ethane / Propane
 BYPRODUCTS
 High Purity Hydrogen
 Hydrogen & Methane Rich Off gas (Fuel and export)
 C3 & Heavier Hydrocarbons (Fuel)
 Pyrolysis Gasoline (Fuel)
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General Process Overview
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HOT SECTION

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Mercury Removal System and Amine System
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Mercury Removal System
and Amine System
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and Amine System
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and Amine System
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Cracking Heater
Caustic &
Quench Process Charge Gas Water
Mercury Acid Gas Amine Amine Wash Tower
Tower Water Compressor
Removal Absorber Stripper Stripper
Strippe 1st - 3rd Stages
Reflux S r
Bed. Drum
M
W
Process Water
Ethane/Propane Treating unit
feedstock.
Pyrolysis Condebsate
Gasoline to Quench
Tower
Acetylene Ethylene
Demethanizer Deethanizer Converter Fractionator
Dryer Demethanizer
Demethanizer Off-Gas expander
Effluent Feed Cooler
Wash Reflux drum
Charge Gas Fuel Gas System
Compressor Tower Hydrogen
4th Stage
Dryer Ethylene Storage
Dryer Sphere
Effluent
Wash Tower
Reflux drum
Demethanizer
Feed Separator
1,2,3
Ethylene Ethane Storage
Dryer Sphere
Condebsate
to Quench
Tower Butadiene Unit
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Cracking Heater
Function :
• Heat hydrocarbon feed to cracking temperatures
• Mix feed with dilution steam
• Thermally crack hydrocarbon molecules to produce

more valuable products like Ethylene
• Recover combustion heat to generate SHP Steam
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Cracking Heater
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Cracking Heater System
Place Your Picture Here
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Feed Handling
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Feed Handling
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Cracking Heater Primary TLE’s
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Cracking Heater Primary TLE’s
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Cracking Heater Secondary TLE’s
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Cracking Heater Secondary TLE’s
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Quench Water System
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Quench Water System
 Function of Quench Tower :
 Cool Charge Gas to 41oC
 Transfer recovered heat to Quench Water for process users
 Condense Dilution Steam as Process Water
 Separates Pyrolysis Gasoline
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Quench Water System
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Process Water Stripper and DS
 The main purpose of the Process Water Stripper and DS system
 To remove acid gases from process water

 To remove volatile hydrocarbon from process water
 To remove heavy hydrocarbon by Process Water Treating
Unit
 To generate dilution steam to Cracking Heaters
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Process Water Stripper and DS
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COLD SECTION

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Charge Gas Compression & Caustic Tower
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Charge Gas Compression
 Charge Gas Compressor Design
 4 stage centrifugal compressor

 Inter stage coolers (2-EA-201/202/203/) to remove heat of
compression
 Knock-Out Drums for condensed liquid separation
 Compressor driven by Super high pressure steam turbine
 Wash oil injection to control fouling
 BFW injection to control discharge temperature
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Charge Gas Compression System
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Charge Gas Compression System
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Caustic/Water Wash Tower
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Caustic/Water Wash Tower
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Charge Gas Dryer
&
Dryer Effluent Wash Tower
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Charge Gas Dryers
 Function
 Remove moisture from charge gas down to < 1 mol ppm

 Removal of moisture is necessary to prevent the
formation of ice and hydrates in the cold equipment

downstream of the chilling train, the Cold Box and the
Demethanizer.
 The dryers function by absorbing the water into synthetic

zeolites called molecular sieve.
 Zeolites are silicate materials with an affinity for water.
 One dryer is on stream while the other dryer is being

regenerated in a cyclic operation.
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Charge Gas Dryers
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Charge Gas Dryers
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 Function
 Remove such components (mainly Benzene) from

dryer effluent which could freeze at chilling train.
 High Benzene level (~2000 ppm)causes freezing in
Demethanizer.
 Maintain the required minimum amount of methane

at the bottoms in order to meet the correct methane
specification in the ethylene product.
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Chilling Train
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Chilling Train
 Function
 Chilling train consists of a series of heat exchangers

which chill the dried charge gas.
 Condensing methane and heavier hydrocarbons which

are feeds to Demethanizer (condensed liquids are
sent to Demethanizer as Demethanizer feed at four
intermediate temperatures.
 Produce a hydrogen rich stream about 90 mol%

purity.
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Chilling Train System
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Chilling Train System
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Demethanizer & Deethanizer
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Demethanizer System
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Demethanizer
 Function
 Separate methane from ethylene and heavier components
 Provide Deethanizer feed as bottom product
 Considerations
 Bottom product < 500 wt ppm methane
 Net overhead product < 1 mol% ethylene
 Operate at just enough pressure to deliver methane to fuel
gas
 Proper operation depends on chilling train temperature
profile
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Deethanizer System
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Deethanizer
 Function
 Fractionates the ethylene rich Demethanizer bottoms
into two streams
 Overhead – mixed C2 stream (minimum C3’s)
 Bottom – C3’s and heavier (minimum C2’s)
 Considerations
 Bottom product < 0.14 mol% C2’s
 Net overhead product < 0.1 mol% C3’s
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Acetylene Hydrogenation
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 Function
 Selectively hydrogenated the Deethanizer net

overhead stream to convert acetylene to ethylene and
ethane
 Two fundamental reactions occurring :

 conversion of acetylene to ethylene (desirable)
 conversion of ethylene to ethane (undesirable)
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 Considerations
 Acetylene is impurity in ethylene product which must be

removed.
 Acetylene conversion reaction is exothermic.
 Temperature control is required due to the possibility of

runaway reaction in the acetylene converter
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 Regeneration :
 Regeneration of each Acetylene Converter is required

after a certain period of time of operation.
 Regeneration is performed using a mixture of steam,

air, and hydrogen as well as heated ethane recycle.
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C2 Green Oil & Ethylene Dryer
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 C2 Green Oil KO Drum:

 Green oil is a polymer which is formed inside the
Acetylene Converter.
 Green oil can plug the fractionator trays, if it is
allowed to enter the fractionator.
 The function of a C2 Green Oil KO Drum is to prevent
the heavy green oil from entering the Ethylene
Fractionator.
 C2 Green Oil KO Drum receives the vapor product
from Acetylene Converter and scrubs it with a C2
stream in the C2 Green Oil Wash Mixer.
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 Ethylene Dryer:
 The function of a Ethylene Dryer is to dry the vapor
effluent from C2 Green Oil KO Drum as any amount
of water is not allowed to Ethylene Fractionator to
prevent hydrate formation.
 Ethylene Dryer is inventoried molecular sieve.
 One bed and regeneration of the bed is manual.
 Dryer is bypassed during regeneration.
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Ethylene Fractionator
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Ethylene Fractionator System
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Ethylene Fractionator
 Function
 Fractionates the Deethanizer overhead stream (dry C2 feed)
from Ethylene Dryer.
 Overhead – Hydrogen + Methane + Ethylene recycle
 Sidedraw – Ethylene product (99.95min wt%)
 Bottom – Ethane
 Ethylene product is taken as Sidedraw from tray#9

because methane is condensed with the reflux.
 The 8 trays between the reflux and product draw achieve a

large reduction in methane, CO and hydrogen.
 Ethane is recycled.
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Ethylene and Ethane Storage
(Ethylene Storage System)
Function
• The function of ethylene storage system is to provide an uninterrupted

and smooth ethylene product supply to downstream plant during
unscheduled shutdown of ethylene plant.
• Vaporizer is to vaporize and superheat the liquid ethylene for export to

downstream plants.
• The heating medium is methanol
• This is a back-up system to vaporize/superheated liquid ethylene.
• During plant shutdown, BOG (Boil off gas) is routed to Ethylene Storage
BOG Package.
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(Ethane Storage System)
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(Ethane Storage System)
Function
• The function of ethane storage system is to store ethane

leaving from the Ethylene Fractionator bottom as back-
up feed to the plant.
• This is not a continuous operation. It will take place only

until the storage spheres are filled up with ethane and
only after ethane has been used up as back-up feed.
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REFRIGERATION

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Propane Refrigeration
Function
• Most of the separations effected in the plant depend on the removal of heat at
the lower than ambient temperatures.
• The Propane Refrigeration system is to provide chilling media down to a
level of -37oC.
• Refrigeration is provided at four nominal temperature levels :

 -37oC
 -21oC
 4o C
 18oC
• The refrigeration is supplied by vaporizing the propane at pressures

corresponding to the indicated temperatures.
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Propane Refrigeration
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Ethylene Refrigeration
• Function
• The Ethylene Refrigeration System supplies the chilling media for

the low level refrigeration requirements in the process purification
steps.
• Ethylene refrigeration is provided at three nominal temperature

levels :
• -101oC
• -79oC
• -61oC
• The ethylene product is used as refrigerant. The refrigeration is

supplied by vaporizing the ethylene at pressures corresponding to
the indicated temperatures.
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Ethylene Refrigeration
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UTILITIES

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Steam Generation
• SHP Steam :
• Produced in Transfer Line Exchangers

• Superheated by Cracking Heaters flue gases
• Majorly used for CGC turbine.
• Intermittently used for the regeneration of
Acetylene Converter
• HP Steam :
• Produced from HP Steam Boilers.
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Steam Generation
• MP Steam :
• Mainly supplied by let down from HP steam system

through letdown and desuperheater station and also
by the exhaust from ERC and Quench Water Turbine.
• Superheated LP Steam :
• Mainly supplied by the exhaust from various turbines

(Treated Condensate Pump Turbine, SHP BFW Pump
Turbines and HP BFW Pump Turbine) and let down
from the MP steam system.
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Cooling Water
• Cooling water flows to the ethylene plant from cooling tower cells via
an underground line.
• Cooling water system is designed as a two pass distribution network.
• Cooling water entering the unit at 32oC, the primary cooling water, is
distributed to the first pass heat exchangers where it is heated
approximately 5oC to 37oC.
• Cooling water leaving the first pass exchangers, the secondary cooling
water, is collected and redistributed and heated up to approximately
42oC.
• Cooling water leaving the second pass heat exchangers are returned to
the cooling tower.
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Fuel Gas
• The fuel system separated in two parts -
• Fuel gas including vaporized liquid fuel
• Liquid fuel
• During normal plant operation, fuel gas is generated in Ethylene plant.

Additional fuel gas is imported from OSBL to Fuel Gas Mixing Drum as
needed on pressure control.
• Fuel gas mainly consumed in –

• Cracking Heater Burners
• HP Steam Boilers
• Incinerators
• Excess amount of fuel gas is sent to flare stack.
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Fuel Gas
• The fuel generated in Ethylene Plant consists of the following process
off gases and liquid –
• Methane Off Gas

• Hydrogen Off Gas
• PSA Off Gas
• C3’s and heavier liquid from Deethanizer bottom
• Methane and Hydrogen rich off gases are mixed together in the Fuel
Gas Mixing Drum and fed to Cracking Heaters Burners and HP Steam
Boilers.
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Nitrogen
• Nitrogen is mainly used in the plant as an inert gas.
• The major uses of Nitrogen is for purging, blanketing etc.
• Nitrogen is supplied from Nitrogen Package.
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Utility Water and Portable Water
• Utility Water (UW) System :
• Utility water is distributed from OSBL.
• The uses of utility water :

• Various hose stations in the plant (used for cleaning
site, equipment etc.)
• Automatic water filling of pump casings.
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Utility Water and Portable Water
• Potable Water (EW) System :
• Potable water is distributed from OSBL.
• The uses of potable water :

• Eye washers
• Safety showers.
• Supplied to Site Operator Shelter (S.O.S) for
operator use.
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BUTADIENE PLANT

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Process overview
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Depropanizer
Deethanizer bottoms stored in Butadiene Surge Drum (2-FA-7601) are introduced to
Depropanizer (2-DA-7001) where the propane, propylene and propyne are separated from
Depropanizer Overhead and are routed to OSBL LPG Unit
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Debutanizer
The feed from the Depropanizer bottom is sent to the Debutanizer (2-DA-
7002) where the C4 fraction as an overhead distillate is separated from C5’s
and heavier which are removed in the bottom product. The bottom
product is normally combined with the Depropanizer distillate and is sent
to the OSBL LPG Unit.
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Feed Vaporization
The liquid mixed C4 feedstock from Debutanizer is sent to the Feed Vaporization Drum (2-
FA-7110). The liquid feed is circulated through two sets of thermosiphon heat exchangers,
Feed Vaporizer No. 1 (2-EA-7110) and Feed Vaporizer No. 2 (2-EA-7111). The C4 vapor
stream leaving the vaporizers is sent to the Main Washer (2-DA-7121) which is the first
extractive distillation column. The heat supplied to Feed Vaporizer No. 2 is base loaded.
Heat supplied to Feed Vaporizer No.1 is adjusted by the level in the Feed Vaporizer Drum. A
portion of lean solvent from 2-EA-7110 is sent to Rectifier/Afterwasher.
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Main Washer and Rectifier/Afterwasher
Column System
The function of this system is to separate the vaporized mixed C4 feed into a crude
1, 3 -butadiene product and a raffinate product via a 2-step extractive distillation
process. The Rectifier/Afterwasher Column is a divided wall column which
combines the Rectifier and Afterwasher Columns. The upper portion of the
Rectifier Column and the Afterwasher are mechanically separated by a dividing
wall. N-methyl pyrrolidone (NMP) is used as the extraction solvent and is fed to the
Main Washer and Rectifier/ Afterwasher Column.
Raffinate (butanes and butenes), free of butadiene, 1-butyne, and vinyl acetylene is
taken as a product from the overhead of the Main Washer. Crude butadiene, free
of butanes, butenes, vinyl acetylene and most of the ethyl acetylene contained in
the feedstock, forms the product from the top of the Rectifier/Afterwasher
Column..
Butene rich vapor stream (dilution raffinate) from the Main Washer Condenser 2-
EA-7121, is sent to the Acetylene Washer overhead to maintain the C4 acetylene
concentration in that stream under safe limits.
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Main Washer and Rectifier/Afterwasher
Column System
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Degassing, Compression and C4 Acetylenes
Removal System
The partially unloaded solvent containing 1,3 -butadiene and other more
soluble hydrocarbons is pumped by the Degasser Feed Pump (2-GA-
7130A/B), from the bottom of the Rectifier/Afterwasher Column
through the Solvent Heater (2-EA-7131), to the top of the Degasser (2-
DA-7231).
The pressure is decreased from about 4.1 kg/cm2g in the extractive

distillation section to about 0.70 kg/cm2g in the Degasser. The Solvent
Heater (2-EA-7131) is used to preheat the solvent to further enhance
flashing of gases during this depressurizing step.
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Removal System
The C4 acetylenes are more soluble in NMP than 1,3 -butadiene. The
concentration of C4 acetylenes in the vapor will be at the maximum in the middle
section of the Degasser. Thus, a side stream of C4 acetylenes is withdrawn from
the mid-part of the Degasser and sent to the Acetylene Washer (2- DA-7232). In
order to keep the maximum concentration of the C4 acetylenes at a safe level, the
side stream flow rate is kept high enough to ensure a minimum 1,3-butadiene
concentration of about 20 wt% of the total hydrocarbons in the Acetylene
Washer overhead (before dilution with raffinate gas). The condensed C4
acetylenes are collected in the C4 Acetylenes Accumulator (2-FA-7238), and
pumped to Raffinate Dryer (2-FF-7601A/B), by the C4 Acetylenes Pump (2-GA-
7238A/B).
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Removal System
The overhead product from the Degasser is cooled in the Cooling

Column (2-DA-7234), by a descending stream of water/solvent mixture.
The water/solvent collected in the Cooling Column bottoms is pumped
by the Cooling Column Bottoms Pump (2-GA-7234A/B), first through the
Feed Vaporizer No.2 (2-EA-7111) for heat recovery and then through the
Water and Solvent Cooler (2- EA-7234), for cooling to the desired
temperature before being recycled to the top of the Cooling Column.
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Removal System
The gaseous hydrocarbons from the overhead of the Cooling

Column are compressed in the Recycle Gas Compressor (2-
GB-7231), and recycled to the bottom of the
Rectifier/Afterwasher Column where they are used as
stripping gas.
The lean solvent is withdrawn from the bottom of the

Degasser and circulated through a number of heat
exchangers for heat recovery before being sent to the Main
Washer and the Afterwasher.
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Removal System
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Distillation (Product Purification)
The crude 1,3 -butadiene is pumped from the Afterwasher
Accumulator by Crude Butadiene Pumps (2-GA-7124A/B) to
the Butadiene Column (2-DA-7345). In this column the 1,3 -
butadiene is distilled as a liquid side draw (from tray 12) to
the required product specification.
Product inhibitor, tertiary butyl catechol (TBC), diluted by a slip

stream from the Butadiene Column Accumulator is sprayed
into the Butadiene Column Condenser (2-EA-7345), to reduce
the propensity for polymer formation. (TBC) is also be added
to the product that is sent to Storage.
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Distillation (Product Purification)
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Thank you
E T H Y D C O O p e rati o n Te a m
The Egyptian Ethylene & Derivatives Company
Petroleum Complex - 19th km Alex-Cairo Desert
Road - Merghem - Amreya - Alexandria
M.B. 44, Mubarak Housing, Alex, Egypt.
TEL : 03 - 2020175 FAX : 03 – 2020338
marketing@ethydco-eg.com
www.ethydco-eg.com
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Classroom Training

for Ethylene & Butadiene Technology

‫الشركة المصرية إلنتاج اإليثيلين ومشتقاته‬

» After this session you will understand……..

Purpose of the session

‫الشركة المصرية إلنتاج اإليثيلين ومشتقاته‬

• Heat hydrocarbon feed to cracking temperatures

• Mix feed with dilution steam

• Thermally crack hydrocarbon molecules to produce

• Recover combustion heat to generate SHP Steam

 Cool Charge Gas to 41oC

 Transfer recovered heat to Quench Water for process users

 Condense Dilution Steam as Process Water

 Separates Pyrolysis Gasoline

 To remove acid gases from process water

‫الشركة المصرية إلنتاج اإليثيلين ومشتقاته‬

 4 stage centrifugal compressor

 Remove moisture from charge gas down to < 1 mol ppm

formation of ice and hydrates in the cold equipment

 The dryers function by absorbing the water into synthetic

 One dryer is on stream while the other dryer is being

 Remove such components (mainly Benzene) from

 Maintain the required minimum amount of methane

 Chilling train consists of a series of heat exchangers

 Condensing methane and heavier hydrocarbons which

 Produce a hydrogen rich stream about 90 mol%

 Bottom – C3’s and heavier (minimum C2’s)

 Selectively hydrogenated the Deethanizer net

 Two fundamental reactions occurring :

 conversion of ethylene to ethane (undesirable)

 Acetylene is impurity in ethylene product which must be

 Acetylene conversion reaction is exothermic.

 Temperature control is required due to the possibility of

 Regeneration of each Acetylene Converter is required

 Regeneration is performed using a mixture of steam,

 C2 Green Oil KO Drum:

 Sidedraw – Ethylene product (99.95min wt%)

 Ethylene product is taken as Sidedraw from tray#9

 The 8 trays between the reflux and product draw achieve a

• The function of ethylene storage system is to provide an uninterrupted

• Vaporizer is to vaporize and superheat the liquid ethylene for export to

• The function of ethane storage system is to store ethane

• This is not a continuous operation. It will take place only

‫الشركة المصرية إلنتاج اإليثيلين ومشتقاته‬

• Refrigeration is provided at four nominal temperature levels :

• The refrigeration is supplied by vaporizing the propane at pressures

• The Ethylene Refrigeration System supplies the chilling media for

• Ethylene refrigeration is provided at three nominal temperature

• The ethylene product is used as refrigerant. The refrigeration is

‫الشركة المصرية إلنتاج اإليثيلين ومشتقاته‬

• Produced in Transfer Line Exchangers

• Produced from HP Steam Boilers.

• Mainly supplied by let down from HP steam system

• Mainly supplied by the exhaust from various turbines

• Cooling water system is designed as a two pass distribution network.

• During normal plant operation, fuel gas is generated in Ethylene plant.

• Fuel gas mainly consumed in –

• Excess amount of fuel gas is sent to flare stack.

• Methane Off Gas

• The major uses of Nitrogen is for purging, blanketing etc.

• Nitrogen is supplied from Nitrogen Package.

• Utility water is distributed from OSBL.

• The uses of utility water :

• Potable water is distributed from OSBL.