Sulzer Chemtech

Sulzer Chemtech Pte Ltd

Key to Success in Ethylene Plant Quench Water Column Revamp

Lee Siang Hua Senior Process Engineer

14th ROPTC

PATTAYA, THAILAND

October 19 22, 2009

Content
Sulzer Chemtech

Background Process Evaluation Column Internals Selection Mechanical Design Job List

14th ROPTC_Sulzer | 19-22 Oct 09 | slide 2

Content
Sulzer Chemtech

Background Process Evaluation Column Internals Selection Mechanical Design Job List

14th ROPTC_Sulzer | 19-22 Oct 09 | slide 3

Background
Sulzer Chemtech

A Naphtha Cracker in Asia Pacific intended to revamp the existing quench water tower from random packing to structured packing. Sulzer worked closely with customer and provide full support on process and hydraulic evaluation of the column. Two cases was considered , i.e. base case and alternative case, to ensure the revamp will enable the column to handle slightly changes of feedstock and flexibility in operations. The revamp study was conducted in second quarter of 2007, installation in first quarter 2008 and the column was started-up successfully in Mid 2008.

14th ROPTC_Sulzer | 19-22 Oct 09 | slide 4

Background
Sulzer Chemtech

Furnace

Oil Quench

Water Quench

3-Stage Gas Compression

Caustic Tower

4th-Stage Gas Compression

Feedstock e.g. Naphtha, Ethane, Gasoil

Olefins

Steam Caustic Soda

Water Dehydration Unit:

Activated alumina

Fuel Oil Aromatics

Molsieves TEG System

PFD - HOT SECTION

Cold Section

Refrigeration Unit

14th ROPTC_Sulzer | 19-22 Oct 09 | slide 5

Background
Sulzer Chemtech

Demethanizer

Deethanizer
C2H2 Acetylene

C2 Splitter

Depropanizer

C3 Splitter

Debutanizer

PFD - COLD SECTION

Acetylene Recovery
catalytic hydrogenation

EO Plant C2H4 Ethylene C3H6 Propylene

CH4, H2

Hot Section

C2Hx C3Hx

C2H6 Ethane (recycle) C2+ C3+

C3H8 Propane C4+ C5+

14th ROPTC_Sulzer | 19-22 Oct 09 | slide 6

Background
Sulzer Chemtech

ID 5.3m

Reason for Revamp

1. Replacement of existing internals due to timeworn Upgrade of internals for more flexibility, higher capacity and lower pressure drop

Random packing

2.
Random packing Radial vapor inlet device

ID 6.7m

14th ROPTC_Sulzer | 19-22 Oct 09 | slide 7

Content
Sulzer Chemtech

Background Process Evaluation Column Internals Selection Mechanical Design Job List

14th ROPTC_Sulzer | 19-22 Oct 09 | slide 8

Process Evaluation
Sulzer Chemtech
Figure: Diagram Direct Heat Nusselt Transfer Correlation
220

200

Heat exchange calculation based on paper "Direct Heat and Mass Transfer in Structured Packings" by L.Spiegel, P.Bomio and R.Hunkeler in Chem. Eng. Process. 35 (1996) 479-485 Experimental tests with the system air/water and air/dibutylphthalate
Bed2-btm

180

160

Calculation of the overall heat transfer coefficient

Nusselt/Prandtl^(1/3)

140

120

100

80 Be d2-top 60 Be d1-top Be d1-btm

40

20

Plotting the results of this tests against the Reynolds Number shows the good correspondence of the different calculation methods and the possibility of a regression analysis
20000 25000

0 0 5000 10000 15000 Re ynolds Num be r

Examination of different industrial columns shows good results with this calculation

14th ROPTC_Sulzer | 19-22 Oct 09 | slide 9

Process Evaluation
Sulzer Chemtech

Packing hydraulic calculation result with Sulzer hydraulic program The % capacity < Sulzer guideline of 80%.
14th ROPTC_Sulzer | 19-22 Oct 09 | slide 10

Process Evaluation
Sulzer Chemtech

Design
ID 5.3m < 33C p = 50 mbar MELLAPAK 880 kg/h 31C T = 2C

S/U Operation
ID 5.3m 30.5C 894 kg/h 29C MELLAPAK T = 1.5C

p = 2.83 mbar 943 kg/h 53C p = 5.37 mbar Schoepentoeter 90C

MELLAPAK MELLAGRID 596 t/h, 98C

880 kg/h 43C

MELLAPAK MELLAGRID 504 t/h, 106C

Schoepentoeter 89C

ID 6.7m

ID 6.7m
14th ROPTC_Sulzer | 19-22 Oct 09 | slide 11

Content
Sulzer Chemtech

Revamp Objective Process Evaluation Column Internals Selection Mechanical Design Job List Summary

14th ROPTC_Sulzer | 19-22 Oct 09 | slide 12

Selection of Internals
Sulzer Chemtech

Key Characteristics: Sensitivity to fouling Heat and mass transfer Pressure drop essential Capacity Concerns: Capacity limitation with existing internals Fouling problems Vapor and liquid mal distribution Bad efficiencies High energy consumption

14th ROPTC_Sulzer | 19-22 Oct 09 | slide 13

Selection of Internals
Sulzer Chemtech

Packing

Top mixed bed Mellapak M2X 2 m height Mellapak M170.X 0.9 m height

Bottom mixed bed Mellapak M170.X 2.5 m height Mellagrid MG90.X 0.5 m height

14th ROPTC_Sulzer | 19-22 Oct 09 | slide 14

Selection of Internals
Sulzer Chemtech

Mellapak or MellapakPlus
High Mass Transfer Efficiency Smooth Surface Good resistance to fouling Suitable for uplift resistance if needed

Mellagrid:
Geometrical structure as Mellapak Higher efficiency than conventional grids Smooth surface Great resistance to fouling and or Coking High mechanical stability Suitable for dismantling and cleaning via water and or steam jetting
14th ROPTC_Sulzer | 19-22 Oct 09 | slide 15

Selection of Internals
Sulzer Chemtech

Liquid Distributors

VKH2 distributor with drip tube IV pre-distrubutors H-pipes transmit liquid to pre-distributors Hats on arm channels

Advantages

Good for high liquid loads, e.g. greater than 20 m3/m2h Liquid is discharged laterally from rectangular channels onto the packing

Revamp issues

Large 14" and 20" feed pipes had to be modified and re-used Welding on-site for modification of existing feed pipe

14th ROPTC_Sulzer | 19-22 Oct 09 | slide 16

Selection of Internals
Sulzer Chemtech

Vapor Inlet

Schoepentoeter vane inlet device High velocity vapor feed in 49" nozzle F-factor of 88 Pa0.5

Advantages

Even distribution of vapor ensures proper vapor / liquid contact Eliminates erosion of column shell Can be segmented to fir through vapor nozzle

14th ROPTC_Sulzer | 19-22 Oct 09 | slide 17

Content
Sulzer Chemtech

Background Process Evaluation Column Internals Selection Mechanical Design Job List

14th ROPTC_Sulzer | 19-22 Oct 09 | slide 18

Mechanical Design
Sulzer Chemtech

Modified and reused existing feed pipe New H-pipe from first elbow, welding to existing feed pipe at site New trough type liquid distributor New mixed bed (Mellapak) for better capacity and better heat exchange Reuse existing support beam Modified and reused existing feed pipe New H-pipe from first flange New trough type liquid distributor New mixed bed for better capacity and better heat exchange Reuse existing support beam New Schoepentoeter radial vapor inlet device
14th ROPTC_Sulzer | 19-22 Oct 09 | slide 19

Content
Sulzer Chemtech

Background Process Evaluation Column Internals Selection Mechanical Design Job List

14th ROPTC_Sulzer | 19-22 Oct 09 | slide 20

Job List
Sulzer Chemtech

1 2

Gas Cracker Grassroots

14th ROPTC_Sulzer | 19-22 Oct 09 | slide 21

Job List
Sulzer Chemtech

1 2

Gas Cracker Grassroots

14th ROPTC_Sulzer | 19-22 Oct 09 | slide 22

THANKS FOR ATTENTION!

Sulzer Chemtech

SULZER YOUR SPECIALIST FOR MTT IN OLEFIN PLANTS

14th ROPTC_Sulzer | 19-22 Oct 09 | slide 23