Engineering and technologies

Ethylene plant modernization

Unmatched technologies and optimized solutions

ETHYLENE LEADERSHIP
Grassroots and modernization

Technip is a world leader in ethylene technology for grassroots plants

(including mega-crackers) and plant modernizations / expansions

Ethylene in our daily life

Ethylene, the simplest of olefins, is used as a base product for many syntheses in the petrochemical industry: plastics, solvents,
cosmetics, pneumatics, paints, packaging, etc.
Today, the demand for ethylene is over 150 million tons per year with a growth rate of 3.5% per year. To meet the average yearly
growth rate, new capacity is being provided through grassroots plants and plant expansions.

Ethylene plant modernization

The increased availability of ethane from shale-derived natural gas is driving numerous chemical producers to expand their
ethylene capacity, particularly on the US Gulf Coast. Many of these producers, who are looking for reliable, efficient, low-cost
gas-cracking facilities, are turning to Technip for their solutions.
For complete modernization of existing plants, including modification of the cracking section, compression and separation
sections, Technip offers a unique proven approach, applied successfully in several recent projects using decades of experience.
Since 2000, more than 150 cracking furnaces have been modernized for increased production, energy efficiency and overall
performance, using Technip's technology.

Centers of excellence
Thanks to our highly qualified process engineers and experts, Technip can provide its clients with sound technological expertise
and the ability to design and develop proprietary technologies.
Our centers of ethylene expertise based in the U.S. (California and Texas), the Netherlands, Italy, England and France, supported
by a global procurement network, contribute to Technip’s leadership, experience and resources, making it the partner of choice
for any ethylene project.
Our approach to ethylene
plant modernization Terneuzen - The Netherlands

Ethylene plant optimization, modernization and capacity expansion projects

Ethylene plant modernization projects vary in scope and size. Existing cracking furnaces, even if they originate from
a recent generation, may be redesigned to increase the original ethylene capacity by 20% to more than double.
At the same time, specific feed consumption is drastically reduced, thereby contributing to an attractive low cost of
production per ton of incremental ethylene while improving energy and environmental performance.

The systematic approach to modernization

Technip’s systematic approach to modernization enables an in-depth evaluation of technology options and project
implementation scenarios, leading to the most cost effective, energy efficient and high performance of an existing
ethylene plant.
This approach ensures that bottlenecks are identified and prioritized to ensure a maximum return on investment,
reduction of operating costs and application of the highest standards of HSE, quality and sustainability.

Main steps involved in

the systematic approach Client's objective
to modernization
CAPACITY
Capacity: Equipment technology TARGET Equipment technology

Furnace technology
ENERGY Process technology
Energy: Process technology, key Energy users TARGET Heat exchange network
Rotating machinery
Performance data

Equipment cost
ECONOMIC Plot plan arrangement
Investment: Key equipment cost & schedule & HSE TARGETS Scheduling
Erection cost

Iterations

FINAL REPORT
Technip proprietary equipment

Proprietary furnace technology

Thanks to a variety of associated proprietary
technologies and equipment, Technip offers
ethylene producers the ability to meet
the toughest production related challenges,
reduce capital costs and improve operational
efficiency of existing furnaces.
USC-M SMK GK6 USC-U

Ripple Trays™ Liquid

The furnace technologies contain a wide
range of design options for reliable, flexible
Ripple Trays are designed to avoid the solids
and highly selective solutions best suited to
collection and polymer formation problems
the operational needs of our clients. Standard
that reduce capacity levels in towers that use
design features include radiant coils,
conventional trays in fouling service. Ripple
combustion systems, quench exchangers and
Trays provide outstanding anti-fouling service in
multi-level shutdown features.
a number of applications: more than 150 in
quench towers and more than 90 in caustic Today, the largest gas cracking furnace is more
towers. The use of Ripple Trays improves than 250 KTA, and the largest liquids cracking
column capacity by more than 40%. furnace is 260 KTA.
Vapor

SFT® (Swirl Flow Tube) technology

SFT® technology is designed to boost olefins production through
the highest heat transfer increase at the lowest cost with respect to
increased pressure drop.
SFT® can be implemented in all furnaces to further improve
performance (selectivity, capacity and run-length). Typical capacity
increases of 10 to 30% have been recorded at similar or same
ethylene yield.

Enhanced heat transfer solutions

Technip and Wieland jointly market innovative heat exchangers
and offer two main products:
GEWA-PB enhanced boiling tubes
GEWA-KS enhanced condensing tubes
In ethylene mega-crackers, the Technip-Wieland enhanced heat
exchangers allow further reduction in energy consumption and
CO2 emissions. They have been successfully implemented in
ethylene plants across the world.

Applications using GEWA-PB tubes

Ethylene plant modernization

Key plant modernization
references

Kazanorgsintez
In 2007, Technip completed the modernization and capacity expansion of
three existing ethylene plants in Kazan in the Russian Federation. The capacity
was increased from 400,000 (three plants) to 605,000 tons per year in a single
facility, ensuring 20% of the national Russian ethylene production.

Westlake Calvert City

In early 2013, Technip was awarded the expansion and modernization of the
ethylene cracking furnaces and recovery section of the Westlake ethylene plant in
Calvert City, Kentucky, USA. The ethylene production capacity will be increased by
40% and will use low-cost ethane feedstock instead of propane, due to shale gas
development.

Eastman Chemical Company

In 2012, Technip was selected to provide its technology and engineering services for
a new Ultra Selective Conversion® furnace for Eastman’s ethylene plant in Longview,
Texas, USA. The technology contained a range of design options which provided
flexible solutions for the plant’s operating needs.

Williams – Single-pass furnace revamp

Between 2010 and 2013, Technip proceeded with the phased modernization of the
three existing single-pass furnaces at the Williams ethylene plant in its Geismar
complex, Louisiana, USA. The initial goal of improving run length and furnace
availability was achieved with higher results than planned.

Multi-lane GK6 application

In 2011 Technip was awarded an EPC contract to revamp a furnace section consisting
of single pass furnaces. The project required the upgrading of the Radiant Section
with Technip’s proprietary Three-Lane Coil design. A significant run length increase
together with a capacity increase over 15% was achieved while meeting all the latest
safety and environmental requirements. The Three-Lane Coil technology has
provided a yearly ethylene capacity increase of approximately 25%.
 HEADQUARTERS
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Phone: +33 (0)1 47 78 24 00
Client advantages CONTACTS
Ethylene Business Unit
Jean-Paul LAUGIER
Paris
Phone: +33 (0)1 47 78 34 96
Fax: +33 (0)1 47 78 37 87
Email: jplaugier@technip.com
Our state-of-the-art steam cracking
MAIN OFFICES
furnaces are equipped with the latest coil USA
Texas
designs featuring high selectivity and Technip Stone & Webster Process
Technology, Inc.
Brent SCHIER
excellent on-stream time characteristics. 11740 Katy Freeway - Suite 100
Houston
These furnaces are combined with Texas 77079 - USA
Phone: +1 281 368 4273
separation technologies that offer lowest Fax: +1 281 368 4097
Email: bschier@technip.com
energy consumption, environmental California
Technip Stone & Webster Process
emissions and commercially attractive Technology
Ravi LAL
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Claremont
California 91711-4805 - USA
Phone: +1 909 447 3717
Fax: +1 909 447 3706
Email: rlal@technip.com
UK
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Alyn JONES
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Milton Keynes, MK9-1BA
United Kingdom
Phone: +44 1908 602197
Fax: +44 1908 602366
Email: aljones@technip.com
France
Technip France
Technip Stone & Webster Process
Technology
Yvon SIMON
92973 Paris La Défense Cedex
France
Phone: +33 1 47 78 38 61
Fax: +33 1 47 78 22 55
Email: ysimon@technip.com
Italy
Technip Italy SpA
Technip Stone & Webster Process
Technology
Enzio VIVIANO
68 Viale Castello della Magliana
00148 Roma - Italy
Phone: +39 06 65 98 35 65
Fax: +39 06 65 98 37 12
Email: eviviano@technip.com

Our clients benefit from furnace The Netherlands

Technip Benelux BV
modernization through: Technip Stone & Webster Process
Technology
Increased ethylene capacity or reduced feed Frank OUWERKERK
Boerhaavelaan 31
consumption 2713 HA Zoetermeer
The Netherlands
Phone: +31 79 3293 470
Increased selectivity for better yields Fax: +31 79 3522 551
Red ucing the specific energy consumption per ton of Email: fouwerkerk@technip.com

ethylene
Increased flexibility:
for wider range of feed qualities
in operating severity / conversion
www.technip.com
Increased plant capacity
Reduced maintenance cost with new state-of-the-art
technology
Reduced emissions

Our capabilities and extensive experience in

separation technologies allow
modernization of:
Front-end hydrogenation
Back-end hydrogenation
at lower investment costs and reduced energy consumption.

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Any information contained herein shall not result in any binding obligation on the part of Technip, or
any of its affiliates, and is provided for information purposes only.
Technip - Group Communications - July 2015 - Photo credits: Technip