A FULL- SERVICE ETHYLENE PRODUCT LINE

TECHNIP - COFLEXIP
ETHYLENE TECHNOLOGY
TECHNIP-COFLEXIP offers the ethylene manufacturing industry SINGLESOURCE PROJECT RESPONSIBILITY throughout all phases of a new
grassroots ethylene plant or revamp project, from basic design phase
up to project implementation, start-up and operational services.

THE TECHNOLOGY CORNERSTONES

TECHNIP-COFLEXIP applies unique technology features :
SPYRO FURNACE DESIGN AND OPTIMIZATION SOFTWARE
TECHNIP-COFLEXIP CRACKING FURNACE TECHNOLOGY
PROGRESSIVE SEPARATION TECHNOLOGY
THE T-PAR PROCESS
OPERATIONS SUPPORT SERVICES: e-OSS
- CLX anti-coking services developed jointly with ATOFINA of France,
- Unattended operations concepts.
And for capacity expansion of existing plants :
THE SYSTEMATIC APPROACH TO MODERNIZATION
THE CAPACITY AND PERFORMANCE IMPROVEMENTS OF EXISTING
FURNACES.
The application of these proven proprietary technologies in the design of
modern large-scale grassroots ethylene plants and in the revamp of existing
ethylene crackers offers the plant operator a SAFE, RELIABLE ethylene
plant, easy to operate and maintain, resulting in a very efficient cost saving
olefin production unit for the Owner.
SPYRO , e -OSS and T- PAR are registered trademarks of TECHNIPCOFLEXIP.

Simulation of a large
capacity furnace

THE SPYRO FURNACE DESIGN AND

OPTIMIZATION SOFTWARE
Hydrocarbons are thermally cracked in a
tubular fired reactor, the cracking furnace.
The thermal cracking process requires
high temperatures and to be selective to
the desired light olefins, optimal residence
times and pressure profile have to be selected. Due to the complex nature of the
cracking process, accurate predictive
design and simulation tools are needed
to arrive at the best reactor coil and firebox design.
TECHNIP-COFLEXIP ETHYLENE TECHNOLOGY makes use of TECHNIPs proprietary SPYRO yield prediction program.
The heart of SPYRO is a rigorous kinetic
model describing in detail the thousands
of elementary reactions occurring during
pyrolysis of hydrocarbons, ranging from
light gases such as ethane to heavy oils
such as hydrocracked VGO ( Hydrowax ).
SPYRO is the result of more than 30
years of joint development and continuing
improvements in close cooperation with
the original authors of the program, the
team of Professor Dente in Milan.

SPYRO is now used by the vast majority

of ethylene producers and is applied for
feedstock selection, process scheduling
and production optimization. A large
number of plants run on-line control and
optimization systems having a dedicated
SPYRO program embedded in the system software. The application of the proven
SPYRO program provides detailed information on yields and furnace availability
which can also be used to set up revamp
scenarios for the furnace and downstream
sections of the plant.
For optimum design of large-capacity
GK , and SMK , cracking furnaces, TECHNIP - COFLEXIP applies SPYRO linked
with CFD ( computational fluid dynamics ),
enabling the best design of burner arrangement, cracking coil layout and flue gas
ducting.

THE TECHNIP-COFLEXIP
CRACKING FURNACE
TECHNIP-COFLEXIP CRACKING FURNACES use the proven high selective,
short residence time coils of the GK and
SMK types (originally developed by KTI ).
The Cracking Coils of GK and SMK furnaces are tailored to the specific needs
of the ethylene plant. Normally these are
geared towards the maximum production
of the light olefins, ethylene and propylene.
Additionally, for liquid crackers integrated
with downstream production units,
requirements such as maximum BTX
co-production and feed / products flexibility are also important parameters for
an optimal coil design.
TECHNIP-COFLEXIP CRACKING FURNACES are equipped with a combination
of low NOx bottom and up-shot side wall
burners. The specific GK or SMK coil
arrangement, burner lay-out and the box
dimensions allow for a very large capacity
per furnace cell, while maintaining high
radiant fuel efficiency. In most cases the
application of low NOx burners will meet
emission specifications imposed by country or state legislation. For stringent NOx
specifications, the application of flue gas
NOx removal using low temperature SCR
(selective catalytic NOx removal) can also
be applied.

TECHNIP-COFLEXIP CRACKING FURNACES feature shell - and - tube TLEs

(transfer line exchangers ) as well as double pipe direct quench coolers. High onstream time is achieved by minimizing
mechanical decoke cycles of the TLEs.
In 1999 TECHNIP introduced the GK6 furnace. The GK6 furnace features an 8-8
cracking coil configuration. The GK6 furnace can be equipped with all available
types of quench coolers.
The GK6 cracking furnace is a large capacity furnace with high selectivity and large
on- stream time characteristics at the
lowest possible capital costs. The applied
design tools and expertise contained in
TECHNIP-COFLEXIP ETHYLENE TECHNOLOGY enables TECHNIP-COFLEXIP
to offer its customers an optimized,
tailor-made cracking furnace design
at the LOWEST COST OF
OWNERSHIP for their
specific need.
GK and SMK are
registered trademarks
of TECHNIP-COFLEXIP.

PROGRESSIVE
SEPARATION
PROGRESSIVE SEPARATION technology
is a stepwise separation of the lightest
and the heaviest components in a multicomponent hydrocarbon mixture. It uses
a series of condensate strippers that have
only bottom product purity specifications.
Hence, easy controllability and operability
make multivariable optimizers redundant.
The tailgas from the strippers is processed for recovery of valuable ethylene by
self-contained cryogenic technology. This
concept lends itself well to revamp projects where the standard package can be
implemented without extensively modifying the existing equipment. PROGRESSIVE SEPARATION can be applied for the
revamping of existing back-end and frontend hydrogenation schemes in relation to
either high pressure or low pressure demethanizers.
Due to the intrinsic autostability of new
and revamped ethylene plants equipped
with PROGRESSIVE SEPARATION, startup is extremely smooth and easy. New
and revamped ethylene plants based on
PROGRESSIVE SEPARATION have a track
record of short start-up times, typically 24
hours from first feed intake to full operations.
As one operator put it: You start it up and
you experience a new feeling of comfort
and ease.

THE T-PAR PROCESS

The ethylene recovery and purification
process is energy and investment cost
intensive. For large capacity gas or liquid
feed crackers TECHNIP-COFLEXIP has
developed a unique processing sequence
centered on the efficient acetylene removal
by either hydrogenation or liquid absorption. The main features of this process are:
Controlled acetylene hydrogenation
avoiding runaway reaction and poisoning
Reduced equipment dimensions and
piece count
Reduced compression machine size
and power
Excellent control stability by
process-to-process
heat integration
Very competitive
investment cost.

Main steps involved

in the Systematic Approach
to Modernization

ETHYLENE PLANT
MODERNIZATION,
CAPACITY EXPANSION
AND REVAMP 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
their ethylene capacity by some 20 % to
100 % of original capacity. At the same
time, specific feed consumption is drastically reduced, thereby contributing to an
attractive low cost of production per ton
of incremental ethylene. For complete
modernization of existing ethylene plants,
including revamp of the cracking section,
compression and separation sections,
TECHNIP-COFLEXIP offers a unique proven approach, applied successfully in
several recent revamp projects .

THE SYSTEMATIC
APPROACH
TO MODERNIZATION
The SYSTEMATIC APPROACH TO MODERNIZATION developed and applied by
TECHNIP-COFLEXIP is a project oriented
methodology which enables an indepth
evaluation of the technology options and
project implementation scenarios, leading
to the most economical capacity expansion of the existing ethylene plant. With the
application of the Systematic Approach to
Modernization, bottlenecks in an existing
plant are identified and prioritized such
that a maximum return on a given investment is obtained.

The SYSTEMATIC APPROACH TO MODERNIZATION concept considers the

ethylene plant to consist of a series of
interrelated functional blocks.
To determine the best capacity increase
option versus energy demand and investment cost, to yield lowest cost of production per ton of incremental ethylene,
each functional block can be evaluated
separately on those three targets that are
related to particular technical and economic aspects. The final result of the evaluation is an insight into the relationship

Interrelated functional
blocks of an ethylene plant

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between required investment cost and

target capacity increase. This enables the
choice of the best revamp scenario leading to incremental ethylene production
at lowest cost.

IMPROVEMENT OF
EXISTING CRACKING
FURNACES
When extra capacity is needed in an
existing ethylene plant, to consider one
or more additional furnaces seems to be
the obvious choice. The recoiling or even
complete modernization of existing furnaces however can be a more attractive
option.
Capital cost per ton of incremental ethylene can be significantly reduced, and

furnace fuel consumption, as well as

emissions ( noise, NOx ), can be brought
into line with todays standards.
Many existing furnace designs of different
origins have a large potential for extra ethylene output when a redesign is applied.
This extra ethylene can be more than
double, as is proven by recent real life
revamp references.
TECHNIP-COFLEXIP has the tools and
expertise to quantify this potential and to
study the available revamp options in comparison with newly built furnace capacity.
TECHNIP-COFLEXIP has executed many
furnace conversion projects, resulting in
minimum downtime requirements and
minimum impact on existing plant operations.

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Insight into the relation between

required investment cost
and target capacity increase

OPERATIONS SUPPORT
SERVICES : e-OSS
e-OSS : advanced technology for optimal
operations of ethylene plants.
Under e-OSS , TECHNIP-COFLEXIP is
offering services based on recent advances in automation, control and information
technologies that are dramatically impacting the economics of ethylene plants:
Process observability
Use of Near Infrared Spectroscopy with
the TOPNIR technology to measure at
high frequency the naphtha feed properties, including the PIONA distribution per
number of carbon atoms which is used
by SPYRO .
Real time data reconciliation using the
DATREC technology to close mass and
heat balances and detect abnormal behaviour of instruments.
Unattended operations
Use of field-bus, wireless equipment,
smart sensors to automate most sequential operations.
Abnormal situation management to
detect potentially hazardous situations
before they escalate into incidents.
Equipment health management to remotely perform diagnosis of critical hardware.
Optimal operations
Optimized scheduling of operations
using the FORWARD technology: Feeds
sequencing, de-coking schedule, modes
of operations.
Overall plant accounting and losses
monitoring using the GERA technology.

CLX Anti-coking Services

CLX : On-line pretreatment of radiant coil
to improve cracking furnace performance.
TECHNIP-COFLEXIP and ATOFINA, a subsidiary of TotalFinaElf, have developed a
system to pretreat radiant coils of gascracking furnaces. When applied, the furnace run-length is dramatically improved
and doubling of the run-length is proven
to be achievable.
The CLX system is based upon a proprietary sulphur-silica organic component
mixture and is well tested both on lab
and pilot scales and on an industrial scale
in ATOFINA's commercial installations.
The CLX system is easy to apply. The CLX
ingredients are injected during a very short
period in the dilution steam directly after
the decoke cycle of a running furnace
before next feed is taken in. The system
works optimally when followed by continuous DMDS dosing with the feed.
The CLX system contains chemicals,
which fall in the category of normal paraffins on the aspects of toxicity, safety
and environment.
The CLX system is exclusively available
through TECHNIP-COFLEXIP for new furnace installations and through ATOFINA
for existing installations.
The service which is provided by ATOFINA consists of a dosing kit lease, CLX
inhibitor, maintenance, training and hot
line support.

ETHYLENE PLANT
PROJECT EXECUTION
TECHNIP-COFLEXIP is active in many
areas of the petrochemical industry. For
the ethylene production units, which form
the heart of the petrochemical industry,
TECHNIP-COFLEXIP executes grassroots and modernization projects worldwide. TECHNIP-COFLEXIP offers the full
scope of engineering, procurement and
construction services ranging from the
execution of feasibility studies, FEED
( front end engineering and design ) packages, EPC (engineering, procurement and
construction ) projects up to full LSTK
(lump sum turn key ) project responsibility.
This also includes the supply of proprietary technology, the start-up capabilities
for the olefins plant, its ancillary units and
the associated off-sites and utility sections. TECHNIP-COFLEXIP has the process capabilities and resources to serve
the industry through TECHNIPs multiple
offices in all parts of the world.

Project services offered by TECHNIP to

satisfy the need of the customer are :
TECHNIP-COFLEXIP applies high standard safety related procedures in a constant dialog with the client to arrive at an
intrinsically safe plant throughout all phases of the project, from basic design stage
to start-up and plant hand-over.
TECHNIP-COFLEXIPs recognized expertise in quality assurance and quality
control procedures ensures the future
plant operator is able to run a troublefree plant which is safe and reliable and
which meets its production objectives
from day one.
TECHNIP-COFLEXIP is a world leader in
executing projects under the LSTK ( lump
sum turn key ) contract type with or without financing constraints. TECHNIPCOFLEXIPs global presence and access
to international resources enable TECHNIP
to include local knowledge and domestic
capabilities in its projects teams, thus ensuring a smooth interface with the client.

Financing support

Procurement including purchasing,

expediting and inspection

Project management

Construction

Feasibility study

Start-up services

Conceptual design

Environmental permitting

Cost estimating

HAZOP & HAZAN

Project planning and scheduling

Safety studies

Front end engineering and design

(FEED)

Support in authority approval and

permit procedures

Detailed engineering of equipment,

piping, civil, instrumentation, electrical
and automation

Photographs :
Technip-Coflexip photo library, Synchro Copyright , X.

Cover photo :
GK6 furnace.

ULTIMUM - RCS Nanterre B 402 961 320

Did you know

that apples
produce
ethylene?

So does TECHNIP-COFLEXIP with its in-house technology

TECHNIP - COFLEXIP
Tour Technip - La Dfense 6
92973 Paris La Dfense cedex
Phone: + 33 1 47 78 21 21
Fax: + 33 1 47 78 33 40

TECHNIP FRANCE
Phone: + 33 1 47 78 21 21
Fax: + 33 1 47 78 33 40

TECHNIP ITALY
Phone: + 39 06 65981
Fax: + 39 06 655 1402

TECHNIP BENELUX BV
Phone: + 31 79 329 36 00
Fax: + 31 79 351 35 61

TECHNIP GERMANY
Phone: + 49 211 659-1
Fax: + 49 211 659-3264

TECHNIP MALAYSIA
Phone: + 60 3 21 16 78 88
Fax: + 60 3 21 16 79 99

TECHNIP USA CORP.

Phone: + 1 713 548 4000
Fax: + 1 713 548 4013
Phone: + 1 909 592 4455
Fax: + 1 909 592 3399

www.technip-coflexip.com