Chemical Fact Sheet

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Other names
Ethylene (compressed)
Ethene (compressed)

Molecular formula
C -H
2 4

Physical properties
Relative Vapour Density: 0.980
Flash Point: –135.0°C
Percent Volatile by volume: 100
Boiling point: –104°C
Explosive Limits: 2.7 mol%–36 mol%
Automatic Ignition Temperature: 543°C in air at atmospheric pressure.

Colourless compressed gas with sweet odour. Slightly soluble in water, soluble in most organic solvents.

End uses
Ethylene is the major raw material at the Orica Botany, Botany, New South Wales Site for the
manufacture of polythene, ethylene oxide and its range of derivatives. Ethylene is also used for the
manufacture of polyester fibre and film, vinyl acetate and a range of alcohols and solvents.

Production process
The principal raw material used in the manufacture of ethylene at the Orica Botany plant is ethane.
This is a light fraction of hydrocarbon extracted from underground gas fields in the Cooper Basin in
South Australia. This is piped directly to Botany in a dedicated pipeline commissioned in 1996. The plant
is also capable of using naphtha, a light fraction produced in the distillation of crude oil and purchased
from the local refinery, or liquefied petroleum gas (LPG).
The production of ethylene occurs over a number of different process stages:
1 Cracking and Steam Generation

The feed (principally ethane) is mixed with steam, and cracked at 850°C in the furnace coils.
The furnace effluent gas is cooled in transfer line exchangers (TLE's) where the heat removed
from the cracked gas is used to raise 10,000 kPa steam.
2 Quench

The cracked gas is further cooled by direct injection of quench oil and then by passage up the
quench oil tower where it is cooled by circulating quench oil and, in the top section, by a gasoline
reflux stream. The heat recovered in the quench oil is used to heat various other process
streams. The cracked gas is further cooled in the quench water tower, against circulating quench
water. The heat recovered in the quench water is used to reboil three distillation columns. Also in
the quench water tower, gasoline and water are condensed out. The gasoline is used for reflux in
2 Ethylene

the quench oil tower, and the water is used to raise dilution stream which is then returned to the
cracking furnaces.
3 Compression

The gas is cooled between each stage, and water and gasoline condensed. Between the fourth
and fifth stages, the gas is scrubbed with a caustic soda solution to remove acid gases H2S and
CO2.
4 Distillation

The compressed gas is cooled, and a liquid fraction is condensed out. This stream is dried, and
fed to the de-ethanizers. The gas fraction is also dried (to less than 1ppm) and further cooled in
several stages before being fed to the de-ethanizers. In the de-ethanizers, two columns are used
to separate a C2 and lighter stream (ethylene, methane etc) from a C3 and heavier stream
(Propylene, Butanes etc.). The C3 + stream is fed to the depropanizer and debutanizer which
yield propylene and butadiene-rich streams respectively. The C2 and lighter stream is fed
forward to the Acetylene Hydrogenation reactors, where acetylene is converted to ethylene in
two packed-bed adiabatic reactors, using a Palladium catalyst.

Next the gases are fed to the cold section where they are progressively cooled and condensed
until only hydrogen remains uncondensed. The cooling is achieved using ethylene refrigerant
and by expansion of some of the liquid formed (the Joule-Thompson effect). The liquid from the
cold section is fed to the demethanizer, which removes the methane for eventual use as a fuel
gas. The bottoms from the demethanizer is fed to the C2 splitter, which separates ethylene from
ethane. The splitter is integrated with the ethylene refrigeration system and the column
overheads eventually become ethylene product. The ethane is returned to the furnaces for
cracking.
During the production of ethylene, several different chemicals are also co-produced. The most important
is propylene, which is used at the Montell plant at Clyde in the manufacture of polypropylene. The
quantity required is greater than that produced in the manufacture of ethylene and additional propylene is
obtained from the local refinery at Kurnell by pipeline (under Botany Bay). This material is dried and de-
sulphurised then purified in the C3 splitter, where the overheads are propylene which are road tankered
to the Montell Polypropylene plant. The bottoms are Propane which is returned to the suppliers for use in
the local LPG markets.
Other products include a mixed C4 stream which is hydrogenated and recycled as feedstock and a
pyrolysis gasoline stream which is exported

Handling
Storage and transport
Ethylene is classified as a flammable gas for the purpose of transport. Refer to State Regulations for
storage and transport requirements.
The product must not be loaded with flammable liquids (Class 3) in bulk, flammable solids (Class 4) or
oxidising agents (Class 5).
Personal protection
Wear impervious gloves, full face shield or chemical goggles, rubber boots and overalls. Use with
adequate ventilation. If inhalation risk exists wear air supplied mask.
Avoid all contat with liquid product to prevent cold burn situations.
Spills
Warn occupants down wind of explosion hazard. Shut off all possible sources of ignition. For liquid
leakage wear full protective equipment, including impervious footwear. Clear area of all unprotected
personnel. Increase ventilation. Shut off leak if possible without risk. Cover with alcohol-type foam to
prevent ignition and reduce evaporation. Use water spray or steam to disperse vapour. DO NOT spray
Ethylene 3

water directly onto the liquid pool. Contain. Use sand and earth. Prevent run-off into drains or waterways.
If contamination of sewers or waterways has occurred advise emergency services.
Disposal
Vapour should be discharged to a burning flare. Otherwise, dissipate gas in remote area using water or
steam jets or spray to ensure that concentration is below explosive limit.
Fire/explosion hazard
Flammable. Stop flow of gas if possible. Otherwise, allow gas to burn and avoid explosion risk. Heating
of containers can cause hydrostatic failure or metal yield leading to violent rupture. Keep containers cool
with water spray. Where possible, remove cool containers from the path of the fire. Use water spray/fog
for gas isolation purposes. Use dry chemical powder on residual fires.

Safety data

Health effects
Short term exposure by inhalation is considered to be practically non-harmful.
Skin and eyes
Contact with liquid ethylene will produce freezing injury to skin and eye tissue.
Inhalation
Ethylene vapour is an asphyxiant, depriving respired air of oxygen. At moderate to high concentrations,
inhalation of vapour can result in headaches, dizziness and possible nausea.
As with any chemical, ingestion, inhalation and prolonged or repeated skin contact should be avoided.

First aid
Skin
Immediately wash contaminated skin with plenty of water. Remove contaminated clothing. Seek
immediate medical assistance. In case of 'cold burns' immerse affected area in warm water for at least
15 minutes.
Eyes
Immediately irrigate with copious quantities of water for at least 15 minutes. Eyelids to be held open.
Remove contaminated clothing and wash contaminated skin. Urgently seek medical assistance.
Transport to hospital or medical centre.
Inhalation
Remove from exposure—avoid becoming a casualty. Remove contaminated clothing and loosen
remaining clothing. Allow patient to assume most comfortable position and keep warm. Keep at rest until
fully recovered. If breathing laboured and patient cyanotic (blue), ensure airways are clear and have
qualified person give oxygen through a face mask. If breathing has stopped apply artificial respiration at
once. In the event of cardiac arrest, apply external cardiac massage. Seek medical advice.
Ventilation
Use with adequate ventilation. DO NOT enter confined spaces where vapour may have collected.
Maintain concentration below recommended exposure limit.

Attachment
Ethylene production process.
Orica Limited
Revised January 1999

Copyright 1991–1999 Orica Limited, ACN 004 145 868.

 ETHYLENE PRODUCTION: PROCESS FLOW DIAGRAM
Hydrogen
Fuel Gas
Methane

Ethylene
Product
C1/C2 Separation
Low DEMETHANISER
Acetylene
Temperature
hydrogenation
Section
C2 SPLITTER

C2-
C2 Fraction

Propylene to
Polypropylene Ethane
Plant Recycle
Refinery
Drying and
Grade Desulphurisation
Propylene
C2/C3 Separation C3 SPLITTER
C3 Fraction
DEETHANISER
1 and 2

Propane Sales
C3/C4 Separation
DEPROPANISER
C3+ C4 C4
Hydrogenation
Pre Cooling
and Drying C4+ C4 recycle
to furnaces
C4/C5 Separation
DEBUTANISER
Acid Gas Removal
- Caustic Scrubbing
and Spent Caustic
Treatment C5+
Gasoline Gasoline

Hydrocarbon C5+ Hydrogenation

Stripper
Cracked Gas
Compression

Dilution Steam Quench Water

Generation System
Fuel Gas

Ethane CRACKING
FURNACES OIL FRACTIONATION
Ethane
Recycle

Fuel Oil

Quench Oil
Cycle

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