Process Intensification of Hydrogen Plants and Naphtha Crackers Koos Overwater – VP Hydrogen Product Line & Technologies Dutch Process Intensification Network NL (PIN NL) 13 November 2013 Dutch Process Intensification Network NL (PIN NL) – 13 November 2013 The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited. 1
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Process Intensification of Hydrogen Plants and Naphtha Crackers
Koos Overwater – VP Hydrogen Product Line & Technologies
Dutch Process Intensification Network NL (PIN NL) 13 November 2013Dutch Process Intensification Network NL (PIN NL) – 13 November 2013
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
1
Contents
1. Who we are
2. Hydrogen
3. Ethylene
4. Conclusion
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
2
1. Who we Are
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
3
Technip TodayWith engineering, technologies and project management, on land and at sea, we safely and successfully deliver the best solutions for our clients in the energy business
Worldwide presence with 38,000 people in 48 countries
Industrial assets on all continents, a fleet of 36 vessels (7 of which under construction)
2012 revenue: €8.2 billion
Energy is at the core of TechnipThe presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
4
Three Business Segments, One Technip
Subsea Offshore Onshore Engineering and fabrication of
fixed platforms for shallow waters (TPG 500, Unideck®)
Design, manufacture and supply of deepwater flexible and rigid pipelines, umbilicals and riser
t
Gas treatment and liquefaction (LNG), Gas-to-Liquids (GTL)
Oil refining (refining, hydrogen
Subsea Offshore Onshore
Engineering and fabrication of floating platforms for deep waters (Spar, semi-submersible platforms, FPSO)
L d hi i fl t t h l
systems
Subsea construction, pipeline installation services and Heavy Lift
Six state-of-the-art flexible pipe d / bili l f t i
Oil refining (refining, hydrogen and sulphur units)
Onshore pipelines
Petrochemicals (ethylene, aromatics olefins polymers Leadership in floatover technology
Floating Liquefied Natural Gas (FLNG)
Construction yard
and / or umbilical manufacturing plants
Five spoolbases for reeled pipeline assembly as well as four logistic bases
aromatics, olefins, polymers, fertilizers)
Process technologies (proprietary or through alliances)
Biofuel and renewable energiesbases
A constantly evolving fleet strategically deployed in the world's major offshore markets
Biofuel and renewable energies (including offshore wind)
Non-oil activities (principally in life sciences, metals & mining, construction))
The best solutions across the value chainThe presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
5
A Unique Worldwide Footprint
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
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Around 38,000 People Throughout the World, Growing Close to ClientsGrowing Close to Clients
4,800 +55%
8,900
8,900
3,900+95% 2,500
+67%
+29%
3,550+97%
+112%
750Fleet & others
4,300+65%
+50%
109 Nationalities across 48 countries June 2013109 Nationalities across 48 countries June 2013
Dec. 2006The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
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Technip Onshore Activity
Refining & heavy oil Gas Processing Petrochemicals Others Clean fuels Grassroots Heavy oil upgraders
Gas treatment GTL LNG
Ethylene Polyolefins Aromatics
Mining and metals Infrastructures Buildings
Hydrogen Fertilizers Life sciences,…
Project management consultancyProject management consultancyStrong process engineering capabilities Process technologies (Hydrogen, Ethylene, Refining, Petrochemical & GTL)Solid reputation with NOCs & IOCs
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
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Leading Contractor in Hydrogen Plants
Expertise Multiple feed flexibility
50 years of core H2 competence Proprietary Steam Reformer
Tailored advanced solutions for high Efficiency and Cost-effectiveness
Highest focus on Reliability and HSE Single-point responsibility from
t t i i iconcept to commissioning Global alliance with Air Products for
“over-the-fence” H2 plants
Key references
• High energy efficiency• High reliability• High quality steam
Technip is consistent global leader in
Key references 223,000 Nm3/h (200 mmscfd ) H2 for
Syncrude, Canada (world’s largest single-train plant) 111 000 N 3/h (100 fd ) H f
Recent State-of-the Art Hydrogen plant in Thailand
Technip is consistent global leader in the design and supply of Hydrogen plants, having >35% market share and >260 plants world-wide
111,000 Nm3/h (100 mmscfd ) H2 for PKN, Poland (1st largest plant on multiple feeds)
128,000 Nm3/h (115 mmscfd ) H2 for Air Products USA (with 100 MW pAir Products, USA (with 100 MW cogeneration)
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
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Ethylene - Technip is Licensor & Contractor
Expertise One of four ethylene licensors worldwide
S EPC i Strong EPC experience Proprietary cracking furnace technologies Proprietary separation technologies Alliance with Dow (No 1 in ethylene production) Alliance with Dow (No. 1 in ethylene production) Largest ethylene plants in operation World leader of cracking prediction software;
SPYRO® (70% of the market) Ultra Selective Conversion Furnace Technology
(USC®) Ripple TrayTM Technology
Largest cracking furnaces in the world, Yansab, KSA
With respectively 70 years of expertise for Stone & Webster and 40 years for
Key references Ras Laffan, Qatar, 1300kta, 2010
Yansab, Sabic, KSA, 1380kta, 2009 for Stone & Webster and 40 years for Technip, and a total of 150 grassroots plants, Technip is the leader in the field of ethylene
, , , ,
OL2K, Kuwait, 850kta, 2008
10th complex, 1400kta, 2008
SHARQ 3rd Expansion Project, 1300kta, 2010
NOVA E-3, Joffre, Alberta, Canada (1500kta) 2000
PetroRabigh Ethane Cracker (1350kta), 2010The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
10
Hydrogen Centers
The Hague (formerly KTI)
Los Angeles (formerly KTI)
Delhi (formerly KTI)
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
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Ethylene Centers
The Hague (formerly KTI)London (formerly Stone & Webster)
P i (f l T h i )
Los Angeles (formerly KTI)
Houston (formerly Stone & Webster)
Paris (formerly Technip)
Rome (formerly Technipetrol)
Delhi
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
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Why revamping?
E i ti l tExisting plot area
Existing interfacing of utilities
Operational staff and facilities in place
Maintenance staff in place and familiar with plantMaintenance staff in place and familiar with plant
Plant life cycle extension
Fast track in conjunction with turnaround schedule
Cost effective plant capacity increase
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2. Hydrogen
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Refining Landscape and Role of Hydrogen
“Inconvenient Consequence”
CO2Energy and
Cost IntensityDemand growth
RefineryRefinery Product slate
Crudemix
Heavier &
Sourer
Lighter &
CleanerslatemixSourer Cleaner
HH22
CarbonManagement
B‐o‐B Strategies
Typical 25% of the refinery CO2 emission is related to hydrogen production for crude to product shift
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
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Hydrogen Plant Typical Flow Sheet
SteamVentSteam
BFWSteam Drum
Purge GasTo Burners
LP Steam
Degassifier
Reformer
ConvectionSection
ProductProduct
HydrogenHydrogenPSAPSA
UnitUnit
Process SteamColdSeparator
HydrogenHydrogenDeaerated DM Water
B ilSteam
HTShift
FeedPre-warmer
CW
AirCooler
CoMoX/ZnOReactor
Boiler warmerHot Separator
BFW
FeedPreheat
FeedFeed Preheat
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
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Characteristics of Steam Reforming
Highly endothermic• Requires external heat input
Catalytic process• Tubular reactor• Sensitive to catalyst• Sensitive to catalyst
poisoning: apply feed pre-treatment
Severe conditions• 850 - 920 oC• 850 - 920 oC• 25 - 35 bar
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
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Composite heating/cooling curves
Red line : Hot stream providing heatBl li C ld t i i h tBlue line : Cold stream receiving heat
ture
External heat demand
Tempe
rat
T
St ti
Enthalpy exchangedExternal cooling demand
Steam generation
Enthalpy exchanged
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
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Technip’s Parallel Regenerative Reformer (TPR)
Feed +Feed + steam High temperature
reactor/exchanger
Uses reformer effluent as
Catalyst tubes
Uses reformer effluent as heat source
Advanced process and Lined Shell
mechanical design
Reformer
• Up to 30% more H2• Reduced fuel firing • Reduced Carbon emissionReformer
Effluent Reduced Carbon emission
• Minimized export steam
To process
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TPR Retrofit Model
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25The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
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3. Ethylene
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
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Characteristics of Olefins Production
Strongly endothermic processg y p
Ab b d d t Q 1 6 G l / t f f dAbsorbed duty: Q ~1.6 Gcal / tonne of feed
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A cracking furnace….
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Convection SectionCracking Furnace
Convection Section
~Hydrocarbon Feed
Boiler Feed Water
120 oC
Steam Drum
~Boiler Feed Water Steam Drum
Dilution Steam Cracked Gas toSeparation Section
380 oC
Desuper-heater
BFW
HP Steam Transferline Exchanger
BFW520 oC
Radiant efficiency: 40 – 42%O ll ffi i 92 95 %
850 oC1250 oC620 oC
Radiant Section
Overall efficiency: 92 – 95 %
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
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Feedstock Selection and Ethylene Yields
Ethane C3-LPG C4-LPG Naphtha Gasoil
Feedstock Selection and Ethylene Yields
Feed 125 226 300 334 433
Eth l 100 100 100 100 100Ethylene 100 100 100 100 100
Propylene 0 35 45 52 60
Butadiene 0 6 1 14 18
Raffinate-1 0 4 4 17 21
Benzene 1 8 9 22 18
Other (fuel) 24 73 141 129 216
(Feed and Products in tons per 100 ton of ethylene product)(Feed and Products in tons per 100 ton of ethylene product)
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
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Olefins Complex
HydrogenMixedButanesGasoline
Acid GasMaterial Movements
Utilities
Quench
DrierCompressor andChilling
Steam
Ethylene
PropanePropylene
NAPDConverter
Acid Gas
PrimaryFractionator
FeedsMixedProducts
Quench
Quench Methane
AcetyleneConverter
Ethane
Ethane
Feeds
Fuel Oil
Quench
CrackingFurnacesNaphtha Furnaces
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
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Cracking Technology
“Cracking” is:
non-catalytic governed by reaction kinetics intrinsically non-selective
Hence:
l ki i iti d hi ti t d b t looking primitive and unsophisticated, but requires advanced engineering modelling:
SPYRO®
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
Integrated “SPYRO® / CONVEC / Integrated SPYRO / CONVEC / FIREBOX® / TES®”The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
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SPYRO®: Tool Kit for Cracking Furnace design
SPYRO® enables optimization of :
Coil selection
Coil sizing
against : CONVENTIONAL (MK) GK1 OR GK2 GK3SMK
Yields
Runlengths
Feedstock flexibility
Operating costp g
Investment cost GK4 GK5 GK6
34The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
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Process intensification
GK6 two-lane design
in-line arrangement two-lane arrangemente a a ge e t t o a e a a ge e t
pitch / OD 1.5-1.8 pitch / OD 2.8-3.0
Proper selection of tube spacing allows effective application of 2-lane lay-outeffective application of 2-lane lay-out
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
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GK6 Coil Design
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GK6 Development History
1988-1998: GK5 (for liquid ) and SMK (for gas) furnace widely li d GK3 f i l li tiapplied, GK3 for special applications
1996 Ch ll t d l t f f SRT1 t 1996: Challenge to develop new concept for revamp of SRT1 at DOW TERNEUZEN
Answer: GK6 dual lane concept in combination with furnace overhauloverhaul
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
Selectivity Q2 ‘97 : base Q2 ‘98 : base + 0.24 wt % C2H4( )
Thermal efficiencyQ2 ‘9 8 %
NOx emissionsQ2 ‘9 b Q2 ‘97 : 87 %
Q2 ‘98 : 92 % Q2 ‘97 : base Q2 ‘98 : base - 45 %
Furnace run length Q2 ‘97 : < 35 days
Noise Q2 ‘97 : base
Q2 ‘98 : 60 days Q2 ‘98 : base - 10 %
1998 – 2013: 81 GK6 furnaces builtCracking LPG through VGOCracking LPG through VGOYearly Ethylene capacity 6.9 million tons
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From GK6 to GK7…….
GK6 in 2 lanes
(radiant coil top view)
GK6 in 3 lanes
= GK7= GK7
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Circumferential Distribution of View Factors
1.0180o
0.6
0.7
0.8
0.9
SMK outlet
GK6 3-Lane outlet
GK6 tl t
0 2
0.3
0.4
0.5GK6 outlet
0.0
0.1
0.2
GK7 OUTLETS
90o 270o
GK6 OUTLETS
SMK OUTLETS
0o
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New development: Swirl Flow Technology
GK6 Coil Design with Swirl Flow Technology• Swirl Flow Tubes are small amplitude helical tubesSwirl Flow Tubes are small amplitude helical tubes
• Internal heat transfer considerably higher
• 15% higher capacity15% higher capacity
Swirl Flow Tube performance evaluated using
CFD calculations
Laboratory scale testsThe presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
42
Maximum Tube Metal TemperatureComparisonComparison
GK6 2 GK6 3 GK6 SFTGK6-2 GK6-3 GK6-SFT
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4. Conclusion
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Concluding remarks
For hydrogen plants TPR® technology enables 20-30 % capacity increase while keeping the steam reforming furnace the same
Coil replacements in steam cracking furnaces can enhance capacity by 10 – 100% from the same firebox
Three lane GK6 reduces TMT and increases capacity further
Study new coils like: GK6 - Swirl Flow Tubes (Helical coils)
Process Technology and simulation tools (such as SPYRO®) are key for new developments
Process intensification is a natural way to go for revamps
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.
The presentation herein is intended for presentation purposes and contains confidential information; any unauthorized use, review, transmission, dissemination, distribution or copying is strictly prohibited.