Advances in Ethane Cracking Gabriel Castaneda, P.E. Gabchem Solutions (713) 873 1708 Gabriel@gabcheminc.com Linde

Table of Contents Economics Process Overview Areas of Improvement Energy Consumption Reliability / Operational Issues Compression and Fouling Refrigeration Furnaces

Economical Advantage Mark Eramo, IHS Low gas prices thanks to hydraulic fracturing technology Mark Eramo, IHS

Ethylene Capacity Expansions Company Project Capacity Location Start-up Sasol New cracker 1.5m tonnes Lake Charles, Louisiana 2017 Occidental Chemical/Mexichem 544,000 tonnes Ingleside, Texas Feb-17 ExxonMobil Chemical Baytown, Texas Late 2016 Chevron Phillips Chemical Cedar Bayou, Texas mid-late 2017 Dow Chemical Freeport, Texas Shell 1m tonnes Monaca, Pennsylvania 2019-2020* Formosa Plastics 1.2m tonnes Point Comfort, Texas Williams Expansion 272,158 tonnes Geismar, Louisiana Q4 2013** INEOS Debottleneck 115,000 tonnes Chocolate Bayou, Texas end 2013 Westlake Chemical 113,399 tonnes 2014 82,000 tonnes Calvert City, Kentucky Q2 2014 LyondellBasell 363,000 tonnes La Porte, Texas mid-2014 113,000 tonnes Channelview, Texas 2015 Corpus Christi, Texas Late 2015 BASF Fina Petrochemicals 180,000 tonnes Port Arthur, Texas Joseph Chang, ICIS * ICIS Estimate **did not consider 2013 explosion

Considered Expansions Company Project Capacity Location Start-up LyondellBasell New cracker World-scale US NA Hanwha Chemical Axiall Indorama Ventures 1.3m tonnes SABIC Braskem PTT Global Chemical Aither Chemicals 272,000 tonnes US Northeast 2016 NOVA Chemicals Expansion Corunna, Ontario, Canada Joseph Chang, ICIS

Process Overview Emerson

Areas to Improve Energy Consumption Reliability / Operational Issues

Energy Consumption, Ethane Cracking Operation Fraction Pyrolysis 65 Compression 15 Separation 20 Fuel gas provides most of the energy Tao Ren, Utrecht University

Production Loss due Reliability Solomon Associates

Equipment Fouling GE, Dorf Ketal

Polymerization Rate Constant 120oF 160oF 200oF 230oF ABB/Lummus

Fouling Deposits in Compressors Labyrinth Ends Balance Piston Inserts Return channel Impeller Mitsubishi Hans Joachim Moellering Siemens

Fouling Control in Cracked Gas Compressors Hans Joachim Moellering Siemens

Water and Wash Oil Injection Oil composition > 80% aromatics Hans Joachim Moellering Siemens

Water Injection in Compressors Hans Joachim Moellering Siemens

Refrigeration

Ethane Cracker Process Flow Diagram Chevron Phillips

Single Refrigerant Chevron Phillips Frank Del Nogal Ethylene : 3 levels Propylene : 2 levels Chevron Phillips Frank Del Nogal

Cascade Process Environment Propylene Ethylene Process Ethylene and propylene used

Mixed Refrigerant

Cooling Curve of Gas Natural gas MR: 8% N2 45% C1,45%C2, 2% C3 Cracked Gas MR: Methane/Ethylene, Methane/Ethylene/Propylene 7-20% Methane, 7-20% ethylene, 50-86 %propylene Lee

Natural Gas Cooling Curves Double Mixed Refrigerant Mixed and Single Refrigerant Single Refrigerant Mixed Refrigerant Il Moon et al

Efficient Heat Exchanger Arrangement used with Mixed Refrigerants Kettle vs BAHE Frank Del Nogal

Olefin Plant Refrigeration System In 2010 there were 13 mixed refrigeration systems in operation and 9 more in engineering Lummus US 6,637,237

Coalescers Pall

Furnace Linde

Tubes 1-2.5 in DI tubes Length reduced to about 30-40 feet Operate between 1900-2100oF Residence time : 0.2 seconds Element C Ni Cr Mn Al Ta Ti Si % min .35 38 28 .5 - Add 0.5 % max .6 42 32 1.5 3 add 2 Carburization resistance, longer run lengths Sandvik G Verdier, Manoir Industries

Gas Chromatography Mass Chromatograph vs GC Emerson

Coke Resistant Coating CAMOL Coating, BASF, Quantiam majid.keyvani@lyondellbasell.com

Camol Coating Benefits Quantiam / BASF

Effect of Fins on Furnace Efficiency Nova Chemicals, US 2012/0251407 A1

Thanks! Gabriel Castaneda, P.E. 713 873 1708 Gabriel@gabcheminc.com

Water Injection In Compressors Hans Joachim Moellering Siemens

Steam Cracking Furnace A Chauvel

Heat Exchanger for Cracked Gas US 2008/0121383

Linde Furnace US 20030070963

KM Van Geem

Steam Cracking Furnace Nova Chemicals, US 2012/0251407 A1

Mixed Refrigerant Loop for Ethylene Process M Amidpour

Composite Curve of System

Selection of Mixed Refrigerant Composition C1 to C4 and Nitrogen

Cracked Gas Compressor Failures/ Problems Overview Bill Broussard Emerson

Steam Cracking Furnace A Chauvel

Linde Furnace US 20030070963

Cold Separation of Products A Chauvel

Hydraulic Fracturing Propublica.org

North America New Polyethylene Projects Sarpol

Global Polyethylene Capacity Additions Sorpol

Furnace Main Components Linde

Hydrocarbon Pyrolisis Furnace US 7718052

Heat Exchanger for Cracked Gas US 2008/0121383

Announced Capacity, 1000 MT IHS 2012-2014 2016-2020   2012-2014 2016-2020 BASF/Total (Port Arthur) 180 Chevron Phillips (Cedar Bayou) 1500 Dow (Taft/ Freeport) 396 1500* Eastman 90 Equistar (all locations) 521 Exxon (Baytown) Formosa (Point Comfort) 800 Ineos (Chocolate Bayou) 107 Oxy (Ingleside) 550* Sasol (Lake Charles) 1400 Shell (Northeast) 1000*% Westlake (Lake Charles / Calvert City) 310 Williams (Geismar) 300 Nova (Sarnia) 250* Braskem / Idesa (Mexico) 1000 Total 1894 9500 Cummulative Total 11394 IHS

Coalescers/ Filters in Ethane Cracking Process Pall

Ethylene Production Costs, Naphtha, 2010 item dollars/ton naphtha 1651.1 catalyt and chemicals 3.6 raw materials cost 1655 fuel 195.1 high pressure steam, (40 bar) 24.1 cooling water 14 electricity 5.9 other utilities 0.3 total utilities 239.4 total variable costs 1894.4 direct fixed cost 38.8 allocated fixed cost 31.8 total costs 1965