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Ethylene Furnace PGC Applications

Ethylene Furnace PGC Applications. Ethylene Plant Cracking Furnace. Takes the feedstock and cracks the molecules in the presence of a catalyst at high temperatures Typically 12 -15 furnaces are used in a single ethylene plant

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Ethylene Furnace PGC Applications

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  1. Ethylene Furnace PGC Applications

  2. Ethylene Plant Cracking Furnace • Takes the feedstock and cracks the molecules in the presence of a catalyst at high temperatures • Typically 12 -15 furnaces are used in a single ethylene plant • The feedstock is typically naphtha (outside U.S.) and ethane / propane mix (within U.S.) • The stream is also run through a caustic wash system to remove H2S and CO2 between compression stages

  3. Improving Furnace Performance with PGC’s • Advanced control of the cracking furnace is critical to the ethylene plant's entire efficiency • “Over-cracking” leads to a premature furnace shutdown • Excessive coke formation on catalyst • “Under-cracking” is a direct reduction in overall production • ABB PGC’s provide the data to the plant's control system to help optimize the right balance for cracking severity

  4. Typical Cracking Furnace in a Ethylene Plant GC #1 GC #2 GC #3

  5. Analytical Instruments – PGC and DRS • The primary analysis point for this measurement is the exit from the transfer line exchangers • Before either analyzer can extract a sample, a specialized sample probe called a "pyrolysis" or "reflux“ probe must first condition it – DRS • GC #1 • Fast analysis, limited measurements, quick update on cracking severity • One PGC per furnace • Possibly backups in case of failures, this is critical data

  6. Analytical Instruments – PGC and DRS (cont.) • GC #2 • More through analysis on furnace effluent • Used by the plant control system to optimize the furnace cracking model • More than one stream from multiple furnaces could be measured on a single GC • GC #3 • For the plants with the ethane / propane feedstocks • Monitor variations in feed compositions • Naphtha feeds take too long to be analyzed by a GC, but there has been some success with FT-NIR analyzers

  7. PGC Analysis Summary

  8. GC #1 Example

  9. GC #1 Chromatogram

  10. GC #2 Example

  11. GC #2 Chromatogram – TCD 1

  12. GC #2 Chromatogram – TCD 2

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