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Petrochemical Process HandBook
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0REMIER 3PONSOR
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'ULF 0UBLISHING #OMPANY
02/'2!- ,)#%.3% !'2%%-%.4
9/5 3(/5,$ 2%!$ 4(% 4%2-3 !.$ #/.$)4)/.3 #!2%&5,,9 "%&/2% 53).' 4()3
!00,)#!4)/. ).34!,,).' 4(% 02/'2!- ).$)#!4%3 9/52 !##%04!.#% /& 4(%3%
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0REMIER 3PONSOR
0ROCESSES INDEX
!CETIC ACID
!CRYLONITRILE
!LKYLBENZENE
!LPHA OLElNS
!MMONIA
!NILINE
!ROMATICS
!ROMATICS EXTRACTION
!ROMATICS EXTRACTIVE DISTILLATION
!ROMATICS RECOVERY
"ENZENE
"ISPHENOL !
"48 AROMATICS
"UTADIENE EXTRACTION
"UTADIENE
"UTANEDIOL
"UTENE
"UTYRALDEHYDE N AND I
#UMENE
#YCLOHEXANE
$I
METHYL ETHER $-%
$IMETHYL TEREPHTHALATE
$IMETHYLFORMAMIDE
%$#
%THANOLAMINES
%THERS
%THERS-4"%
%THYL ACETATE
%THYLBENZENE
%THYLENE
%THYLENE FEED
%THYLENE GLYCOL
%THYLENE OXIDE
%THYLENE OXIDE%THYLENE GLYCOLS
&ORMALDEHYDE
(YDROGEN
-ALEIC ANHYDRIDE
-ETHANOL
-ETHYLAMINES
-IXED XYLENES
M
8YLENE
/CTENES
/LElNS
0ARAFlN NORMAL
0ARAXYLENE
0ARAXYLENE CRYSTALLIZATION
0HENOL
0HTHALIC ANHYDRIDE
0OLYALKYLENE TEREPHTHALATES
0OLYCAPROAMIDE
0OLYESTERS
0OLYETHYLENE
0OLYPROPYLENE
0OLYSTYRENE
0ROPYLENE
06# SUSPENSION
0YROLYSIS GASOLINE
3TYRENE
3TYRENE ACRYLONITRILE
4EREPHTHALIC ACID
5PGRADING STEAM CRACKER # CUTS
5PGRADING STEAM CRACKER # CUTS
5REA
5REA
FORMALDEHYDE
6#- BY THERMAL CRACKING OF %$#
6#- REMOVAL
7ET AIR OXIDATION
8YLENE ISOMERIZATION
0REMIER 3PONSOR
#OMPANY INDEX
!"" ,UMMUS 'LOBAL
!KER +VAERNER
!XENS
!XENS .!
"ADGER ,ICENSING ,,#
"ASELL 0OLYOLElNS
"!3& !'
"0
"0 #HEMICALS
#$4%#(
#HEMICAL 2ESEARCH ,ICENSING
#HISSO #ORP
#HIYODA #ORP
$AVY 0ROCESS 4ECHNOLOGY
%XXON-OBIL #HEMICAL
%XXON-OBIL #HEMICAL 4ECHNOLOGY ,ICENSING ,,#
'% 0LASTICS
'4# 4ECHNOLOGY
(ALDOR 4OPSE !3
(YDRO
)LLA )NTERNATIONAL
*APAN 0OLYPROPYLENE #ORP
*OHNSON -ATTHEY #ATALYSTS
*OHNSON -ATTHEY 0,#
+ELLOGG "ROWN 2OOT )NC
,INDE !'
,ONZA 'ROUP
,URGI !'
,YONDELL #HEMICAL #O
-ITSUBISHI #HEMICAL #ORP
-ITSUI #HEMICALS )NC
.IPPON 0ETROCHEMICALS #O ,TD
.IRO 0ROCESS 4ECHNOLOGY "6
./6! #HEMICALS )NTERNATIONAL 3!
.OVOLEN 4ECHNOLOGY (OLDINGS #6
/NE 3YNERGY
3!")#
3CIENTIlC $ESIGN #OMPANY )NC
3HELL )NTERNATIONAL #HEMICALS "6
3INOPEC 2ESEARCH )NSTITUTE OF 0ETROLEUM 0ROCESSING
3TAMICARBON "6
3TONE 7EBSTER )NC
3UD
#HEMIE )NC
3UNOCO
4ECHNIP
4HE $OW #HEMICAL #O
4OYO %NGINEERING #ORP
5HDE 'MB(
5HDE )NVENTA
&ISCHER
5NION #ARBIDE #ORP
5NIVATION 4ECHNOLOGIES
5/0 ,,#
6INNOLIT
0ROCESSES
!XENS !XENS IS A RElNING PETROCHEMICAL AND
NATURAL GAS MARKET FOCUSED SUPPLIER OF PROCESS TECH
NOLOGY CATALYSTS ADSORBENTS AND SERVICES BACKED
BY NEARLY YEARS OF COMMERCIAL SUCCESS !XENS IS A
WORLD LEADER IN SEVERAL AREAS SUCH AS
!LPHA OLElNS
!ROMATICS RECOVERY
"ENZENE
"48 AROMATICS
s 0ETROLEUM HYDROTREATING HYDROCONVERSION
"UTENE
s &## GASOLINE DESULFURIZATION
#YCLOHEXANE
s #ATALYTIC 2EFORMING
%THYLENE FEED
s "48 BENZENE TOLUENE XYLENES PRODUCTION
PURIlCATION
-IXED XYLENES
/CTENES
s 3ELECTIVE (YDROGENATION OF OLElN CUTS
0ARAXYLENE
s 3ULFUR RECOVERY CATALYSTS
0ARAXYLENE
!XENS IS A FULLY OWNED SUBSIDIARY OF )&0
0ROPYLENE
0YROLYSIS GASOLINE
5PGRADING STEAM CRACKER # CUTS
5PGRADING STEAM CRACKER # CUTS
8YLENE ISOMERIZATION
Acetic
acid
Application: 4O PRODUCE ACETIC ACID USING THE PROCESS !#%4)#! -ETHA
NOL AND CARBON MONOXIDE #/ ARE REACTED WITH THE CARBONYLATION REAC
TION USING A HETEROGENEOUS 2H CATALYST
Description: &RESH METHANOL IS SPLIT INTO TWO STREAMS AND IS CONTACTED
WITH REACTOR OFFGAS IN THE HIGH
PRESSURE ABSORBER AND LIGHT GASES
IN THE LOW
PRESSURE ABSORBER 4HE METHANOL EXITING THE ABSORBERS
ARE RECOMBINED AND MIXED WITH THE RECYCLE LIQUID FROM THE RECYCLE
SURGE DRUM 4HIS STREAM IS CHARGED TO A UNIQUE BUBBLE
COLUMN
REACTOR
#ARBON MONOXIDE IS COMPRESSED AND SPARGED INTO THE REACTOR RISER
4HE REACTOR HAS NO MECHANICAL MOVING PARTS AND IS FREE FROM LEAKAGE
MAINTENANCE PROBLEMS 4HE !#%4)#! #ATALYST IS AN IMMOBILIZED 2H
COMPLEX CATALYST ON SOLID SUPPORT WHICH OFFERS HIGHER ACTIVITY AND OP
ERATES UNDER LESS WATER CONDITIONS IN THE SYSTEM DUE TO HETEROGENEOUS
SYSTEM AND THEREFORE THE SYSTEM HAS MUCH LESS CORROSIVITY
2EACTOR EFm UENT LIQUID IS WITHDRAWN AND m ASH
VAPORIZED IN THE &LASH
ER 4HE VAPORIZED CRUDE ACETIC ACID IS SENT TO THE DEHYDRATION COLUMN
TO REMOVE WATER AND ANY LIGHT GASES $RIED ACETIC ACID IS ROUTED TO
THE l NISHING COLUMN WHERE HEAVY BYPRODUCTS ARE REMOVED IN THE
BOTTOM DRAW OFF 4HE l NISHED ACETIC
ACID PRODUCT IS TREATED TO REMOVE
TRACE IODIDE COMPONENTS AT THE IODIDE REMOVAL UNIT
6APOR STREAMS FROM THE DEHYDRATION COLUMN OVERHEAD CONTACTED
WITH METHANOL IN THE LOW
PRESSURE ABSORBER 5NCONVERTED #/ METH
ANE OTHER LIGHT BYPRODUCTS EXITING IN THE VAPOR OUTLETS OF THE HIGH
AND
LOW
PRESSURE ABSORBERS AND HEAVY BYPRODUCTS FROM THE l NISHING COLUMN
ARE SENT TO THE INCINERATOR WITH SCRUBBER
&EED AND UTILITY CONSUMPTION
-ETHANOL MTMT
#/ MTMT
0OWER #/ 3UPPLY +' K7HMT
7ATER COOLING MMT
3TEAM PSIG MTMT
-ETHANOL FEED
3TEAM
0ROCESS
COOLER
!CETIC ACID PRODUCT
"&7
#/ FEED
!IR
&UEL
&LUE GAS
-AKEUP #()
Commercial
plant: /NE UNIT IS UNDER CONSTRUCTION FOR A #HINESE CLIENT
Reference: h!CETIC !CID 0ROCESS #ATALYZED BY )ONICALLY )MMOBILIZED 2HO
DIUM #OMPLEX TO 3OLID 2ESIN 3UPPORT v *OURNAL OF #HEMICAL %NGINEERING
OF *APAN 6OL PP n
h4HE #HIYODA5/0 !#%4)#! PROCESS FOR THE PRODUCTION OF ACETIC
ACID v TH !NNUAL 3AUDI
*APANESE 3YMPOSIUM ON #ATALYSTS IN 0ETROLEUM
2El NING AND 0ETROCHEMICALS +&50-
2) $HAHRAN 3AUDI !RABIA .OV
n
Licensor: #HIYODA #ORP
Acrylonitrile
Application: ! PROCESS TO PRODUCE HIGH
PURITY ACRYLONITRILE AND HIGH
PU
RITY HYDROGEN CYANIDE FROM PROPYLENE AMMONIA AND AIR 2ECOVERY OF
BYPRODUCT ACETONITRILE IS OPTIONAL
2EACTION
1UENCH
0URIFICATION
(#. PRODUCT
3PENT AIR
Description: 0ROPYLENE AMMONIA AND AIR ARE FED TO A m UIDIZED BED RE
ACTOR TO PRODUCE ACRYLONITRILE !#2. USING $U0ONTS PROPRIETARY CATALYST
SYSTEM /THER USEFUL PRODUCTS FROM THE REACTION ARE HYDROGEN CYANIDE
(#. AND ACETONITRILE !#% 4HE REACTION IS HIGHLY EXOTHERMIC AND HEAT
IS RECOVERED FROM THE REACTOR BY PRODUCING HIGH PRESSURE STEAM 4HE
REACTOR EFm UENT IS QUENCHED AND NEUTRALIZED WITH A SULFURIC SOLUTION TO
REMOVE THE EXCESS AMMONIA
4HE PRODUCT GAS FROM THE QUENCH IS ABSORBED WITH WATER TO
RECOVER THE !#2. (#. AND !#% 4HE AQUEOUS SOLUTION OF !#2.
(#. AND !#% IS THEN FRACTIONATED AND PURIl ED INTO HIGH QUALITY
PRODUCTS 4HE PRODUCTS RECOVERY AND PURIl CATION IS A HIGHLY EFl CIENT
AND LOW ENERGY CONSUMPTION PROCESS 4HIS !#2. TECHNOLOGY
MINIMIZES THE AMOUNT OF AQUEOUS EFm UENT A MAJOR CONSIDERATION FOR
ALL ACRYLONITRILE PRODUCERS
4HIS !#2. TECHNOLOGY IS BASED ON A HIGH ACTIVITY HIGH THROUGHPUT
CATALYST 4HE PROPYLENE CONVERSION IS WITH A SELECTIVITY OF
TO USEFUL PRODUCTS OF !#2. (#. AND !#% 4HE $U0ONT CATALYST IS A
MECHANICALLY SUPERIOR CATALYST RESULTING IN A LOW CATALYST LOSS $U0ONT
HAS DEVELOPED A #ATALYST "ED -ANAGEMENT 0ROGRAM #"-0 TO
MAINTAIN THE PROPERTIES OF THE CATALYST BED INSIDE THE REACTOR AT OPTIMAL
PERFORMANCE THROUGHOUT THE OPERATION 4HE CATALYST PROPERTIES THE
#"-0 AND PROPRIETARY REACTOR INTERNALS PROVIDE AN OPTIMAL PERFORMANCE
OF THE !#2. REACTOR RESULTING IN HIGH YIELDS
7ITH OVER YEARS OF OPERATING EXPERIENCE $U0ONT HAS DEVELOPED
KNOW HOW TO INCREASE THE ONSTREAM FACTOR OF THE PLANT 4HIS KNOW
HOW INCLUDES THE EFFECTIVE USE OF INHIBITORS TO REDUCE THE FORMATION OF
CYANIDE AND NITRILE POLYMERS AND EFFECTIVE APPLICATION OF AN ANTIFOULANT
SYSTEM TO INCREASE ONSTREAM TIME FOR EQUIPMENT
2ECOVERY
(0
STEAM
0ROPYLENE
!MMONIA
(3/
!IR
.( 3/
WASTEWATER
#RUDE
ACETONITRILE
7ASTEWATER
!CRYLONITRILE
PRODUCT
(EAVIES
PURGE
Commercial
plants: $U0ONT #HEMICAL 3OLUTION %NTERPRISE "EAUMONT
4EXAS MTPY
Licensor: +ELLOGG "ROWN 2OOT )NC
Alkylbenzene,
linear
Application: 4HE $ETAL PROCESS USES A SOLID HETEROGENEOUS CATALYST TO
PRODUCE LINEAR ALKYLBENZENE ,!" BY ALKYLATING BENZENE WITH LINEAR
OLEl NS MADE BY THE 0ACOL PROCESS
Description: ,INEAR PARAFl NS ARE FED TO A 0ACOL REACTOR TO DEHYDRO
GENATE THE FEED INTO CORRESPONDING LINEAR OLEl NS 2EACTOR EFm UENT IS
SEPARATED INTO GAS AND LIQUID PHASES IN A SEPARATOR $IOLEl NS IN THE
SEPARATOR LIQUID ARE SELECTIVELY CONVERTED TO MONO
OLEl NS IN A $E&INE
REACTOR ,IGHT ENDS ARE REMOVED IN A STRIPPER AND THE RESULTING
OLEl N
PARAFl N MIXTURE IS SENT TO A $ETAL REACTOR WHERE THE OLEl NS ARE
ALKYLATED WITH BENZENE 4HE REACTOR EFm UENT IS SENT TO A FRACTIONATION
SECTION FOR SEPARATION AND RECYCLE OF UNREACTED BENZENE TO THE
$ETAL REACTOR AND SEPARATION AND RECYCLE OF UNREACTED PARAFl NS TO THE
0ACOL REACTOR ! RERUN COLUMN SEPARATES THE ,!" PRODUCT FROM THE
HEAVY ALKYLATE BOTTOMS STREAM
&EEDSTOCK IS TYPICALLY # TO # NORMAL PARAFl NS OF PURITY
,!" PRODUCT HAS A TYPICAL "ROMINE )NDEX OF LESS THAN
Yields: "ASED ON WEIGHT PARTS OF ,!" PARTS OF LINEAR PARAFl NS
AND PARTS OF BENZENE ARE CHARGED TO A 5/0 ,!" PLANT
Economics: )NVESTMENT 53 'ULF #OAST INSIDE BATTERY LIMITS FOR THE PRO
DUCTION OF TPY OF ,!" TPY
Commercial
plants: 4WENTY
NINE 5/0 ,!" COMPLEXES BASED ON THE 0A
COL PROCESS HAVE BEEN BUILT &OUR OF THESE PLANTS USE THE $ETAL PROCESS
Reference: 'REER $ ET AL h!DVANCES IN THE -ANUFACTURE OF ,INEAR
!LKYLBENZENE v TH 7ORLD 3URFACTANTS #ONFERENCE #%3)/ "ERLIN 'ER
MANY *UNE
Licensor: 5/0 ,,#
( RICH
OFFGAS
(
RECYCLE
&RESH
BENZENE
-AKEUP
(
"ENZENE
RECYCLE
,%
,!"
,INEAR
PARAFFIN
CHARGE
(EAVY
ALKYLATE
0ARAFFIN RECYCLE
Alpha
olefins,
linear
Application: 4O PRODUCE HIGH
PURITY ALPHA OLEl NS # n # SUITABLE AS
#ATALYST
PREPARATION
AND STORAGE
COPOLYMERS FOR ,,$0% PRODUCTION AND AS PRECURSORS FOR PLASTICIZER ALCO
HOLS AND POLYALPHAOLEl NS USING THE !LPHA3ELECT PROCESS
Description: 0OLYMER GRADE ETHYLENE IS OLIGOMERIZED IN THE LIQUID PHASE
REACTOR WITH A CATALYSTSOLVENT SYSTEM DESIGNED FOR HIGH ACTIVITY AND
SELECTIVITY ,IQUID EFm UENT AND SPENT CATALYST ARE THEN SEPARATED THE
LIQUID IS DISTILLED FOR RECYCLING UNREACTED ETHYLENE TO THE REACTOR THEN
FRACTIONATED INTO HIGH PURITY ALPHA OLEl NS 3PENT CATALYST IS TREATED TO
REMOVE VOLATILE HYDROCARBONS AND RECOVERED 4HE TABLE BELOW ILLUSTRATES
THE SUPERIOR PURITIES ATTAINABLE WT WITH THE !LPHA 3ELECT PROCESS
N "UTENE
N (EXENE
N /CTENE
N $ECENE
"UTENE
%THYLENE
FEED
(EXENE
/CTENE
$ECENE
#
3OLVENT
RECYCLE
#ATALYST
REMOVAL
(EAVY ENDS WITH
SPENT CATALYST
4HE PROCESS IS SIMPLE IT OPERATES AT MILD OPERATING TEMPERATURES
AND PRESSURES AND ONLY CARBON STEEL EQUIPMENT IS REQUIRED 4HE CATALYST
IS NONTOXIC AND EASILY HANDLED
Yields: 9IELDS ARE ADJUSTABLE TO MEET MARKET REQUIREMENTS AND VERY LITTLE
HIGH BOILING POLYMER IS PRODUCED AS ILLUSTRATED
!LPHA
OLEl N PRODUCT DISTRIBUTION WT
N
"UTENE
n
N
(EXENE
n
N
/CTENE
n
N
$ECENE
n
Economics: 4YPICAL CASE FOR A )3", INVESTMENT AT A 'ULF #OAST LOCA
TION PRODUCING TPY OF # n # ALPHA
OLEl NS IS
)NVESTMENT MILLION 53
2AW MATERIAL
%THYLENE TONS PER TON OF PRODUCT
"YPRODUCTS TONTON OF MAIN PRODUCTS
# OLEl NS
&UEL GAS
(EAVY ENDS
5TILITIES COST 53TON PRODUCT
#ATALYST CHEMICALS 53TON PRODUCT
Commercial
plants: 4HE !LPHA3ELECT PROCESS IS STRONGLY BACKED BY EXTEN
SIVE !XENS INDUSTRIAL EXPERIENCE IN HOMOGENEOUS CATALYSIS IN PARTICULAR
THE !LPHABUTOL PROCESS FOR PRODUCING BUTENE
FOR WHICH THERE ARE
UNITS PRODUCING TPY
Licensor: !XENS !XENS .!
Alpha
olefins
Application: 4HE A
3ABLIN PROCESS PRODUCES A
OLEl NS SUCH AS BUTENE
HEXANE
OCTENE
DECENE
ETC FROM ETHYLENE IN A HOMOGENOUS
CATALYTIC REACTION 4HE PROCESS IS BASED ON A HIGHLY ACTIVE BIFUNCTIONAL
CATALYST SYSTEM OPERATING AT MILD REACTION CONDITIONS WITH HIGHEST SELEC
TIVITIES TO A
OLEl NS
"UTENE
%THYLENE
(EXENE
/CTENE
Description: %THYLENE IS COMPRESSED AND INTRODUCED TO A BUBBLE COL
UMN TYPE REACTOR IN WHICH A HOMOGENOUS CATALYST SYSTEM IS INTRO
DUCED TOGETHER WITH A SOLVENT 4HE GASEOUS PRODUCTS LEAVING THE REACTOR
OVERHEAD ARE COOLED IN A COOLER AND COOLED IN A GAS LIQUID SEPARATOR
FOR REm UX AND FURTHER COOLED AND SEPARATED IN A SECOND GAS LIQUID
SEPARATOR
5NREACTED ETHYLENE FROM THE SEPARATOR IS RECYCLED VIA A COM
PRESSOR AND A HEAT EXCHANGER TOGETHER WITH ETHYLENE MAKEUP
TO THE REACTOR ! LIQUID STREAM IS WITHDRAWN FROM THE REACTOR CON
TAINING LIQUID A OLEl NS AND CATALYST WHICH IS REMOVED BY THE CATALYST
REMOVAL UNIT 4HE LIQUID STREAM FROM THE CATALYST REMOVAL UNIT
IS COMBINED WITH THE LIQUID STREAM FROM THE PRIMARY SEPARATION
4HESE COMBINED LIQUID STREAMS ARE ROUTED TO A SEPARATION SECTION IN
WHICH VIA A SERIES OF COLUMNS THE A OLEl NS ARE SEPARATED INTO THE
INDIVIDUAL COMPONENTS
"Y VARYING THE CATALYST COMPONENTS RATIO THE PRODUCT MIXTURE CAN
BE ADJUSTED FROM LIGHT PRODUCTS BUTENE HEXENE OCTENE DECENE
TO HEAVIER PRODUCTS # TO # A OLEl NS 4YPICAL YIELD FOR LIGHT OLEl NS
IS OVER WT WITH HIGH PURITIES THAT ALLOW TYPICAL PRODUCT APPLICATIONS
4HE LIGHT PRODUCTS SHOW EXCELLENT PROPERTIES AS COMONOMERS IN ETHYLENE
POLYMERIZATION
Economics: $UE TO THE MILD REACTION CONDITIONS PRESSURE AND TEMPERA
TURE THE PROCESS IS LOWER IN INVESTMENT THAN COMPETITIVE PROCESSES
4YPICAL UTILITY REQUIREMENTS FOR A
METRIC TPY PLANT ARE TPH
COOLING WATER -7 FUEL GAS AND K7 ELECTRIC POWER
$ECENE
#ATALYST
SOLVENT
#
Commercial
plants: /NE PLANT OF METRIC TPY CAPACITY IS CURRENTLY
UNDER CONSTRUCTION FOR *UBAIL 5NITED IN !L
*UBAIL 3AUDI !RABIA
Licensor: 4HE TECHNOLOGY IS JOINTLY LICENSED BY ,INDE !' AND 3!")#
Ammonia
Application: 4O PRODUCE AMMONIA FROM A VARIETY OF HYDROCARBON FEED
STOCKS RANGING FROM NATURAL GAS TO HEAVY NAPHTHA USING 4OPSES LOW
ENERGY AMMONIA TECHNOLOGY
$ESULFURIZATION
0ROCESS STEAM
2EFORMING
3HIFT
0ROCESS AIR
Description: .ATURAL GAS OR ANOTHER HYDROCARBON FEEDSTOCK IS COMPRESSED
IF REQUIRED DESULFURIZED MIXED WITH STEAM AND THEN CONVERTED INTO
SYNTHESIS GAS 4HE REFORMING SECTION COMPRISES A PREREFORMER OPTIONAL
BUT GIVES PARTICULAR BENEl TS WHEN THE FEEDSTOCK IS HIGHER HYDROCARBONS
OR NAPHTHA A l RED TUBULAR REFORMER AND A SECONDARY REFORMER WHERE
PROCESS AIR IS ADDED 4HE AMOUNT OF AIR IS ADJUSTED TO OBTAIN AN ( .
RATIO OF AS REQUIRED BY THE AMMONIA SYNTHESIS REACTION 4HE TUBULAR
STEAM REFORMER IS 4OPSES PROPRIETARY SIDE
WALL
l RED DESIGN !FTER THE
REFORMING SECTION THE SYNTHESIS GAS UNDERGOES HIGH
AND LOW
TEMPERA
TURE SHIFT CONVERSION CARBON DIOXIDE REMOVAL AND METHANATION
3YNTHESIS GAS IS COMPRESSED TO THE SYNTHESIS PRESSURE TYPICALLY
RANGING FROM TO KG CMG AND CONVERTED INTO AMMONIA IN A
SYNTHESIS LOOP USING RADIAL m OW SYNTHESIS CONVERTERS EITHER THE TWO
BED 3
THE THREE
BED 3
OR THE 3
CONCEPT USING AN 3
CONVERTER FOLLOWED BY A BOILER OR STEAM SUPERHEATER AND A ONE
BED
3
CONVERTER !MMONIA PRODUCT IS CONDENSED AND SEPARATED BY
REFRIGERATION 4HIS PROCESS LAYOUT IS m EXIBLE AND EACH AMMONIA PLANT WILL
BE OPTIMIZED FOR THE LOCAL CONDITIONS BY ADJUSTMENT OF VARIOUS PROCESS
PARAMETERS 4OPSE SUPPLIES ALL CATALYSTS USED IN THE CATALYTIC PROCESS
STEPS FOR AMMONIA PRODUCTION
&EATURES SUCH AS THE INCLUSION OF A PREREFORMER INSTALLATION OF A
RING
TYPE BURNER WITH NOZZLES FOR THE SECONDARY REFORMER AND UPGRADING
TO AN 3
AMMONIA CONVERTER ARE ALL FEATURES THAT CAN BE APPLIED
FOR EXISTING AMMONIA PLANTS 4HESE FEATURES WILL EASE MAINTENANCE AND
IMPROVE PLANT EFl CIENCY
Commercial
plants: -ORE THAN PLANTS USE THE 4OPSE PROCESS CON
CEPT 3INCE OF THE NEW AMMONIA PRODUCTION CAPACITY HAS
BEEN BASED ON THE 4OPSE TECHNOLOGY #APACITIES OF THE PLANTS CON
.ATURAL GAS
0REREFORMING OPTIONAL
0URGE GAS
3TACK
3 OPTIONAL
#/n
REMOVAL
!MMONIA
PRODUCT
!MMONIA SYNTHESIS
-ETHANATION
#/
STRUCTED WITHIN THE LAST DECADE RANGE FROM MTPD UP TO MTPD
BEING THE WORLDS LARGEST AMMONIA PLANT $ESIGN OF NEW PLANTS WITH
EVEN HIGHER CAPACITIES ARE AVAILABLE
Licensor: (ALDOR 4OPSE !3
Ammonia,
KAAPplus
Application: 4O PRODUCE AMMONIA FROM HYDROCARBON FEEDSTOCKS USING A
%XCESS AIR
HIGH PRESSURE HEAT EXCHANGE BASED STEAM REFORMING PROCESS INTEGRATED
WITH A LOW PRESSURE ADVANCED AMMONIA SYNTHESIS PROCESS
&EED
Description: 4HE KEY STEPS IN THE +!!0PLUS PROCESS ARE REFORMING US
ING THE +"2 REFORMING EXCHANGER SYSTEM +2%3 CRYOGENIC PURIl CATION
OF THE SYNTHESIS GAS AND LOW
PRESSURE AMMONIA SYNTHESIS USING +!!0
CATALYST
&OLLOWING SULFUR REMOVAL THE FEED IS MIXED WITH STEAM HEATED
AND SPLIT INTO TWO STREAMS /NE STREAM m OWS TO THE AUTOTHERMAL REFORMER
!42 AND THE OTHER TO THE TUBE SIDE OF THE REFORMING EXCHANGER
WHICH OPERATES IN PARALLEL WITH THE !42 "OTH CONVERT THE HYDROCARBON
FEED INTO RAW SYNTHESIS GAS USING CONVENTIONAL NICKEL CATALYST )N THE !42
FEED IS PARTIALLY COMBUSTED WITH EXCESS AIR TO SUPPLY THE HEAT NEEDED TO
REFORM THE REMAINING HYDROCARBON FEED 4HE HOT AUTOTHERMAL REFORMER
EFm UENT IS FED TO THE SHELL SIDE OF THE +2%3 REFORMING EXCHANGER WHERE
IT COMBINES WITH THE REFORMED GAS EXITING THE CATALYST
PACKED TUBES 4HE
COMBINED STREAM m OWS ACROSS THE SHELL SIDE OF THE REFORMING EXCHANGER
WHERE IT SUPPLIES HEAT TO THE REFORMING REACTION INSIDE THE TUBES
3HELL
SIDE EFm UENT FROM THE REFORMING EXCHANGER IS COOLED IN A WASTE
HEAT BOILER WHERE HIGH
PRESSURE STEAM IS GENERATED AND THEN m OWS TO
THE #/ SHIFT CONVERTERS CONTAINING TWO CATALYST TYPES ONE IS A HIGH
TEMPERATURE CATALYST AND THE OTHER IS A LOW
TEMPERATURE CATALYST
3HIFT REACTOR EFm UENT IS COOLED CONDENSED WATER SEPARATED AND THEN
ROUTED TO THE GAS PURIl CATION SECTION #/ IS REMOVED FROM SYNTHESIS
GAS USING A WET #/ SCRUBBING SYSTEM SUCH AS HOT POTASSIUM CARBONATE
OR -$%! METHYL DIETHANOLAMINE
!FTER #/ REMOVAL l NAL PURIl CATION INCLUDES METHANATION GAS
DRYING AND CRYOGENIC PURIl CATION 4HE RESULTING PURE SYNTHESIS
GAS IS COMPRESSED IN A SINGLE
CASE COMPRESSOR AND MIXED WITH A RECYCLE
STREAM 4HE GAS MIXTURE IS FED TO THE +!!0 AMMONIA CONVERTER
WHICH USES A RUTHENIUM
BASED HIGH
ACTIVITY AMMONIA SYNTHESIS
CATALYST )T PROVIDES HIGH CONVERSION AT THE RELATIVELY LOW PRESSURE OF
!IR
COM
PRESSOR
3ULFUR REMOVAL
0ROCESS
HEATER
0ROCESS STEAM
-ETHANATOR
!42
%XPANDER
&EEDEFFLUENT EXCH
,43
-0
STEAM
+2%3
4O "&7 SYSTEM
$RYER
7ASTE GAS
TO FUEL
#ONDENSER
#/ ABSORBER
3YNTHESIS GAS
COMPRESSOR
#/
STRIPPER
4O PROCESS
STEAM
#ONDENSATE
STRIPPER
(43
2EFRIG
COMP
!MMONIA
PRODUCT
2EFRIGERATION
EXCHANGER
2ECTIFIER
COLUMN
BAR WITH A SMALL CATALYST VOLUME %Fm UENT VAPORS ARE COOLED BY AMMONIA
REFRIGERATION AND UNREACTED GASES ARE RECYCLED !NHYDROUS LIQUID
AMMONIA IS CONDENSED AND SEPARATED FROM THE EFm UENT
%NERGY CONSUMPTION OF +"2S +!!0PLUS PROCESS IS LESS THAN --
"TU ,(6 SHORT
TON %LIMINATION OF THE PRIMARY REFORMER COMBINED WITH
LOW
PRESSURE SYNTHESIS PROVIDES A CAPITAL COST SAVINGS OF ABOUT OVER
CONVENTIONAL PROCESSES
Commercial
plants: /VER LARGE
SCALE SINGLE
TRAIN AMMONIA PLANTS
OF +"2 DESIGN ARE ONSTREAM OR HAVE BEEN CONTRACTED WORLDWIDE 4HE
+!!0PLUS ADVANCED AMMONIA TECHNOLOGY PROVIDES A LOW
COST LOW
EN
Ammonia,
KAAPplus, CONTINUED
ERGY DESIGN FOR AMMONIA PLANTS MINIMIZES ENVIRONMENTAL IMPACT RE
DUCES MAINTENANCE AND OPERATING REQUIREMENTS AND PROVIDES ENHANCED
RELIABILITY 4WO PLANTS USE +2%3 TECHNOLOGY AND PLANTS USE 0URIlER
TECHNOLOGY &OUR
MTPD GRASSROOTS +!!0 PLANTS IN 4RINIDAD ARE IN
FULL OPERATION
Licensor: +ELLOGG "ROWN 2OOT )NC
Ammonia,
KBR
Purifier
Application: 4O PRODUCE AMMONIA FROM HYDROCARBON FEEDSTOCKS AND AIR
!IR
Description: 4HE KEY FEATURES OF THE +"2 0URIl ER 0ROCESS ARE MILD PRI
MARY REFORMING SECONDARY REFORMING WITH EXCESS AIR CRYOGENIC PURIl CA
TION OF SYNGAS AND SYNTHESIS OF AMMONIA OVER MAGNETITE CATALYST IN A
HORIZONTAL CONVERTER
$ESULFURIZED FEED IS REACTED WITH STEAM IN THE PRIMARY REFORMER
WITH EXIT TEMPERATURE AT ABOUT # 0RIMARY REFORMER EFm UENT IS RE
ACTED WITH EXCESS AIR IN THE SECONDARY REFORMER WITH EXIT AT ABOUT
# 4HE AIR COMPRESSOR IS NORMALLY A GAS
DRIVEN TURBINE 4URBINE
EXHAUST IS FED TO THE PRIMARY REFORMER AND USED AS PREHEATED COMBUS
TION AIR !N ALTERNATIVE TO THE ABOVE DESCRIBED CONVENTIONAL REFORMING IS
TO USE +"2S REFORMING EXCHANGER SYSTEM +2%3 AS DESCRIBED IN +"2S
+!!0PLUS
3ECONDARY REFORMER EXIT GAS IS COOLED BY GENERATING HIGH
PRESSURE
STEAM 4HE SHIFT REACTION IS CARRIED OUT IN TWO CATALYTIC STEPSHIGH
TEMPERATURE AND LOW
TEMPERATURE SHIFT #ARBON DIOXIDE REMOVAL
USES LICENSED PROCESSES &OLLOWING #/ REMOVAL RESIDUAL CARBON OXIDES
ARE CONVERTED TO METHANE IN THE METHANATOR -ETHANATOR EFm UENT IS
COOLED AND WATER IS SEPARATED BEFORE THE RAW GAS IS DRIED
$RIED SYNTHESIS GAS m OWS TO THE CRYOGENIC PURIl ER WHERE IT IS
COOLED BY FEEDEFm UENT HEAT EXCHANGE AND FED TO A RECTIl ER 4HE SYNGAS
IS PURIl ED IN THE RECTIl ER COLUMN PRODUCING A COLUMN OVERHEAD THAT IS
ESSENTIALLY A RATIO OF HYDROGEN AND NITROGEN 4HE COLUMN BOTTOMS
IS A WASTE GAS THAT CONTAINS UNCONVERTED METHANE FROM THE REFORMING
SECTION EXCESS NITROGEN AND ARGON "OTH OVERHEAD AND BOTTOMS ARE RE
HEATED IN THE FEEDEFm UENT EXCHANGER 4HE WASTE GAS STREAM IS USED TO
REGENERATE THE DRYERS AND THEN IS BURNED AS FUEL IN THE PRIMARY REFORMER
! SMALL LOW
SPEED EXPANDER PROVIDES THE NET REFRIGERATION
4HE PURIl ED SYNGAS IS COMPRESSED IN THE SYNGAS COMPRESSOR
MIXED WITH THE LOOP
CYCLE STREAM AND FED TO THE CONVERTER #ONVERT
ER EFm UENT IS COOLED AND THEN CHILLED BY AMMONIA REFRIGERATION !MMO
NIA PRODUCT IS SEPARATED FROM UNREACTED SYNGAS 5NREACTED SYNGAS
3TEAM
&EED
4O FUEL
!MMONIA
PRODUCT
IS RECYCLED BACK TO THE SYNGAS COMPRESSOR ! SMALL PURGE IS SCRUBBED
WITH WATER AND RECYCLED TO THE DRYERS
Commercial
plants: /VER SINGLE
TRAIN PLANTS OF +"2 DESIGN HAVE
BEEN CONTRACTED WORLDWIDE 3EVENTEEN OF THESE PLANTS USE THE +"2 0U
RIl ER PROCESS
Licensor: +ELLOGG "ROWN 2OOT )NC
Ammonia
Application: 4HE ,INDE AMMONIA CONCEPT ,!# PRODUCES AMMONIA FROM
LIGHT HYDROCARBONS 4HE PROCESS IS A SIMPLIl ED ROUTE TO AMMONIA CON
SISTING OF A MODERN HYDROGEN PLANT STANDARD NITROGEN UNIT AND A HIGH
EFl CIENCY AMMONIA SYNTHESIS LOOP
&UEL
Description: (YDROCARBON FEED IS PREHEATED AND DESULFURIZED 0RO
!IR
CESS STEAM GENERATED FROM PROCESS CONDENSATE IN THE ISOTHERMAL SHIFT
REACTOR IS ADDED TO GIVE A STEAM RATIO OF ABOUT REFORMER FEED IS
FURTHER PREHEATED 2EFORMER OPERATES WITH AN EXIT TEMPERATURE
OF #
2EFORMED GAS IS COOLED TO THE SHIFT INLET TEMPERATURE OF # BY
GENERATING STEAM 4HE #/ SHIFT REACTION IS CARRIED OUT IN A SINGLE
STAGE IN THE ISOTHERMAL SHIFT REACTOR INTERNALLY COOLED BY A SPIRAL
WOUND TUBE BUNDLE 4O GENERATE -0 STEAM IN THE REACTOR DE
AERATED
AND REHEATED PROCESS CONDENSATE IS RECYCLED
!FTER FURTHER HEAT RECOVERY l NAL COOLING AND CONDENSATE SEPARATION
THE GAS IS SENT TO THE PRESSURE SWING ADSORPTION 03! UNIT ,OADED
ADSORBERS ARE REGENERATED ISOTHERMALLY USING A CONTROLLED SEQUENCE OF
DEPRESSURIZATION AND PURGING STEPS
.ITROGEN IS PRODUCED BY THE LOW
TEMPERATURE AIR SEPARATION IN A
COLD BOX !IR IS l LTERED COMPRESSED AND PURIl ED BEFORE BEING
SUPPLIED TO THE COLD BOX 0URE NITROGEN PRODUCT IS FURTHER COMPRESSED
AND MIXED WITH THE HYDROGEN TO GIVE A PURE AMMONIA SYNTHESIS GAS
4HE SYNTHESIS GAS IS COMPRESSED TO AMMONIA
SYNTHESIS PRESSURE BY THE
SYNGAS COMPRESSOR WHICH ALSO RECYCLES UNCONVERTED GAS THROUGH
THE AMMONIA LOOP 0URE SYNGAS ELIMINATES THE LOOP PURGE AND ASSOCIATED
PURGE GAS TREATMENT SYSTEM
4HE AMMONIA LOOP IS BASED ON THE !MMONIA #ASALE AXIAL
RADIAL
THREE
BED CONVERTER WITH INTERNAL HEAT EXCHANGERS GIVING A HIGH
CONVERSION (EAT FROM THE AMMONIA SYNTHESIS REACTION IS USED TO
GENERATE (0 STEAM PREHEAT FEED GAS AND THE GAS IS THEN COOLED
AND REFRIGERATED TO SEPARATE AMMONIA PRODUCT 5NCONVERTED GAS
IS RECYCLED TO THE SYNGAS COMPRESSOR AND AMMONIA PRODUCT CHILLED
&EED
"&7
!IR
!MMONIA
TO n# FOR STORAGE 5TILITY UNITS IN THE ,!# PLANT ARE THE POWER
GENERATION SYSTEM WHICH PROVIDES POWER FOR THE PLANT FROM (0
SUPERHEATED STEAM "&7 PURIl CATION UNIT AND THE REFRIGERATION
UNIT
Economics: 3IMPLIl CATION OVER CONVENTIONAL PROCESSES GIVES IMPORTANT
SAVINGS SUCH AS INVESTMENT CATALYST
REPLACEMENT COSTS MAINTENANCE
COSTS ETC 4OTAL FEED REQUIREMENT PROCESS FEED PLUS FUEL IS APPROXI
MATELY 'CALMETRIC TON MT AMMONIA --"TUSHORT TON DE
PENDING ON PLANT DESIGN AND LOCATION
Ammonia, CONTINUED
Commercial
plants: 4HE lRST COMPLETE ,!# PLANT FOR
MTD AM
MONIA HAS BEEN BUILT FOR '3&# IN )NDIA 4WO OTHER ,!# PLANTS FOR
AND
MTD AMMONIA WERE COMMISSIONED IN !USTRALIA 4HE LATEST ,!#
CONTRACT IS UNDER ERECTION IN #HINA AND PRODUCES HYDROGEN AMMONIA
AND #/ UNDER IMPORT OF NITROGEN FROM ALREADY EXISTING FACILITIES 4HERE
ARE EXTENSIVE REFERENCE LISTS FOR ,INDE HYDROGEN AND NITROGEN PLANTS AND
!MMONIA #ASALE SYNTHESIS SYSTEMS
References: h! #OMBINATION OF 0ROVEN 4ECHNOLOGIES v .ITROGEN
-ARCH n !PRIL
Licensor: ,INDE !'
Ammonia
&UEL
(0
STEAM
&EED
-0 STEAM
(0 STEAM
Description: 4HE FEEDSTOCK NATURAL GAS AS AN EXAMPLE IS DESULFURIZED
MIXED WITH STEAM AND CONVERTED INTO SYNTHESIS GAS OVER NICKEL CATALYST
AT APPROXIMATELY BAR AND # TO # IN THE PRIMARY REFORMER
4HE 5HDE STEAM REFORMER IS A TOP
l RED REFORMER WITH TUBES MADE OF
CENTRIFUGAL HIGH ALLOY STEEL AND A PROPRIETARY hCOLD OUTLET MANIFOLDv SYS
TEM WHICH ENHANCES RELIABILITY
)N THE SECONDARY REFORMER PROCESS AIR IS ADMITTED TO THE SYNGAS VIA
A SPECIAL NOZZLE SYSTEM ARRANGED AT THE CIRCUMFERENCE OF THE SECONDARY
REFORMER HEAD THAT PROVIDES A PERFECT MIXTURE OF AIR AND GAS 3UBSEQUENT
HIGH
PRESSURE (0 STEAM GENERATION AND SUPERHEATING GUARANTEE MAXIMUM
PROCESS HEAT USAGE TO ACHIEVE AN OPTIMIZED ENERGY EFl CIENT PROCESS
#/ IS CONVERTED TO #/ IN THE (4 AND ,4 SHIFT OVER STANDARD CATA
LYSTS #/ IS REMOVED IN A SCRUBBING UNIT WHICH IS NORMALLY EITHER THE
"!3&
A-$%! OR THE 5/0
"ENl ELD PROCESS 2EMAINING CARBONOXIDES
ARE RECONVERTED TO METHANE IN THE CATALYTIC METHANATION TO TRACE PPM
LEVELS
4HE AMMONIA SYNTHESIS LOOP USES TWO AMMONIA CONVERTERS WITH
THREE CATALYST BEDS 7ASTE HEAT IS USED FOR STEAM GENERATION DOWN
STREAM THE SECOND AND THIRD BED 7ASTE
HEAT STEAM GENERATORS WITH
INTEGRATED BOILER FEEDWATER PREHEATER ARE SUPPLIED WITH A SPECIAL COOLED
TUBESHEET TO MINIMIZE SKIN TEMPERATURES AND MATERIAL STRESSES 4HE CON
VERTERS THEMSELVES HAVE RADIAL CATALYST BEDS WITH STANDARD SMALL GRAIN
IRON CATALYST 4HE RADIAL m OW CONCEPT MINIMIZES PRESSURE DROP IN THE
(0 STEAM FROM SYNTHESIS
3TEAM
DRUM
-ETHANATION
,4
SHIFT
(4 SHIFT
3ECONDARY
REFORMER
0ROCESS
AIR
!MMONIA
CONVERTER
"&7
3YNGAS COMPRESSOR
#/
"&7
0ROCESS GAS
#OMBUSTION AIR
-AKE UP GAS
#7
THA /THER HYDROCARBONSCOAL OIL RESIDUES OR METHANOL PURGE GAS
ARE POSSIBLE FEEDSTOCKS WITH AN ADAPTED FRONT END 4HE PROCESS USES
CONVENTIONAL STEAM REFORMING SYNTHESIS GAS GENERATION FRONT END AND
A MEDIUM PRESSURE -0 AMMONIA SYNTHESIS LOOP )T IS OPTIMIZED WITH
RESPECT TO LOW ENERGY CONSUMPTION AND MAXIMUM RELIABILITY 4HE LARG
EST SINGLE TRAIN PLANT BUILT BY 5HDE WITH A CONVENTIONAL SYNTHESIS HAS
A NAMEPLATE CAPACITY OF METRIC TONS PER DAY MTPD &OR HIGHER
CAPACITIES REFER TO 5HDE $UAL 0RESSURE 0ROCESS
2EFORMER
Application: 4O PRODUCE AMMONIA FROM NATURAL GAS ,.' ,0' OR NAPH
#/
REMOVAL
"&7
2EFRIGERATION
0URGE
.(
LIQUID
#ONVECTION BANK COILS
(0 STEAM SUPERHEATER
&EEDSTEAM PREHEATER
0ROCESS AIR PREHEATER
&EED PREHEATER
#OMBUSTION AIR
PREHEATER
SYNTHESIS LOOP AND ALLOWS MAXIMUM AMMONIA CONVERSION RATES
,IQUID AMMONIA IS SEPARATED BY CONDENSATION FROM THE SYNTHESIS
LOOP AND IS EITHER SUBCOOLED AND ROUTED TO STORAGE OR CONVEYED AT MOD
ERATE TEMPERATURE TO SUBSEQUENT CONSUMERS
!MMONIA m ASH AND PURGE GASES ARE TREATED IN A SCRUBBING SYSTEM AND
A HYDROGEN RECOVERY UNIT NOT SHOWN AND THE REMAINS ARE USED AS FUEL
Commercial
plants: 3EVENTEEN AMMONIA PLANTS HAVE BEEN COMMIS
SIONED BETWEEN AND WITH CAPACITIES RANGING FROM MTPD
UP TO MTPD
Licensor: 5HDE 'MB(
Ammonia,
PURIFIERplus
%XCESS AIR
Application: 4O PRODUCE AMMONIA FROM HYDROCARBON FEEDSTOCKS USING A
HIGH
PRESSURE (0 HEAT EXCHANGE
BASED STEAM REFORMING PROCESS INTE
GRATED WITH CRYOGENIC PURIl CATION OF SYNGAS
&EED
USING THE +"2 REFORMING EXCHANGER SYSTEM +2%3 WITH EXCESS AIR CRYO
GENIC PURIl CATION OF THE SYNTHESIS GAS AND SYNTHESIS OF AMMONIA OVER
MAGNETITE CATALYST IN A HORIZONTAL CONVERTER
&OLLOWING SULFUR REMOVAL THE FEED IS MIXED WITH STEAM HEATED
AND SPLIT INTO TWO STREAMS /NE STREAM m OWS TO THE AUTOTHERMAL REFOR
MER !42 AND THE OTHER TO THE TUBE SIDE OF THE REFORMING EXCHANGER
WHICH OPERATES IN PARALLEL WITH THE !42 "OTH CONVERT THE HYDROCAR
BON FEED INTO RAW SYNTHESIS GAS USING CONVENTIONAL NICKEL CATALYST )N
THE !42 FEED IS PARTIALLY COMBUSTED WITH EXCESS AIR TO SUPPLY THE HEAT
NEEDED TO REFORM THE REMAINING HYDROCARBON FEED 4HE HOT AUTOTHER
MAL REFORMER EFm UENT IS FED TO THE SHELL SIDE OF THE +2%3 REFORMING EX
CHANGER WHERE IT COMBINES WITH THE REFORMED GAS EXITING THE CATALYST
PACKED TUBES 4HE COMBINED STREAM m OWS ACROSS THE SHELL SIDE OF THE
REFORMING EXCHANGER WHERE IT SUPPLIES HEAT TO THE REFORMING REACTION
INSIDE THE TUBES
3HELL SIDE EFm UENT FROM THE REFORMING EXCHANGER IS COOLED IN A
WASTE HEAT BOILER WHERE (0 STEAM IS GENERATED AND THEN m OWS TO THE
#/ SHIFT CONVERTERS CONTAINING TWO CATALYST TYPES ONE IS A HIGH
TEMPERATURE CATALYST AND THE OTHER IS A LOW TEMPERATURE CATALYST
3HIFT REACTOR EFm UENT IS COOLED CONDENSED WATER SEPARATED AND
THEN ROUTED TO THE GAS PURIl CATION SECTION #/ IS REMOVED FROM SYN
THESIS GAS USING A WET #/ SCRUBBING SYSTEM SUCH AS HOT POTASSIUM
CARBONATE OR -$%! METHYL DIETHANOLAMINE
&OLLOWING #/ REMOVAL RESIDUAL CARBON OXIDES ARE CONVERTED TO ME
THANE IN THE METHANATOR -ETHANATOR EFm UENT IS COOLED AND WATER IS
SEPARATED BEFORE THE RAW GAS IS DRIED $RIED SYNTHESIS GAS m OWS
TO THE CRYOGENIC PURIl ER WHERE IT IS COOLED BY FEEDEFm UENT HEAT
EXCHANGE AND FED TO A RECTIl ER 4HE SYNGAS IS PURIl ED IN THE RECTIl ER
3ULFUR
REMOVAL
(EAT
RECOVERY
!42
!IR COMPRESSOR
.' COMPRESSOR
Description: 4HE KEY STEPS IN THE 052)&)%2PLUS PROCESS ARE REFORMING
(43
3TEAM
3TM
0ROCESS STEAM
0ROCESS HEATER
!UTO
2EFORMING
THERMAL EXCHANGER
REFORMER +2%3
-ETHANATOR
#ONDENSATE
STRIPPER
,43
(EAT
RECOVERY
(EAT
RECOVERY
4O PROCESS
STEAM
-0
STEAM
4O "&7
SYSTEM
#/
STRIPPER
#/
$RYER
7ASTE GAS
TO FUEL
3YNTHESIS GAS
COMPRESSOR
3YNTHESIS
COMPRESSOR
(EAT
RECOVERY
#ONDENSER
!MMONIA
PRODUCT
#/
ABSORBER
%XPANDER
&EEDEFFLUENT
EXCHANGER
5NITIZED CHILLER
(ORIZONTAL MAGNETITE
CONVERTER
2ECTIFIER
COLUMN
COLUMN PRODUCING A COLUMN OVERHEAD THAT IS ESSENTIALLY A RATIO
OF HYDROGEN AND NITROGEN 4HE COLUMN BOTTOMS IS A WASTE GAS THAT CON
TAINS UNCONVERTED METHANE FROM THE REFORMING SECTION EXCESS NITROGEN
AND ARGON "OTH OVERHEAD AND BOTTOMS ARE RE
HEATED IN THE FEEDEFF
LUENT EXCHANGER 4HE WASTE GAS STREAM IS USED TO REGENERATE THE DRYERS
AND THEN IS BURNED AS FUEL IN THE PRIMARY REFORMER ! SMALL LOW
SPEED
EXPANDER PROVIDES THE NET REFRIGERATION
4HE PURIl ED SYNGAS IS COMPRESSED IN THE SYNGAS COMPRESSOR
MIXED WITH THE LOOP
CYCLE STREAM AND FED TO THE HORIZONTAL CONVERTER
#ONVERTER EFm UENT IS COOLED AND THEN CHILLED BY AMMONIA REFRI
GERATION IN A UNITIZED CHILLER !MMONIA PRODUCT IS SEPARATED
Ammonia,
PURIFIERplus, CONTINUED
FROM UNREACTED SYNGAS 5NREACTED SYNGAS IS RECYCLED BACK TO THE SYNGAS
COMPRESSOR ! SMALL PURGE IS SCRUBBED WITH WATER AND RECYCLED TO
THE DRYERS
Commercial
plants: /VER LARGE
SCALE SINGLE
TRAIN AMMONIA PLANTS
OF +"2 DESIGN ARE ONSTREAM OR HAVE BEEN CONTRACTED WORLDWIDE 4HE
052)&)%2PLUS AMMONIA TECHNOLOGY PROVIDES A LOW
COST LOW
ENERGY
DESIGN FOR AMMONIA PLANTS MINIMIZES ENVIRONMENTAL IMPACT REDUCES
OPERATING REQUIREMENTS AND PROVIDES ENHANCED RELIABILITY 4WO PLANTS
USE +2%3 TECHNOLOGY AND PLANTS USE 052)&)%2 TECHNOLOGY
Licensor: +ELLOGG "ROWN 2OOT )NC
AmmoniaDual
pressure
process
&UEL
Application: 0RODUCTION OF AMMONIA FROM NATURAL GAS ,.' ,0' OR
NAPHTHA 4HE PROCESS USES CONVENTIONAL STEAM REFORMING SYNTHESIS GAS
GENERATION IN THE FRONT
END WHILE THE SYNTHESIS SECTION COMPRISES A
ONCE
THROUGH SECTION FOLLOWED BY A SYNTHESIS LOOP )T IS THUS OPTIMIZED
WITH RESPECT TO ENABLE AMMONIA PLANTS TO PRODUCE VERY LARGE CAPACITIES
WITH PROVEN EQUIPMENT 4HE l RST PLANT BASED ON THIS PROCESS WILL BE
THE 3!&#/ )6 AMMONIA PLANT IN !L
*UBAIL 3AUDI !RABIA WHICH IS CUR
RENTLY UNDER CONSTRUCTION 4HIS CONCEPT PROVIDES THE BASIS FOR EVEN LARGER
PLANTS n MTPD
"&7
(0 STEAM
-0 STEAM
&EED
0ROCESS AIR
#OMBUSTION AIR
0URGE
2EFRIGERATION
Description: 4HE FEEDSTOCK EG NATURAL GAS IS DESULFURIZED MIXED WITH
STEAM AND CONVERTED INTO SYNTHESIS GAS OVER NICKEL CATALYST AT APPROXI
MATELY BAR AND n # IN THE PRIMARY REFORMER 4HE 5HDE STEAM
REFORMER IS A TOP l RED REFORMER WITH TUBES MADE OF CENTRIFUGAL MICRO
ALLOY STEEL AND A PROPRIETARY hCOLD OUTLET MANIFOLD v WHICH ENHANCES
RELIABILITY
)N THE SECONDARY REFORMER PROCESS AIR IS ADMITTED TO THE SYNGAS VIA
A SPECIAL NOZZLE SYSTEM ARRANGED AT THE CIRCUMFERENCE OF THE SECONDARY
REFORMER HEAD THAT PROVIDES A PERFECT MIXTURE OF AIR AND GAS
3UBSEQUENT HIGH PRESSURE (0 STEAM GENERATION AND SUPERHEATING
GUARANTEE MAXIMUM PROCESS HEAT RECOVERY TO ACHIEVE AN OPTIMIZED EN
ERGY EFl CIENT PROCESS
#/ CONVERSION IS ACHIEVED IN THE (4 AND ,4 SHIFT OVER STANDARD CATA
LYST WHILE #/ IS REMOVED EITHER IN THE "!3& A-$%! THE 5/0 "ENl ELD
OR THE 5/0 !MINE 'UARD PROCESS 2EMAINING CARBONOXIDES ARE RECON
VERTED TO METHANE IN CATALYTIC METHANATION TO TRACE PPM LEVELS
4HE AMMONIA SYNTHESIS LOOP CONSISTS OF TWO STAGES -AKEUP GAS IS
COMPRESSED IN A TWO STAGE INTER COOLED COMPRESSOR WHICH IS THE LOW
PRESSURE CASING OF THE SYNGAS COMPRESSOR $ISCHARGE PRESSURE OF THIS
COMPRESSOR IS ABOUT BAR !N INDIRECTLY COOLED ONCE THROUGH CON
VERTER AT THIS LOCATION PRODUCES ONE THIRD OF THE TOTAL AMMONIA %Fm UENT
FROM THIS CONVERTER IS COOLED AND THE MAJOR PART OF THE AMMONIA PRO
DUCED IS SEPARATED FROM THE GAS
"&7
#/
!MMONIA
SYNTHESIS LOOP
#/
REMOVAL
#7
.( LIQUID
"&7
-AKEUP GAS
/NCE
THROUGH
AMMONIA SECTION
$RYERS
#7 .(
.(
#7
(0 STEAM
)N THE SECOND STEP THE REMAINING SYNGAS IS COMPRESSED TO THE OP
ERATING PRESSURE OF THE AMMONIA SYNTHESIS LOOP APPROX BAR IN
THE (0 CASING OF THE SYNGAS COMPRESSOR 4HIS (0 CASING OPERATES AT A
MUCH LOWER THAN USUAL TEMPERATURE 4HE HIGH SYNTHESIS LOOP PRESSURE
IS ACHIEVED BY COMBINATION OF THE CHILLED SECOND CASING OF THE SYNGAS
AmmoniaDual
pressure
process, CONTINUED
COMPRESSOR AND A SLIGHTLY ELEVATED FRONT
END PRESSURE
,IQUID AMMONIA IS SEPARATED BY CONDENSATION FROM THE ONCE
THROUGH SECTION AND THE SYNTHESIS LOOP AND IS EITHER SUBCOOLED AND
ROUTED TO STORAGE OR CONVEYED AT MODERATE TEMPERATURE TO SUBSE
QUENT CONSUMERS
!MMONIA mASH AND PURGE GASES ARE TREATED IN A SCRUBBING SYSTEM
AND A HYDROGEN RECOVERY UNIT NOT SHOWN THE REMAINING GASES BEING
USED AS FUEL
Economics: 4YPICAL CONSUMPTION lGURES FEED FUEL RANGE FROM TO
'CAL PER METRIC TON OF AMMONIA AND WILL DEPEND ON THE INDIVIDUAL
PLANT CONCEPT AS WELL AS LOCAL CONDITIONS
Commercial
plants: 4HE lRST PLANT BASED ON THIS PROCESS WILL BE THE 3!&
#/ )6 AMMONIA PLANT WITH MTPD CURRENTLY UNDER CONSTRUCTION IN
!L
*UBAIL 3AUDI !RABIA
Licensor: 5HDE 'MB(
Aniline
Application: ! PROCESS FOR THE PRODUCTION OF HIGH
QUALITY ANILINE FROM
BENZENE AND NITRIC ACID
Description: !NILINE IS PRODUCED BY THE NITRATION OF BENZENE WITH NITRIC
ACID TO MONONITROBENZENE -." WHICH IS SUBSEQUENTLY HYDROGENATED
TO ANILINE )N THE $U0ONT+"2 PROCESS BENZENE IS NITRATED WITH MIXED
ACID NITRIC AND SULFURIC AT HIGH EFl CIENCY TO PRODUCE MONONITROBENZENE
-." IN THE UNIQUE DEHYDRATING NITRATION $(. SYSTEM 4HE $(. SYS
TEM USES AN INERT GAS TO REMOVE THE WATER OF NITRATION FROM THE REACTION
MIXTURE THUS ELIMINATING THE ENERGY
INTENSIVE AND HIGH
COST SULFURIC
ACID CONCENTRATION SYSTEM
!S THE INERT GAS PASSES THROUGH THE SYSTEM IT BECOMES HUMIDIl ED
REMOVING THE WATER OF REACTION FROM THE REACTION MIXTURE -OST OF THE
ENERGY REQUIRED FOR THE GAS HUMIDIl CATION COMES FROM THE HEAT OF
NITRATION 4HE WET GAS IS CONDENSED AND THE INERT GAS IS RECYCLED TO THE
NITRATOR 4HE CONDENSED ORGANIC PHASE IS RECYCLED TO THE NITRATOR WHILE
THE AQUEOUS PHASE IS SENT TO EFm UENT TREATMENT 4HE REACTION MIXTURE IS
PHASE SEPARATED AND THE SULFURIC ACID IS RETURNED TO THE NITRATOR
4HE CRUDE -." IS WASHED TO REMOVE RESIDUAL ACID AND THE IMPURITIES
FORMED DURING THE NITRATION REACTION 4HE PRODUCT IS THEN DISTILLED
AND RESIDUAL BENZENE IS RECOVERED AND RECYCLED 0URIl ED -." IS FED
TOGETHER WITH HYDROGEN INTO A LIQUID PHASE PLUG
m OW HYDROGENATION
REACTOR THAT CONTAINS A $U0ONT PROPRIETARY CATALYST 4HE SUPPORTED NOBLE
METAL CATALYST HAS A HIGH SELECTIVITY AND THE -." CONVERSION PER PASS IS
4HE REACTION CONDITIONS ARE OPTIMIZED TO ACHIEVE ESSENTIALLY
QUANTITATIVE YIELDS AND THE REACTOR EFm UENT IS -."
FREE 4HE REACTOR
PRODUCT IS SENT TO A DEHYDRATION COLUMN TO REMOVE THE WATER OF REACTION
FOLLOWED BY A PURIl CATION COLUMN TO PRODUCE HIGH
QUALITY ANILINE
PRODUCT
Commercial
plants: $U0ONT PRODUCES ANILINE USING THIS TECHNOLOGY FOR
THE MERCHANT MARKET WITH A TOTAL PRODUCTION CAPACITY OF TPY AT
6ENT
2EACTION
WATER
"ENZENE
.ITRIC ACID
!NILINE
!LKALI
3ULFURIC
ACID
#ONDEN
SATION
7ASHING
)NERT
GAS
(YDROGEN
$EHYDRATING
NITRATION
4ARS
2EACTION
WATER
7ASH -."
WATER
"ENZENE
STRIPPING
$EHYDRATION
!NILINE
PURIFICATION
-."
HYDROGENATION
A PLANT LOCATED IN "EAUMONT 4EXAS )N ADDITION $U0ONTS ANILINE TECHNOL
OGY IS USED IN THREE COMMERCIAL UNITS AND ONE NEW LICENSE WAS AWARDED
IN WITH A TOTAL ANILINE CAPACITY OF TPY
Licensor: +ELLOGG "ROWN 2OOT )NC
Aromatics
Application: 4HE TECHNOLOGY PRODUCES BENZENE AND XYLENES FROM TOLU
(
ENE AND # STREAMS 4HIS TECHNOLOGY FEATURES A PROPRIETARY ZEOLITE CATA
LYST AND CAN ACCOMMODATE VARYING RATIOS OF FEEDSTOCK WHILE MAINTAIN
ING HIGH ACTIVITY AND SELECTIVITY
Description: 4HE TECHNOLOGY ENCOMPASSES THREE MAIN PROCESSING AR
EAS SPLITTER REACTOR AND STABILIZER SECTIONS 4HE HEAVY AROMATICS STREAM
# S FEED IS FED TO THE SPLITTER 4HE OVERHEAD # AROMATIC PRODUCT IS
THE FEED TO THE TRANSALKYLATION REACTOR SECTION 4HE SPLITTER BOTTOMS
IS EXCHANGED WITH OTHER STREAMS FOR HEAT RECOVERY BEFORE LEAVING THE
SYSTEM
4HE AROMATIC PRODUCT IS MIXED WITH TOLUENE AND HYDROGEN VAPOR
IZED AND FED TO THE REACTOR 4HE REACTOR GASEOUS PRODUCT IS PRIMARILY
UNREACTED HYDROGEN WHICH IS RECYCLED TO THE REACTOR 4HE LIQUID PROD
UCT STREAM IS SUBSEQUENTLY STABILIZED TO REMOVE FURTHER LIGHT AROMATIC
COMPONENTS 4HE RESULTING AROMATICS ARE ROUTED TO PRODUCT FRACTION
ATION TO PRODUCE THE l NAL BENZENE AND XYLENES PRODUCTS
4HE REACTOR IS CHARGED WITH ZEOLITE CATALYST WHICH EXHIBITS BOTH LONG
LIFE AND GOOD m EXIBILITY TO FEED STREAM VARIATIONS INCLUDING SUBSTANTIAL
# AROMATICS $EPENDING ON FEED COMPOSITIONS AND LIGHT COMPONENTS
PRESENT THE XYLENE YIELD CAN VARY FROM TO AND # CONVERSION
FROM TO
Process
advantages INCLUDE
s 3IMPLE LOW COST l XED
BED REACTOR DESIGN DROP IN REPLACEMENT FOR
OTHER CATALYSTS
s 6ERY HIGH SELECTIVITY BENZENE PURITY IS WITHOUT EXTRACTION
s 0HYSICALLY STABLE CATALYST WITH LONG CYCLE LIFE
s &LEXIBLE TO HANDLE UP TO # COMPONENTS IN FEED WITH HIGH
CONVERSION
s #ATALYST IS RESISTANT TO IMPURITIES COMMON TO THIS SERVICE
s /PERATING PARAMETERS ARE MODERATE
s $ECREASED HYDROGEN CONSUMPTION DUE TO LOW CRACKING RATES
4OLUENE
2EACTOR
,IGHT AROMATICS
(EAVY AROMATICS #
#ATALYST
.ON
REACTED
HYDROGEN TO
RECYCLE
3PLITTER
,IGHT AROMATICS
3EPARATOR
(EAVY CUT
2EACTOR
EFFLUENT
3TABILIZER
(EAVY AROMATICS
PRODUCT STREAM
s 3IGNIl CANT DECREASE IN ENERGY CONSUMPTION DUE TO EFl CIENT HEAT
INTEGRATION SCHEME
Commercial
plants: 4WO COMMERCIAL PLANTS ARE USING '4
4RANS!LK TECH
NOLOGY AND CATALYST
Licensor: '4# 4ECHNOLOGY USING CATALYST MANUFACTURED BY 3UD
#HEMIE
)NC
Aromatics
extraction
Application: 4HE 3ULFOLANE PROCESS RECOVERS HIGH
PURITY # n # AROMAT
ICS FROM HYDROCARBON MIXTURES SUCH AS REFORMED PETROLEUM NAPHTHA
REFORMATE PYROLYSIS GASOLINE PYGAS OR COKE OVEN LIGHT OIL #/,/ BY
EXTRACTIVE DISTILLATION WITH OR WITHOUT LIQUID LIQUID EXTRACTION
Description: &RESH FEED ENTERS THE EXTRACTOR AND m OWS UPWARD COUN
TERCURRENT TO A STREAM OF LEAN SOLVENT !S THE FEED m OWS THROUGH THE
EXTRACTOR AROMATICS ARE SELECTIVELY DISSOLVED IN THE SOLVENT ! RAFl NATE
STREAM VERY LOW IN AROMATICS CONTENT IS WITHDRAWN FROM THE TOP OF THE
EXTRACTOR 4HE RICH SOLVENT LOADED WITH AROMATICS EXITS THE BOTTOM OF
THE EXTRACTOR AND ENTERS THE STRIPPER 4HE LIGHTER NONAROMATICS TAK
EN OVERHEAD ARE RECYCLED TO THE EXTRACTOR TO DISPLACE HIGHER MOLECULAR
WEIGHT NONAROMATICS FROM THE SOLVENT
4HE BOTTOMS STREAM FROM THE STRIPPER SUBSTANTIALLY FREE OF NONARO
MATIC IMPURITIES IS SENT TO THE RECOVERY COLUMN WHERE THE AROMATIC
PRODUCT IS SEPARATED FROM THE SOLVENT "ECAUSE OF THE LARGE DIFFERENCE
IN BOILING POINT BETWEEN THE SOLVENT AND THE HEAVIEST AROMATIC COMPO
NENT THIS SEPARATION IS ACCOMPLISHED EASILY WITH MINIMAL ENERGY INPUT
,EAN SOLVENT FROM THE BOTTOM OF THE RECOVERY COLUMN IS RETURNED
TO THE EXTRACTOR 4HE EXTRACT IS RECOVERED OVERHEAD AND SENT ON TO DIS
TILLATION COLUMNS DOWNSTREAM FOR RECOVERY OF THE INDIVIDUAL BENZENE
TOLUENE AND XYLENE PRODUCTS 4HE RAFl NATE STREAM EXITS THE TOP OF THE
EXTRACTOR AND IS DIRECTED TO THE RAFl NATE WASH COLUMN )N THE WASH
COLUMN THE RAFl NATE IS CONTACTED WITH WATER TO REMOVE DISSOLVED SOL
VENT 4HE SOLVENT RICH WATER IS VAPORIZED IN THE WATER STRIPPER AND
THEN USED AS STRIPPING STEAM IN THE RECOVERY COLUMN 4HE RAFl NATE
PRODUCT EXITS THE TOP OF THE RAFl NATE WASH COLUMN 4HE RAFl NATE PROD
UCT IS COMMONLY USED FOR GASOLINE BLENDING OR ETHYLENE PRODUCTION
4HE SOLVENT USED IN THE 3ULFOLANE PROCESS WAS DEVELOPED BY 3HELL /IL
#O IN THE EARLY S AND IS STILL THE MOST EFl CIENT SOLVENT AVAILABLE FOR
RECOVERY OF AROMATICS
Economics: 4HE PURITY AND RECOVERY PERFORMANCE OF AN AROMATICS EXTRAC
TION UNIT IS LARGELY A FUNCTION OF ENERGY CONSUMPTION )N GENERAL HIGHER
SOLVENT CIRCULATION RATES RESULT IN BETTER PERFORMANCE BUT AT THE EXPENSE
OF HIGHER ENERGY CONSUMPTION 4HE 3ULFOLANE PROCESS DEMONSTRATES THE
LOWEST SOLVENT
TO
FEED RATIO AND THE LOWEST ENERGY CONSUMPTION OF ANY
COMMERCIAL AROMATICS EXTRACTION TECHNOLOGY ! TYPICAL 3ULFOLANE UNIT
CONSUMES n KCAL OF ENERGY PER KILOGRAM OF EXTRACT PRODUCED
EVEN WHEN OPERATING AT WT BENZENE PURITY AND WT
RECOVERY
%STIMATED INSIDE BATTERY LIMITS )3", COSTS BASED ON UNIT PROCESSING
MTPY OF "4 REFORMATE FEEDSTOCK WITH ,6 AROMATICS 53
'ULF #OAST SITE IN
)NVESTMENT 53 MILLION
5TILITIES PER MT OF FEED
%LECTRICITY K7H
3TEAM MT
7ATER COOLING M
Commercial
plants: )N 3HELL COMMERCIALIZED THE 3ULFOLANE PROCESS
IN ITS REl NERIES IN %NGLAND AND )TALY 4HE SUCCESS OF THE 3ULFOLANE PRO
CESS LED TO AN AGREEMENT IN WHEREBY 5/0 BECAME THE EXCLUSIVE
LICENSOR OF THE 3ULFOLANE PROCESS -ANY OF THE PROCESS IMPROVEMENTS
INCORPORATED IN MODERN 3ULFOLANE UNITS ARE BASED ON DESIGN FEATURES
AND OPERATING TECHNIQUES DEVELOPED BY 5/0 5/0 HAS LICENSED A TOTAL
OF 3ULFOLANE UNITS THROUGHOUT THE WORLD
Licensor: 5/0 ,,#
Aromatics
extractive
distillation
Application: 4HE $ISTAPEX PROCESS USES EXTRACTIVE DISTILLATION FOR RECOV
ERING INDIVIDUAL AROMATICS FROM A HEART CUT CONTAINING THE DESIRED ARO
MATIC COMPOUND
%XTRACTIVE
DISTILLATION
COLUMN
2AFFINATE
COLUMN
3OLVENT STRIPPER
2AFFINATE
Description: 4HE FEEDSTOCK IE THE HEART CUT WITH THE AROMATIC COMPO
NENT TO BE RECOVERED IS ROUTED TO THE MIDDLE OF THE EXTRACTIVE DISTILLATION
COLUMN 4HE SOLVENT .-0 IS SUPPLIED AT THE TOP OF THE COLUMN )N
THE PRESENCE OF THE SOLVENT THE AROMATIC COMPONENT AND THE NON ARO
MATICS ARE SEPARATED IN THE COLUMN
4HE AROMATIC COMPONENT PASSES TOGETHER WITH THE SOLVENT TO THE
BOTTOM AND IS ROUTED TO THE STRIPPER )T IS SEPARATED FROM THE SOLVENT
UNDER VACUUM 4HE OVERHEAD AROMATIC COMPONENT LEAVES THE PLANT AS
PURE PRODUCT AND THE SOLVENT IS CIRCULATED TO THE EXTRACTIVE DISTILLATION
COLUMN
(IGH HEAT UTILIZATION IS OBTAINED BY INTENSIVE HEAT EXCHANGE OF THE
CIRCULATING SOLVENT .ECESSARY ADDITIONAL HEAT IS SUPPLIED BY MEDIUM
PRESSURE STEAM AT n BAR
4HE NON AROMATICS STILL CONTAINING SMALL QUANTITIES OF SOLVENT ARE
OBTAINED AT THE TOP OF THE EXTRACTIVE DISTILLATION COLUMN 4HIS SOLVENT
IS RECOVERED IN THE RAFl NATE COLUMN AND RETURNED TO THE SOLVENT RE
CYCLE
"ENZENE RECOVERY FROM PYROLYSIS GASOLINE IS USUALLY ABOVE AT
FEED CONCENTRATION ABOVE
Economics: ! TYPICAL INVESTMENT FOR A $ISTAPEX PLANT TO RECOVER
TPY BENZENE IS APPROXIMATELY % MILLION
4YPICAL ENERGY CONSUMPTION l GURES OF THE $ISTAPEX PLANT CALCULATED
PER TON OF BENZENE PRODUCED ARE
3TEAM n BAR TON
%LECTRIC POWER K7H
7ATER COOLING M
3OLVENT LOSS KG
0URE
AROMATIC
COMPONENT
!ROMATICS
CUT
3OLVENT AROMATIC
3OLVENT
Installations: 4HE $ISTAPEX PROCESS IS APPLIED IN MORE THAN REFERENCE
PLANTS
Reference: ' +REKEL ' "IRKE ! 'LASMACHER ET AL h$EVELOPMENTS IN
!ROMATICS 3EPARATION v %RDL %RDGAS +OHLE -AY
Licensor: ,URGI !'
Aromatics
extractive
distillation
Application: 4HE 3ULFOLANE PROCESS RECOVERS HIGH
PURITY AROMATICS FROM
HYDROCARBON MIXTURES BY EXTRACTIVE DISTILLATION %$ WITH LIQUID
LIQUID EX
TRACTION OR WITH EXTRACTIVE DISTILLATION %$ 4YPICALLY IF JUST BENZENE OR
TOLUENE IS THE DESIRED PRODUCT THEN %$ WITHOUT LIQUID
LIQUID EXTRACTION
IS THE MORE SUITABLE OPTION
Description: %XTRACTIVE DISTILLATION IS USED TO SEPARATE CLOSE
BOILING COM
PONENTS USING A SOLVENT THAT ALTERS THE VOLATILITY BETWEEN THE COMPO
NENTS !N %$ 3ULFOLANE UNIT CONSISTS OF TWO PRIMARY COLUMNS THEY ARE
THE %$ COLUMN AND THE SOLVENT RECOVERY COLUMN !ROMATIC FEED IS PRE
HEATED WITH LEAN SOLVENT AND ENTERS A CENTRAL STAGE OF THE %$ COLUMN
4HE LEAN SOLVENT IS INTRODUCED NEAR THE TOP OF THE %$ COLUMN .ON
AROMATICS ARE SEPARATED FROM THE TOP OF THIS COLUMN AND SENT TO STORAGE
4HE %$ COLUMN BOTTOMS CONTAIN SOLVENT AND HIGHLY PURIl ED AROMATICS
THAT ARE SENT TO THE SOLVENT RECOVERY COLUMN )N THIS COLUMN AROMAT
ICS ARE SEPARATED FROM SOLVENT UNDER VACUUM WITH STEAM STRIPPING 4HE
OVERHEAD AROMATICS PRODUCT IS SENT TO THE "4 FRACTIONATION SECTION ,EAN
SOLVENT IS SEPARATED FROM THE BOTTOM OF THE COLUMN AND RECIRCULATED
BACK TO THE %$ COLUMN
Economics: 4HE SOLVENT USED IN THE 3ULFOLANE PROCESS EXHIBITS HIGHER
SELECTIVITY AND CAPACITY FOR AROMATICS THAN ANY OTHER COMMERCIAL SOL
VENT 5SING THE 3ULFALANE PROCESS MINIMIZES CONCERN ABOUT TRACE NITRO
GEN CONTAMINATION THAT OCCURS WITH NITROGEN
BASED SOLVENTS %STIMATED
INSIDE BATTERY LIMITS )3", COSTS BASED ON A UNIT PROCESSING
MTPY OF "4 REFORMATE FEEDSTOCK WITH ,6 AROMATICS 53 'ULF #OAST
SITE IN
)NVESTMENT 53 MILLION
5TILITIES PER MT OF FEED
%LECTRICITY K7H
3TEAM MT
7ATER COOLING M
2ECOVERY
COLUMN
%$
COLUMN
2AFFINATE
TO STORAGE
!ROMATICS TO "4
FRACTIONATION UNIT
&RESH FEED
3TEAM
GENERATOR
Commercial
plants: )N 3HELL COMMERCIALIZED THE 3ULFOLANE PROCESS
IN ITS REl NERIES IN %NGLAND AND )TALY 4HE SUCCESS OF THE 3ULFOLANE PRO
CESS LED TO AN AGREEMENT IN WHEREBY 5/0 BECAME THE EXCLUSIVE
LICENSOR OF THE 3ULFOLANE PROCESS -ANY OF THE PROCESS IMPROVEMENTS
INCORPORATED IN MODERN 3ULFOLANE UNITS ARE BASED ON DESIGN FEATURES
AND OPERATING TECHNIQUES DEVELOPED BY 5/0 5/0 HAS LICENSED A TOTAL
OF 3ULFOLANE UNITS THROUGHOUT THE WORLD
Licensor: 5/0 ,,#
Aromatics
extractive
distillation
Application: 2ECOVERY OF HIGH
PURITY AROMATICS FROM REFORMATE PYROLYSIS
Description: )N 5HDES PROPRIETARY EXTRACTIVE DISTILLATION %$ -ORPHYLANE
PROCESS A SINGLE
COMPOUND SOLVENT .
&ORMYLMORPHOLINE .&- ALTERS THE
VAPOR PRESSURE OF THE COMPONENTS BEING SEPARATED 4HE VAPOR PRESSURE OF
THE AROMATICS IS LOWERED MORE THAN THAT OF THE LESS SOLUBLE NONAROMATICS
.ONAROMATICS VAPORS LEAVE THE TOP OF THE %$ COLUMN WITH SOME SOLV
ENT WHICH IS RECOVERED IN A SMALL COLUMN THAT CAN EITHER BE MOUNTED ON
THE MAIN COLUMN OR INSTALLED SEPARATELY
"OTTOM PRODUCT OF THE %$ COLUMN IS FED TO THE STRIPPER TO SEPARATE
PURE AROMATICS FROM THE SOLVENT !FTER INTENSIVE HEAT EXCHANGE THE LEAN
SOLVENT IS RECYCLED TO THE %$ COLUMN .&- PERFECTLY SATISl ES THE NECES
SARY SOLVENT PROPERTIES NEEDED FOR THIS PROCESS INCLUDING HIGH SELECTIVITY
THERMAL STABILITY AND A SUITABLE BOILING POINT
Economics:
Pygas
feedstock:
Production
yield
"ENZENE
4OLUENE
Quality
"ENZENE
4OLUENE
Consumption
3TEAM
Benzene
Benzene/toluene
n
WT PPM .!
n
WT PPM .!
WT PPM .!
KGT %$ FEED
KGT %$ FEED
Reformate
feedstock
with
low-aromatics
content
(20
wt%):
Benzene
Quality
"ENZENE
Consumption
3TEAM
WT PPM .!
KGT %$ FEED
-AXIMUM CONTENT OF NONAROMATICS
)NCLUDING BENZENETOLUENE SPLITTER
.ONAROMATICS
%XTRACTIVE
DISTILLATION
COLUMN
GASOLINE OR COKE OVEN LIGHT OIL USING EXTRACTIVE DISTILLATION
!ROMATICS
FRACTION
!ROMATICS
3TRIPPER
COLUMN
3OLVENT
3OLVENT AROMATICS
Commercial
plants: -ORE THAN -ORPHYLANE PLANTS TOTAL CAPACITY
OF MORE THAN --TPY
References: %MMRICH ' & %NNENBACH AND 5 2ANKE h+RUPP 5HDE
0ROCESSES FOR !ROMATICS 2ECOVERY v %UROPEAN 0ETROCHEMICAL 4ECHNOLOGY
#ONFERENCE *UNE n ,ONDON
%MMRICH ' 5 2ANKE AND ( 'EHRKE h7ORKING WITH AN EXTRACTIVE DIS
TILLATION PROCESS v 0ETROLEUM 4ECHNOLOGY 1UARTERLY 3UMMER P
Licensor: 5HDE 'MB(
Aromatics
recovery
Application: 2ECOVERY VIA EXTRACTION OF HIGH PURITY # n # AROMATICS
%XTRACTOR
FROM PYROLYSIS GASOLINE REFORMATE COKE OVEN LIGHT OIL AND KEROSENE FRAC
TIONS
7ATER WASH
3TRIPPER
2ECOVERY
TOWER
2AFFINATE
%XTRACT RECYCLE
Description: (YDROCARBON FEED IS PUMPED TO THE LIQUID
LIQUID EXTRACTION
COLUMN WHERE THE AROMATICS ARE DISSOLVED SELECTIVELY IN THE SULFOLANE
WATER
BASED SOLVENT AND SEPARATED FROM THE INSOLUBLE NON
AROMATICS
PARAFl NS OLEl NS AND NAPHTHENES 4HE NON
AROMATIC RAFl NATE PHASE
EXITS AT THE TOP OF THE COLUMN AND IS SENT TO THE WASH TOWER 4HE
WASH TOWER RECOVERS DISSOLVED AND ENTRAINED SULFOLANE BY WATER EXTRAC
TION AND THE RAFl NATE IS SENT TO STORAGE 7ATER CONTAINING SULFOLANE IS
SENT TO THE WATER STRIPPER
4HE SOLVENT PHASE LEAVING THE EXTRACTOR CONTAINS AROMATICS AND SMALL
AMOUNTS OF NON AROMATICS 4HE LATTER ARE REMOVED IN THE STRIPPER
AND RECYCLED TO THE EXTRACTION COLUMN 4HE AROMATIC
ENRICHED SOLVENT IS
PUMPED FROM THE STRIPPER TO THE RECOVERY TOWER WHERE THE AROMAT
ICS ARE VACUUM DISTILLED FROM THE SOLVENT AND SENT TO DOWNSTREAM CLAY
TREATMENT AND DISTILLATION -EANWHILE THE SOLVENT IS RETURNED TO THE
EXTRACTOR AND THE PROCESS REPEATS ITSELF
Yields /VERALL AROMATICS RECOVERIES ARE WHILE SOLVENT LOSSES ARE
Economics: &OR 53 'ULF #OAST LOCATION
# n #
PYROLYSIS
GASOLINE
n
n
n
n
n
!ROMATICS
4O WATER
STRIPPER
2ICH SOLVENT
# n #
REFORMATE
n
n
n
n
7ATER
,EAN SOLVENT
Commercial
plants: /VER LICENSED UNITS ARE IN OPERATION
Licensor: !XENS !XENS .!
EXTREMELY SMALL LESS THAN LBBBL OF FEED
&EED
&EED BPSD
!ROMATICS WT
5TILITIES PER BBL FEED
#OOLING "TU
3TEAM -0 LB
0OWER K7H
)3", )NVESTMENT 53
&EED
Benzene
Application: 4O PRODUCE HIGH
PURITY BENZENE AND HEAVIER AROMATICS FROM
TOLUENE AND HEAVIER AROMATICS USING THE $ETOL PROCESS
Description: &EED AND HYDROGEN ARE HEATED AND PASSED OVER THE CATALYST
"ENZENE AND UNCONVERTED TOLUENE ANDOR XYLENE AND HEAVIER ARO
MATICS ARE CONDENSED AND STABILIZED
4O MEET ACID WASH COLOR SPECIl CATIONS STABILIZER BOTTOMS ARE PASSED
THROUGH A l XED
BED CLAY TREATER THEN DISTILLED TO PRODUCE THE DESIRED
SPECIl CATION BENZENE 4HE CRYOGENIC PURIl CATION OF RECYCLE HYDROGEN TO
REDUCE THE MAKE
UP HYDROGEN REQUIREMENT IS OPTIONAL
5NCONVERTED TOLUENE ANDOR XYLENES AND HEAVIER AROMATICS ARE
RECYCLED
Yields: !ROMATIC YIELD IS MOL OF FRESH TOLUENE OR HEAVIER AROMATIC
( MAKEUP
( RECYCLE
&UEL GAS
"ENZENE
# !ROMATIC
8YLENES
2ECYCLE TOLUENE AND # AROMATICS
CHARGE 4YPICAL YIELDS FOR PRODUCTION OF BENZENE AND XYLENES ARE
4YPE PRODUCTION
.ONAROMATICS
"ENZENE
4OLUENE
# AROMATICS
# AROMATICS
0RODUCTS WT OF FEED
"ENZENE
# AROMATICS
"ENZENE
FEED WT
8YLENE
# MINIMUM FREEZE POINT
PPM NONAROMATICS MAXIMUM
Economics: "ASIS OF )3", 53 'ULF #OAST
%STIMATED INVESTMENT BPSD
4YPICAL UTILITY REQUIREMENTS PER BBL FEED
%LECTRICITY K7H
&UEL --"TU
7ATER COOLING GAL
3TEAM LB
.O CREDIT TAKEN FOR VENT GAS STREAMS
Commercial
plants: 4WELVE PLANTS WITH CAPACITIES RANGING FROM ABOUT
MILLION TO MILLION GAL Y HAVE BEEN LICENSED
Licensor: !"" ,UMMUS 'LOBAL
Benzene
Application: 0RODUCE BENZENE VIA THE HYDRODEALKYLATION OF # n #
AROMATICS
(YDROGEN MAKEUP
,IGHT ENDS
Description: &RESH # n # TO # FEED IS MIXED WITH RECYCLE HYDROGEN
MAKEUP HYDROGEN AND # AROMATICS FROM THE RECYCLE TOWER 4HE MIX
TURE IS HEATED BY EXCHANGE WITH REACTOR EFm UENT AND BY A FURNACE
THAT ALSO GENERATES HIGH
PRESSURE STEAM FOR BETTER HEAT RECOVERY
4IGHT TEMPERATURE CONTROL IS MAINTAINED IN THE REACTOR TO ARRIVE
AT HIGH YIELDS USING A MULTI
POINT HYDROGEN QUENCH )N THIS WAY CON
VERSION IS CONTROLLED AT THE OPTIMUM LEVEL WHICH DEPENDS ON REACTOR
THROUGHPUT OPERATING CONDITIONS AND FEED COMPOSITION
"Y RECYCLING THE DIPHENYL ITS TOTAL PRODUCTION IS MINIMIZED TO
THE ADVANTAGE OF INCREASED BENZENE PRODUCTION 4HE REACTOR EFm UENT IS
COOLED BY EXCHANGE WITH FEED FOLLOWED BY COOLING WATER OR AIR AND
SENT TO THE m ASH DRUM WHERE HYDROGEN
RICH GAS SEPARATES FROM THE
CONDENSED LIQUID 4HE GAS PHASE IS COMPRESSED AND RETURNED TO THE
REACTOR AS QUENCH RECYCLE (
0ART OF THE STREAM IS WASHED COUNTERCURRENTLY WITH A FEED SIDESTREAM
IN THE VENT ( ABSORBER FOR BENZENE RECOVERY 4HE ABSORBER OVERHEAD
m OWS TO THE HYDROGEN PURIl CATION UNIT WHERE HYDROGEN PURITY IS
INCREASED TO SO IT CAN BE RECYCLED TO THE REACTOR 4HE STABILIZER
REMOVES LIGHT ENDS MOSTLY METHANE AND ETHANE FROM THE m ASH DRUM
LIQUID 4HE BOTTOMS ARE SENT TO THE BENZENE COLUMN WHERE HIGH
PURITY BENZENE IS PRODUCED OVERHEAD 4HE BOTTOMS STREAM CONTAINING
UNREACTED TOLUENE AND HEAVIER AROMATICS IS PUMPED TO THE RECYCLE COL
UMN 4OLUENE # AROMATICS AND DIPHENYL ARE DISTILLED OVERHEAD AND
RECYCLED TO THE REACTOR ! SMALL PURGE STREAM PREVENTS THE HEAVY COMPO
NENTS FROM BUILDING UP IN THE PROCESS
Yields: "ENZENE YIELDS ARE CLOSE TO THE THEORETICAL OWING TO SEVERAL TECH
NIQUES USED SUCH AS PROPRIETARY REACTOR DESIGN HEAVY AROMATIC DIPHE
NYL RECYCLE AND MULTI
POINT HYDROGEN QUENCH
(YDROGEN
PURIFICATION UNIT
"ENZENE
0URGE
&EED
Economics: "ASIS 53 'ULF #OAST
4OLUENE FEED METRIC TPY
"ENZENE PRODUCT METRIC TPY
0OWER K7
7ATER COOLING
&LOW INHR
4EMPERATURE DIFFERENTIAL #
&UEL HEAT RELEASE MILLION KCALHR
BARG STEAM PRODUCTION KGHR
)3", INVESTMENT 53$
# n # RECYCLE
n
Commercial
plants: 4HIRTY
l VE PLANTS HAVE BEEN LICENSED WORLDWIDE FOR
Benzene, CONTINUED
PROCESSING A VARIETY OF FEEDSTOCKS INCLUDING TOLUENE MIXED AROMATICS
REFORMATE AND PYROLYSIS GASOLINE
Licensor: !XENS !XENS .!
Bisphenol
A
2ECYCLE
ACETONE
Application: 4HE "ADGER "0! TECHNOLOGY IS USED TO PRODUCE HIGH
PU
RITY BISHENOL ! "0! PRODUCT SUITABLE FOR POLYCARBONATE AND EPOXY
RESIN APPLICATIONS 4HE PRODUCT IS PRODUCED OVER ION
EXCHANGE RESIN
FROM PHENOL AND ACETONE IN A PROCESS FEATURING PROPRIETARY PURIl CA
TION TECHNOLOGY
Description: !CETONE AND EXCESS PHENOL ARE REACTED BY CONDENSATION IN
AN ION EXCHANGE RESIN
CATALYZED REACTOR SYSTEM TO PRODUCE P P "0!
WATER AND VARIOUS BYPRODUCTS 4HE CRUDE DISTILLATION COLUMN REMOVES
WATER AND UNREACTED ACETONE FROM THE REACTOR EFm UENT !CETONE AND
LIGHTS ARE ADSORBED INTO PHENOL IN THE LIGHTS ADSORBER TO PRODUCE A
RECYCLE ACETONE STREAM 4HE BOTTOMS OF THE CRUDE COLUMN IS SENT TO THE
CRYSTALLIZATION FEED PRE
CONCENTRATOR WHICH DISTILLS PHENOL AND CON
CENTRATES "0! TO A LEVEL SUITABLE FOR CRYSTALLIZATION
"0! IS SEPARATED FROM BYPRODUCTS IN A PROPRIETARY SOLVENT CRYSTAL
LIZATION AND RECOVERY SYSTEM TO PRODUCE THE ADDUCT OF P P "0! AND
PHENOL -OTHER LIQUOR FROM THE PURIl CATION SYSTEM IS DISTILLED IN THE
SOLVENT RECOVERY COLUMN TO RECOVER DISSOLVED SOLVENT 4HE SOLVENT
FREE MOTHER LIQUOR STREAM IS RECYCLED TO THE REACTION SYSTEM ! PURGE
FROM THE MOTHER LIQUOR IS SENT TO THE PURGE RECOVERY SYSTEM ALONG
WITH THE RECOVERED PROCESS WATER TO RECOVER PHENOL 4HE RECOVERED
PURIl ED ADDUCT IS PROCESSED IN A "0! l NISHING SYSTEM TO REMOVE
PHENOL FROM PRODUCT AND THE RESULTING MOLTEN "0! IS SOLIDIl ED IN THE
PRILL TOWER TO PRODUCE PRODUCT PRILLS SUITABLE FOR THE MERCHANT "0!
MARKET
Process
features: 4HE UNIQUE CRYSTALLIZATION SYSTEM PRODUCES A STABLE
CRYSTAL THAT IS EFl CIENTLY SEPARATED FROM ITS MOTHER LIQUOR 4HESE PLANTS
ARE EXTREMELY RELIABLE AND HAVE BEEN ENGINEERED TO MEET THE OPERATING
STANDARDS OF THE MOST DEMANDING REl NING AND CHEMICAL COMPANIES 4HE
CATALYST SYSTEM USES A UNIQUE UPm OW DESIGN THAT IS BENEl CIAL TO CATALYST
LIFE AND PERFORMANCE (IGH CAPACITY OPERATION HAS BEEN FULLY DEMON
STRATED
!CETONE
0HENOL
3OLVENT
7ATER
!DDUCT
-OLTEN "0!
"0! PRILLS
-OTHER LIQUOR
0URGE
7ASTEWATER
2ESIDUE
Product
quality: 4YPICAL VALUES FOR "0! QUALITY ARE
&REEZING POINT #
"0! WW WT
-ETHANOL COLOR !0(!
Commercial
plants: 4HE l RST PLANT AMONG THE LARGEST IN THE WORLD BEGAN
OPERATION IN AT THE $EER 0ARK (OUSTON PLANT NOW OWNED AND OPER
ATED BY 2ESOLUTION 0ERFORMANCE 0RODUCTS ,,# 3INCE THAT TIME TWO OTHER
WORLD
SCALE PLANTS WERE LICENSED TO THE !SIA
0ACIl C MARKET
Licensor: "ADGER ,ICENSING ,,#
BTX
aromatics
Application: 4O PRODUCE HIGH YIELDS OF BENZENE TOLUENE XYLENES AND
2EACTORS AND
HEATERS
HYDROGEN FROM NAPHTHAS VIA THE ##2 !ROMIZING PROCESS COUPLED WITH
2EGEN# CONTINUOUS CATALYST REGENERATION TECHNOLOGY "ENZENE AND TOLU
ENE CUTS ARE FED DIRECTLY TO AN AROMATICS EXTRACTION UNIT 4HE XYLENES
FRACTION OBTAINED BY FRACTIONATION AND SUBSEQUENT TREATMENT BY THE
!ROl NING PROCESS FOR DIOLEl NS AND OLEl NS REMOVAL IS IDEAL FOR PARA
XYLENE AND ORTHOXYLENE PRODUCTION
2EGENERATOR
"OOSTER
COMPRESSOR
2EGEN
LOOP
Yields:
4"0 CUT #
0ARAFl NS
.APHTHENES
!ROMATICS
&EED
n
(YDROGEN
#
"ENZENE
4OLUENE
8YLENES
4OTAL AROMATICS
0RODUCTS
3EPARATOR
Description: 4HIS PROCESS FEATURES MOVING BED REACTORS AND A CONTINU
OUS CATALYST REGENERATION SYSTEM COUPLED WITH A HARD SMOOTH
m OWING
CATALYST &EED ENTERS THE REACTOR PASSES RADIALLY THROUGH THE MOVING
CATALYST BED EXITS AT THE REACTOR BOTTOM AND PROCEEDS IN THE SAME MAN
NER THROUGH THE n REMAINING REACTORS 4HE ROBUST LATEST GENERA
TION !2 CATALYST MOVES DOWNWARD THROUGH EACH REACTOR
,EAVING THE REACTOR THE CATALYST IS GAS
LIFTED TO THE NEXT REACTORS FEED
HOPPER WHERE IT IS DISTRIBUTED FOR ENTRY !FTER THE LAST REACTOR AN INERT
GAS LIFT SYSTEM ISOLATES AND TRANSPORTS THE CATALYST TO THE RECENTLY
IN
TRODUCED 2EGEN# REGENERATION SECTION #OKE IS REMOVED CATALYST IS
RETURNED TO ITS ORIGINAL STATE AND SENT TO THE l RST REACTOR THE CYCLE BEGINS
AGAIN ! RECOVERY SYSTEM SEPARATES HYDROGEN FOR USE IN DOWNSTREAM
UNITS AND THE !ROMIZATE IS SENT TO A STABILIZATION SECTION 4HE UNIT IS FULLY
AUTOMATED AND OPERATING CONTROLS ARE INTEGRATED INTO A $#3 REQUIRING
ONLY A MINIMUM OF SUPERVISORY AND MAINTENANCE EFFORT
(YDROGEN
RICH GAS
&EED
2ECYCLE
COMPRESSOR
2ECOVERY
SYSTEM
!ROMIZATE TO
STABLIZATION
Economics: 4HE )3", INVESTMENT FOR A TYPICAL BPSD ##2 !ROMIZ
ING UNIT WITH A 2EGEN# REGENERATOR 'ULF #OAST LOCATION
)NVESTMENT INCLUDING INITIAL CATALYST INVENTORY
53 MILLION
4YPICAL UTILITY REQUIREMENTS
&UEL KCALH
3TEAM (0 TH NET EXPORT
%LECTRICITY K7HH
#ATALYST OPERATING COST TON FEED
%XCLUSIVE OF NOBLE METALS
BTX
aromatics, CONTINUED
Commercial
plants: 3IXTY
FOUR ##2 REFORMING UNITS HAVE BEEN LICENSED
INCLUDING SEVEN PLANTS IN OPERATION AND FOUR UNDER DESIGN
Licensor: !XENS !XENS .!
BTX
aromatics
Application: !N AROMATICS PROCESS BASED ON EXTRACTIVE DISTILLATION '4
"48 EFl CIENTLY RECOVERS BENZENE TOLUENE AND XYLENES FROM REl NERY OR
PETROCHEMICAL AROMATICS STREAMS SUCH AS CATALYTIC REFORMATE OR PYROLYSIS
GASOLINE
Description: (YDROCARBON FEED IS PREHEATED WITH HOT CIRCULATING SOL
VENT AND FED AT A MIDPOINT INTO THE EXTRACTIVE DISTILLATION COLUMN
%$# ,EAN SOLVENT IS FED AT AN UPPER POINT TO SELECTIVELY EXTRACT
THE AROMATICS INTO THE COLUMN BOTTOMS IN A VAPORLIQUID DISTILLATION
OPERATION .ONAROMATIC HYDROCARBONS EXIT THE COLUMN TOP AND PASS
THROUGH A CONDENSER ! PORTION OF THE OVERHEAD STREAM IS RETURNED
TO THE COLUMN TOP AS REm UX TO WASH OUT ANY ENTRAINED SOLVENT 4HE
BALANCE OF THE OVERHEAD STREAM IS THE RAFl NATE PRODUCT REQUIRING NO
FURTHER TREATMENT
2ICH SOLVENT FROM THE BOTTOM OF THE %$#IS ROUTED TO THE SOLVENT
RECOVERY COLUMN 32# WHERE THE AROMATICS ARE STRIPPED OVERHEAD
3TRIPPING STEAM FROM A CLOSED
LOOP WATER CIRCUIT FACILITATES HYDROCARBON
STRIPPING 4HE 32# OPERATES UNDER VACUUM TO REDUCE THE BOILING POINT
AT THE COLUMN BASE
,EAN SOLVENT FROM THE BOTTOM OF THE 32# IS PASSED THROUGH HEAT
EXCHANGE BEFORE RETURNING TO THE %$# ! SMALL PORTION OF THE LEAN
CIRCULATING SOLVENT IS PROCESSED IN A SOLVENT
REGENERATION STEP TO REMOVE
HEAVY DECOMPOSITION PRODUCTS WHICH ARE PURGED DAILY
4HE PROCESS ADVANTAGES OVER CONVENTIONAL LIQUID
LIQUID EXTRACTION
PROCESSES INCLUDE LOWER CAPITAL AND OPERATING COSTS AND SIMPLICITY OF
OPERATION !DVANTAGES OVER OTHER EXTRACTIVE PROCESSES INCLUDE SUPERIOR
SOLVENT SYSTEM FEWER EQUIPMENT PIECES SMALL EQUIPMENT AND EXPANDED
FEEDSTOCK RANGE $ESIGN m EXIBILITY ALLOWS USE FOR GRASSROOTS AROMATICS
RECOVERY UNITS OR DEBOTTLENECKING CONVENTIONAL SYSTEMS IN MANY REVAMP
CONl GURATIONS
,EAN
SOLVENT
(YDROCARBON FEED
2AFFINATE
%XTRACTIVE
DISTILLATION
COLUMN
!ROMATICS TO
DOWNSTREAM
FRACTIONATION
3OLVENT
RECOVERY
COLUMN
7ATER
3TEAM
!ROMATICS
RICH
SOLVENT
Economics:
.EW UNIT
%XPANSION OF CONVENTIONAL
"48 RECOVERY UNIT
&EED BPD
,T REFORMATE
INCREMENTAL
#APITAL COST --
3IMPLE PRETAX PAYOUT YR
2/)
Commercial
plants: &OURTEEN COMMERCIAL LICENSES ARE IN PLACE
Reference: h"ENZENE REDUCTION IN MOTOR GASOLINE OBLIGATION OR OP
PORTUNITY v (YDROCARBON 0ROCESSING 0ROCESS /PTIMIZATION #ONFER
BTX
aromatics, CONTINUED
ENCE !PRIL h)MPROVE "48 PROCESSING ECONOMICS v (YDROCARBON
0ROCESSING -ARCH
Licensor: '4# 4ECHNOLOGY
BTX
aromatics
Application: 4O PRODUCE REFORMATE WHICH IS CONCENTRATED IN BENZENE
TOLUENE AND XYLENES "48 FROM NAPHTHA AND CONDENSATE FEEDSTOCKS VIA
A HIGH
SEVERITY REFORMING OPERATION WITH A HYDROGEN BYPRODUCT 4HE
##2 0LATFORMING 0ROCESS IS LICENSED BY 5/0
Description: 4HE PROCESS CONSISTS OF A REACTOR SECTION CONTINUOUS CATA
LYST REGENERATION SECTION ##2 AND PRODUCT RECOVERY SECTION 3TACKED
RADIAL m OW REACTORS FACILITATE CATALYST TRANSFER TO AND FROM THE ##2
CATALYST REGENERATION SECTION ! CHARGE HEATER AND INTERHEATERS
ARE USED TO ACHIEVE OPTIMUM CONVERSION AND SELECTIVITY FOR THE ENDO
THERMIC REACTION
2EACTOR EFm UENT IS SEPARATED INTO LIQUID AND VAPOR PRODUCTS
,IQUID PRODUCT IS SENT TO A STABILIZER TO REMOVE LIGHT ENDS 6APOR
FROM THE SEPARATOR IS COMPRESSED AND SENT TO A GAS
RECOVERY SECTION
TO SEPARATE
PURE HYDROGEN BYPRODUCT ! FUEL GAS BYPRODUCT OF
,0' CAN ALSO BE PRODUCED 5/0S LATEST 2
SERIES CATALYST MAXIMIZES
AROMATICS YIELDS
Yields:
&RESH
CATALYST
.ET ( RICH GAS
.APHTHA FEED
FROM TREATING
&UEL GAS
3PENT
CATALYST
,IGHT ENDS
# AROMATICS
4YPICAL YIELDS FROM LEAN -IDDLE %AST NAPHTHA
( WT
"ENZENE WT
4OLUENE WT
8YLENES WT
! WT
Economics: #APITAL INVESTMENT PER MTPY OF FEED
53
5TILITIES PER METRIC TON FEEDRATE
%LECTRICITY K7H
3TEAM (0 MT
7ATER COOLING M
&UEL --KCAL
n
Commercial
plants: 4HERE ARE UNITS IN OPERATION AND ADDITIONAL
UNITS IN DESIGN AND CONSTRUCTION 4OTAL OPERATING CAPACITY REPRESENTS
OVER MILLION BPD
Licensor: 5/0 ,,#
BTX
aromatics
Application:
4O PRODUCE PETROCHEMICAL
GRADE BENZENE TOLUENE AND XY
3TRIPPER OFFGAS
LENES "48 VIA THE AROMATIZATION OF PROPANE AND BUTANES USING THE "0
5/0 #YCLAR PROCESS
LYST REGENERATION ##2 SECTION AND PRODUCT
RECOVERY SECTION 3TACKED
RADIAL
m OW REACTORS FACILITATE CATALYST TRANSFER TO AND FROM THE ##2
CATALYST REGENERATION SECTION ! CHARGE HEATER AND INTERHEATERS
ACHIEVE OPTIMUM CONVERSION AND SELECTIVITY FOR THE ENDOTHERMIC REAC
TION 2EACTOR EFm UENT IS SEPARATED INTO LIQUID AND VAPOR PRODUCTS
4HE LIQUID PRODUCT IS SENT TO A STRIPPER COLUMN TO REMOVE LIGHT SATU
RATES FROM THE #n AROMATIC PRODUCT 6APOR FROM THE SEPARATOR IS COM
PRESSED AND SENT TO A GAS RECOVERY UNIT 4HE COMPRESSED VAPOR IS
THEN SEPARATED INTO A PURE HYDROGEN COPRODUCT A FUEL
GAS STREAM
CONTAINING LIGHT BYPRODUCTS AND A RECYCLED STREAM OF UNCONVERTED ,0'
Description: 4HE PROCESS CONSISTS OF A REACTOR SECTION CONTINUOUS CATA
# !ROMATIC
PRODUCT
.ET FUEL GAS
(YDROGEN
&RESH FEED
&ROM
REACTOR
"OOSTER
COMP
2ECYCLE TO REACTOR
Yields: 4OTAL AROMATICS YIELDS AS A WT OF FRESH FEED RANGE FROM
FOR PROPANE TO FOR MIXED BUTANES FEED (YDROGEN YIELD IS APPROXI
MATELY WT FRESH FEED 4YPICAL PRODUCT DISTRIBUTION IS BENZENE
TOLUENE # AROMATICS AND # AROMATICS
Economics: 53 'ULF #OAST INSIDE BATTERY LIMITS BASIS ASSUMING GAS TUR
BINE DRIVER IS USED FOR PRODUCT COMPRESSOR
)NVESTMENT 53 PER METRIC TON MT OF FEED
4YPICAL UTILITY REQUIREMENTS UNIT PER MT OF FEED
%LECTRICITY K7H
3TEAM -0 MT CREDIT
3TEAM ,0 MT
7ATER COOLING MT
&UEL --KCAL
"OILER FEEDWATER MT
n
Commercial
plants: )N THE l RST #YCLAR UNIT WAS COMMISSIONED AT
THE "0 REl NERY AT 'RANGEMOUTH 3COTLAND 4HIS UNIT WAS DESIGNED TO
PROCESS BPD OF # OR # FEEDSTOCK AT EITHER HIGH OR LOW PRESSURE
OVER A WIDE RANGE OF OPERATING CONDITIONS ! SECOND UNIT CAPABLE OF
PROCESSING # AND # FEEDSTOCK WAS COMMISSIONED IN AND OPER
ATES AT DESIGN CAPACITIES
Reference: $OOLAN 0 # AND 0 2 0UJADO h-AKE AROMATICS FROM ,0' v
(YDROCARBON 0ROCESSING 3EPTEMBER PP n
'OSLING # $ ET AL h0ROCESS ,0' TO "48 PRODUCTS v (YDROCARBON
0ROCESSING $ECEMBER
Licensor: 5/0 ,,#
Butadiene
extraction
Application: 4O PRODUCE A POLYMER
GRADE BUTADIENE PRODUCT FROM
Yields: 4HIS PROCESS CAN EXCEED RECOVERY OF THE BUTADIENE CON
TAINED IN THE FEED AS PRODUCT 4HIS PRODUCT WILL MEET ALL BUTADIENE DE
RIVATIVE REQUIREMENTS WITH TYPICAL SPECIl CATIONS SHOWN BELOW
3OLVENT MAKEUP
"UTANE
BUTYLENE
WASHER
Description: 4HIS BUTADIENE EXTRACTION PROCESS WAS ORIGINALLY DEVELOPED
BY 3HELL #HEMICALS )T IS OFFERED UNDER LICENSE AGREEMENT BY +ELLOGG
"ROWN 2OOT WHO HAS UPDATED AND OPTIMIZED THE PROCESS TO REDUCE
CAPITAL AND OPERATING COSTS
4HE PROCESS SCHEME CONSISTS OF CONTACTING MIXED
# FEED WITH LEAN
SOLVENT IN THE EXTRACTIVE DISTILLATION COLUMN 4HE RAFl NATE BUTENES AND
BUTANES WHICH ARE NOT ABSORBED m OW OVERHEAD TO THE WASH COLUMN
FOR SOLVENT RECOVERY 4HE BUTADIENE
RICH SOLVENT m OWS TO THE STRIPPER
SYSTEM WHERE THE BUTADIENE IS SEPARATED FROM THE SOLVENT 2AW
BUTADIENE IS PURIl ED TO MEET SPECIl CATIONS IN THE PURIl CATION SECTION
(EAVY ENDS # ACETYLENES ARE ALSO SEPARATED IN THE STRIPPER SYSTEM
AS A SIDE PRODUCT AND FURTHER PROCESSED IN THE HEAVY
ENDS STRIPPING
SECTION 4HE SOLVENT RECOVERY STEP MAINTAINS SOLVENT QUALITY AND
RECOVERS SOLVENT FROM VARIOUS PRODUCT STREAMS
5SE OF ACETONITRILE IS ADVANTAGEOUS TO OTHER SOLVENT SYSTEMS FOR A
NUMBER OF REASONS !#.S LOWER BOILING POINT RESULTS IN LOWER OPERATING
TEMPERATURES RESULTING IN LOW FOULING RATES AND LONG RUN
LENGTHS /NLY
LOW
PRESSURE STEAM IS REQUIRED FOR REBOILERS 4HE LOW MOLECULAR WEIGHT
AND LOW MOLAR VOLUME OF !#. COMBINED WITH ITS HIGH SELECTIVITY TO
BUTADIENE RESULT IN LOW SOLVENT CIRCULATION RATES AND SMALLER EQUIPMENT
SIZES 4HE LOW VISCOSITY OF !#. INCREASES TOWER EFl CIENCIES AND
REDUCES COLUMN SIZE AND COST !#. IS ALSO VERY STABLE NONCORROSIVE
AND BIODEGRADABLE 4HE BASIC PROCESS IS NONCORROSIVE AND REQUIRES ONLY
CARBON STEEL MATERIALS OF CONSTRUCTION
"UTANEBUTYLENE PRODUCT
MIXED # STREAMS BY EXTRACTIVE DISTILLATION USING ACETONITRILE !#. AS
THE SOLVENT
#
FEED
3OLVENT BLEED
2ECOVERED SOLVENT
%XTRACTIVE
DISTILLATION
0RODUCT
PURIFICATION
SECTION
,IGHT ENDS
$ILUENT
"UTADIENE
PRODUCT
(EAVY
ENDS
STRIPPING
SECTION
3TRIPPING
SECTION
,EAN SOLVENT
#OMPONENT
"UTADIENE
4OTAL ACETYLENES
-ETHYL ACETYLENE
6INYL ACETYLENES
0ROPADIENE
"UTADIENE
# HYDROCARBONS
7ASH WATER TO
INTERNAL USERS
3OLVENT
RECOVERY
SYSTEM
(EAVY
ENDS
,EAN SOLVENT
6ALUE
5NITS
WT MINIMUM
PPM WT MAXIMUM
PPM WT MAXIMUM
PPM WT MAXIMUM
PPM WT MAXIMUM
PPM WT MAXIMUM
PPM WT MAXIMUM
Commercial
plants: /VER BUTADIENE UNITS HAVE BEEN CONSTRUCTED US
ING THE 3HELL !#. TECHNOLOGY 5NIT CAPACITIES RANGE FROM -TPY TO
OVER -TPY
Licensor: +ELLOGG "ROWN 2OOT )NC
1,3
Butadiene
(Extraction
from
mixed
C4)
-ETHYL ACETYLENE
0ROPYNE
Application: 4O PRODUCE HIGH
PURITY BUTADIENE FROM A MIXED # STREAM
TYPICALLY A BYPRODUCT STREAM FROM AN ETHYLENE PLANT USING LIQUID FEEDS
LIQUIDS CRACKER 4HE "!3& ,UMMUS PROCESS USES N
METHYLPYRROLIDONE
.-0 AS THE SOLVENT
"UTENES RAFFINATE
Description: 4HE MIXED # FEED STREAM IS FED INTO THE l RST EXTRACTIVE
,EAN
.-0
SOLVENT
DISTILLATION COLUMN WHICH PRODUCES AN OVERHEAD BUTENES STREAM RAF
l NATE
THAT IS ESSENTIALLY FREE OF BUTADIENE AND ACETYLENES
4HE BOTTOMS STREAM FROM THIS COLUMN IS STRIPPED FREE OF BUTENES IN
THE TOP HALF OF THE RECTIl ER ! SIDE STREAM CONTAINING BUTADIENE AND
A SMALL AMOUNT OF ACETYLENIC COMPOUNDS VINYL AND ETHYL
ACETYLENE IS
WITHDRAWN FROM THE RECTIl ER AND FED INTO THE SECOND EXTRACTIVE DISTILLATION
COLUMN
4HE # ACETYLENES WHICH HAVE HIGHER SOLUBILITIES IN .-0 THAN
BUTADIENE ARE REMOVED BY THE SOLVENT IN THE BOTTOMS AND RETURNED
TO THE RECTIl ER ! CRUDE BUTADIENE "$ STREAM FROM THE OVERHEAD OF
THE SECOND EXTRACTIVE DISTILLATION COLUMN IS FED INTO THE "$ PURIl CATION
TRAIN "OTH EXTRACTIVE DISTILLATION COLUMNS HAVE A NUMBER OF TRAYS ABOVE
THE SOLVENT ADDITION POINT TO ALLOW FOR THE REMOVAL OF SOLVENT TRACES FROM
THE OVERHEADS
4HE BOTTOMS OF THE RECTIl ER CONTAINING "$ # ACETYLENES AND
# HYDROCARBONS IN .-0 IS PREHEATED AND FED INTO THE DEGASSER THE
SOLVENT STRIPPING COLUMN )N THIS COLUMN SOLVENT VAPORS ARE USED AS
THE STRIPPING MEDIUM TO REMOVE ALL LIGHT HYDROCARBONS FROM .-0
4HE HOT
STRIPPED SOLVENT FROM THE BOTTOM OF THE DEGASSER PASSES
THROUGH THE HEAT ECONOMIZERS A TRAIN OF HEAT EXCHANGERS AND IS FED TO
THE EXTRACTIVE DISTILLATION COLUMNS
4HE HYDROCARBONS LEAVING THE TOP OF THE DEGASSER ARE COOLED IN A
COLUMN BY DIRECT CONTACT WITH SOLVENT .-0 AND WATER AND FED TO THE
BOTTOM OF THE RECTIl ER VIA A RECYCLE GAS COMPRESSOR
(YDROCARBONS HAVING HIGHER SOLUBILITIES IN THE SOLVENT THAN
BUTADIENE ACCUMULATE IN THE MIDDLE ZONE OF THE DEGASSER AND ARE DRAWN
OFF AS A SIDE STREAM 4HIS SIDE STREAM AFTER DILUTION WITH RAFl NATE
IS
,EAN
.-0
SOLVENT
## HEAVIES
STREAM
-IXED
# FEED
"UTADIENE
PRODUCT
# ACETYLENES
STREAM
,EAN .-0 SOLVENT TO HEAT RECOVERY
FED TO A WATER SCRUBBER TO REMOVE A SMALL AMOUNT OF .-0 FROM THE
EXITING GASES 4HE SCRUBBED GASES CONTAINING THE # ACETYLENES ARE
PURGED TO DISPOSAL
)N THE PROPYNE COLUMN THE PROPYNE # ACETYLENE IS REMOVED
AS OVERHEAD AND SENT TO DISPOSAL 4HE BOTTOMS ARE FED TO THE SECOND
DISTILLATION COLUMN THE
BUTADIENE COLUMN WHICH PRODUCES PURE
"$ AS OVERHEAD AND A SMALL STREAM CONTAINING
BUTADIENE AND #
HYDROCARBONS AS BOTTOMS
Yield: 4YPICALLY MORE THAN OF THE BUTADIENE CONTAINED IN THE
FEED IS RECOVERED AS PRODUCT
1,3
Butadiene
(Extraction
from
mixed
C4), CONTINUED
Economics: 5NIT BASED ON A METRIC TPY )3", 53 'ULF #OAST
)NVESTMENT 53 MILLION
5TILITIES PER TON "$
3TEAM TON
7ATER COOLING M
%LECTRICITY K7H
Commercial
plants: #URRENTLY PLANTS ARE IN OPERATION USING THE "!3&
BUTADIENE EXTRACTION PROCESS &IVE ADDITIONAL PROJECTS ARE IN THE DESIGN
OR CONSTRUCTION PHASE
Licensor: "!3& !'!"" ,UMMUS 'LOBAL
Butadiene,
1,3
Application: 4HE +,0 PROCESS SELECTIVELY HYDROGENATES ACETYLENES IN
CRUDE BUTADIENE STREAMS FROM STEAM CRACKERS TO THEIR CORRESPONDING
DIENE OR OLEl N TO RECOVER
BUTADIENE 4HE +,0 PROCESS CAN BE USED IN
NEW INSTALLATIONS TO ELIMINATE THE COSTLY SECOND
STAGE EXTRACTIVE DISTILLA
TION STEP OR AS A RETROl T TO INCREASE PRODUCT QUALITY OR THROUGHPUT
Description: )N THE +,0 PROCESS THE # STREAM IS MIXED WITH AN ESSEN
TIALLY STOICHIOMETRIC AMOUNT OF HYDROGEN AND FED TO TWO l XED
BED REAC
TORS IN SERIES CONTAINING +,0
CATALYST 4HE REACTION PRESSURE IS HIGH
ENOUGH TO MAINTAIN THE REACTION MIXTURE IN THE LIQUID PHASE 4HE +,0
REACTOR EFm UENT THEN m OWS TO A DISTILLATION COLUMN TO REMOVE HYDROGEN
AND A SMALL AMOUNT OF HEAVIES FORMED IN THE PROCESS 4HE +,0 EFm UENT
STREAM IS PROCESSED IN A SINGLE
STAGE EXTRACTIVE DISTILLATION UNIT TO SEPA
RATE AND RECOVER HIGH
PURITY
BUTADIENE
Yields: 4HE COMBINATION OF THE +,0 PROCESS WITH BUTADIENE EXTRACTION
CAN PROVIDE OVER RECOVERY OF THE BUTADIENE CONTAINED IN THE FEED
AS PRODUCT 4HE RECOVERY IS ENHANCED BY THE CONVERSION OF VINYLACETYLENE
TO
BUTADIENE 4OTAL ACETYLENE LEVELS IN THE PRODUCT OF LESS THAN
WT
PPM ARE ACHIEVABLE 4HE PROCESS ALSO OFFERS IMPROVED SAFETY IN OP
ERATIONS BY ELIMINATING CONCENTRATED ACETYLENE BYPRODUCT STREAMS
Economics: 4HE CAPITAL INVESTMENT AND OPERATING COSTS FOR THE COMBI
NATION OF THE +,0 PROCESS WITH BUTADIENE EXTRACTION ARE SIMILAR OR LESS
THAN TWO
STAGE EXTRACTION PROCESSES
Commercial
plants: %IGHT +,0 UNITS ARE IN OPERATION 4HESE UNITS REPRE
SENT NEARLY ONE MILLION METRIC TPY OF OPERATING CAPACITY
Licensor: 5/0 ,,#
(
2AFFINATE
"UTADIENE
3OLVENT
#RUDE #
FEED
(EAVIES
+,0
3OLVENT
"$ AND
HEAVIES
/NE STAGE "$ EXTRACTION
Butanediol,
1,4-
Application: 4O PRODUCE
BUTANEDIOL "$/ OR MIXTURE OF "$/ WITH
TETRAHYDROFURAN 4(& ANDOR GAMMA
BUTYROLACTONE '", FROM NORMAL
BUTANE USING A m UID
BED OXIDATION AND l XED
BED HYDROGENATION REACTOR
COMBINATION
4ETRAHYDROFURAN
PRODUCT
(YDROGEN
4AIL GAS TO
INCINERATOR
Description: "0 #HEMICALS HAS COMBINED ITS YEARS OF EXPERIENCE IN
m UID
BED OXIDATION TECHNOLOGY WITH ,URGI !'S YEARS OF HYDROGENA
TION EXPERTISE TO JOINTLY DEVELOP A DIRECT DUAL
REACTOR PROCESS CALLED
'%-)./8
!IR AND N
BUTANE ARE INTRODUCED INTO A m UID
BED CATALYTIC REACTOR
4HE m UID
BED REACTOR PROVIDES A UNIFORM TEMPERATURE PROl LE FOR OPTIMUM
CATALYST PERFORMANCE 2EACTION GASES ARE COOLED AND l LTERED TO REMOVE
SMALL ENTRAINED CATALYST PARTICLES AND THEN ROUTED TO THE RECOVERY SECTION
2EACTOR EFm UENT IS CONTACTED WITH WATER IN A SCRUBBER WHERE ESSENTIALLY
OF THE REACTOR
MADE MALEIC ANHYDRIDE IS RECOVERED AS MALEIC ACID
4HE PROCESS HAS THE CAPABILITY OF CO
PRODUCING MALEIC ANHYDRIDE -!(
WITH THE ADDITION OF THE APPROPRIATE PURIl CATION EQUIPMENT 3CRUBBER
OVERHEAD GASES ARE SENT TO AN INCINERATOR FOR SAFE DISPOSAL
4HE RESULTING MALEIC ACID FROM THE SCRUBBER IS THEN SENT DIRECTLY TO
THE l XED
BED CATALYTIC HYDROGENATION REACTOR 2EACTOR YIELDS EXCEED
"$/ "Y ADJUSTMENTS TO THE HYDROGENATION REACTOR AND RECOVERY
PURIl CATION SECTIONS MIXTURES OF "$/ WITH 4(& ANDOR '", CAN BE
DIRECTLY PRODUCED AT COMPARABLE OVERALL YIELDS AND ECONOMICS
4HE HYDROGENATION REACTOR EFm UENT IS THEN SENT THROUGH A SERIES OF
DISTILLATION STEPS AND TO PRODUCE l NAL MARKET QUALITY PRODUCTS
4WO UNIQUE PROCESS FEATURES ARE
s .O CONTINUOUS LIQUID WASTE STREAM TO TREAT THE WATER SEPARATED
IN THE PRODUCT PURIl CATION SECTION IS RECYCLED BACK TO THE AQUEOUS -!(
SCRUBBER
s .O PRETREATMENT OF THE TWO CATALYSTS IS NECESSARY
Economics: 4HE '%-)./8 TECHNOLOGY USES FEWER PROCESSING STEPS AS
FOUND IN COMPETING "$/ TECHNOLOGIES LEADING TO SIGNIl CANT CAPITAL
N "UTANE
"UTANEDIOL
PRODUCT
!IR
(EAVIES
TO FUEL
COST SAVINGS AND LOWER OPERATING COSTS 4HE UNIQUE PRODUCT m EXIBILITY
AFFORDED BY THIS PROCESS ALSO ALLOWS THE USER TO QUICKLY MEET CHANGING
CUSTOMER AND MARKET NEEDS
Commercial
plants: "0S l RST WORLD
SCALE
TPY '%-)./8 "$/
PLANT IN ,IMA /HIO HAS BEEN SUCCESSFULLY OPERATING SINCE *ULY
Licensor: "0 #HEMICALS AND ,URGI !'
Butanediol,
1,4-
Application: 4O PRODUCE BUTANEDIOL "$/ FROM BUTANE VIA MALEIC
ANHYDRIDE AND HYDROGEN USING ESTER HYDROGENATION
Description: -ALEIC ANHYDRIDE IS l RST ESTERIl ED WITH METHANOL IN A REAC
TION COLUMN TO FORM THE INTERMEDIATE DIMETHYL MALEATE 4HE METHA
NOL AND WATER OVERHEAD STREAM IS SEPARATED IN THE METHANOL COLUMN
AND WATER DISCHARGED
4HE ESTER IS THEN FED DIRECTLY TO THE LOW
PRESSURE VAPOR
PHASE
HYDROGENATION SYSTEM WHERE IT VAPORIZED INTO AN EXCESS OF HYDROGEN IN
THE VAPORIZER AND FED TO A l XED
BED REACTOR CONTAINING A COPPER
CATALYST 4HE REACTION PRODUCT IS COOLED AND CONDENSED WITH THE
HYDROGEN BEING RECYCLED BY THE CENTRIFUGAL CIRCULATOR
4HE CONDENSED PRODUCT m OWS TO THE LIGHTS COLUMN WHERE IT IS
DISTILLED TO PRODUCE A SMALL CO
PRODUCT TETRAHYDROFURAN 4(& STREAM
4HE HEAVIES COLUMN REMOVES METHANOL WHICH IS RECYCLED TO THE
METHANOL COLUMN 4HE PRODUCT COLUMN PRODUCES HIGH
QUALITY
BUTANEDIOL "$/ 5NREACTED ESTER AND GAMMA BUTYRALACTONE '", ARE
RECYCLED TO THE VAPORIZER TO MAXIMIZE PROCESS EFl CIENCY
4HE PROCESS CAN BE ADAPTED TO PRODUCE HIGHER QUANTITIES OF CO
PRODUCT 4(& AND TO EXTRACT THE '", AS A CO
PRODUCT IF REQUIRED
Economics: PER TON OF "$/ EQUIVALENT
-ALEIC ANHYDRIDE
(YDROGEN
-ETHANOL
%LECTRIC POWER K7H
3TEAM T
7ATER COOLING M
Commercial
plants: 3INCE SIX PLANTS HAVE BEEN LICENSED WITH A
TOTAL CAPACITY OF TPY
Licensor: $AVY 0ROCESS 4ECHNOLOGY 5+
-AKEUP (
-AKEUP
-E/(
&EED
-!(
-E/( RECYCLE
-E/(
(/
(EAVIES
%STER
RECYCLE
( RECYCLE
0RODUCT 4(&
0RODUCT
"$/
Butene-1
Application: 4O PRODUCE HIGH
PURITY BUTENE
THAT IS SUITABLE FOR COPO
#ATALYST
PREPARATION
AND STORAGE
LYMERS IN ,,$0% PRODUCTION VIA THE !LPHABUTOL ETHYLENE DIMERIZATION
PROCESS DEVELOPED BY )&0!XENS IN COOPERATION WITH 3!")#
"UTENE
Description: 0OLYMER GRADE ETHYLENE IS OLIGOMERIZED IN THE LIQUID PHASE
REACTOR WITH A CATALYST SYSTEM THAT HAS HIGH ACTIVITY AND SELECTIVITY
,IQUID EFm UENT AND SPENT CATALYST ARE THEN SEPARATED THE LIQUID IS DIS
TILLED FOR RECYCLING OF UNREACTED ETHYLENE TO THE REACTOR AND FRACTION
ATED INTO HIGH PURITY BUTENE 3PENT CATALYST IS TREATED TO REMOVE
VOLATILE HYDROCARBONS AND RECOVERED
4HE !LPHABUTOL PROCESS FEATURES ARE SIMPLE PROCESSING HIGH
TURNDOWN EASE OF OPERATION LOW OPERATING PRESSURE AND TEMPERATURE
LIQUID PHASE OPERATION AND CARBON STEEL EQUIPMENT 4HE TECHNOLOGY HAS
ADVANTAGES OVER OTHER PRODUCTION OR SUPPLY SOURCES UNIFORMLY HIGH
QUALITY PRODUCT LOW IMPURITIES RELIABLE FEEDSTOCK SOURCE LOW CAPITAL
COSTS HIGH TURNDOWN AND EASE OF PRODUCTION
%THYLENE
FEED
#
#ATALYST
2EMOVAL
(EAVY ENDS WITH
SPENT CATALYST
Yields: ,,$0% COPOLYMER GRADE BUTENE
IS PRODUCED WITH A PURITY EX
CEEDING WT 4YPICAL PRODUCT SPECIl CATION IS
/THER #S BUTENES BUTANES
%THANE
%THYLENE
# OLEl NS
%THERS AS $-%
3ULFUR CHLORINE
$IENES ACETYLENES
#/ #/ / (/ -E/(
WT
WT
WT
PPMW
PPMW
PPMW
PPMW EACH
PPMW EACH
Economics: #ASE FOR A )3", INVESTMENT AT A 'ULF #OAST LOCATION FOR
PRODUCING
TPY OF BUTENE
IS
)NVESTMENT MILLION 53
2AW MATERIAL
%THYLENE TONS PER TON OF BUTENE
"YPRODUCTS # TONS PER TON OF BUTENE
4YPICAL OPERATING COST 53 PER TON OF BUTENE
Commercial
plants: 4HERE ARE LICENSED UNITS PRODUCING
TPY 3IXTEEN UNITS ARE IN OPERATION
Licensor: !XENS !XENS .!
Butyraldehyde,
n
and
i
Application: 4O PRODUCE NORMAL AND ISO
BUTYRALDEHYDE FROM PROPYLENE
AND SYNTHESIS GAS #/ ( USING THE ,0 /XO 3%,%#4/2 4ECHNOLOGY
UTILIZING A LOW
PRESSURE RHODIUM
CATALYZED OXO PROCESS
2EACTOR
6ENT
Description: 4HE PROCESS REACTS PROPYLENE WITH A SYNGAS AT LOW PRES
SURE KGCMG IN THE PRESENCE OF A RHODIUM CATALYST COMPLEXED
WITH A LIGAND $EPENDING ON THE DESIRED SELECTIVITY THE OXONATION
REACTION PRODUCES NORMAL AND ISO
BUTYRALDEHYDE WITH TYPICAL NI RATIOS OF
EITHER OR 3EVERAL DIFFERENT LIGAND SYSTEMS ARE COMMERCIALLY
AVAILABLE WHICH CAN PRODUCE SELECTIVITY RATIOS OF UP TO AND AS LOW
AS 4HE BUTYRALDEHYDE PRODUCT IS REMOVED FROM THE CATALYST SOLUTION
AND PURIl ED BY DISTILLATION .
BUTYRALDEHYDE IS SEPARATED FROM THE
ISO
4HE 3%,%#4/2 4ECHNOLOGY IS CHARACTERIZED BY ITS SIMPLE m OW SHEET
AND LOW
OPERATING PRESSURE 4HIS RESULTS IN LOW CAPITAL AND MAINTENANCE
EXPENSES AND PRODUCT COST AND HIGH PLANT AVAILABILITY -ILD REACTION
CONDITIONS MINIMIZE BYPRODUCT FORMATION ,OW BYPRODUCT FORMATION
ALSO CONTRIBUTES TO HIGHER PROCESS EFl CIENCIES AND PRODUCT QUALITIES
4ECHNOLOGY FOR HYDROGENATION TO NORMAL OR ISO
BUTANOLS OR ALDOLIZA
TION AND HYDROGENATION TO
ETHYLHEXANOL EXISTS AND HAS BEEN WIDELY
LICENSED /NE VERSION OF THE 3%,%#4/2 4ECHNOLOGY HAS BEEN LICENSED TO
PRODUCE A MIXTURE OF ALCOHOLS PREDOMINANTLY PROPYLHEPTANOL FROM AN
N
BUTENE FEEDSTOCK AND ANOTHER VERSION TO PRODUCE HIGHER ALCOHOLS UP
TO # FROM &ISCHER 4ROPSCH PRODUCED OLEl NS
Economics: 4YPICAL PERFORMANCE DATA PER TON OF MIXED BUTYRALDEHYDE
&EEDSTOCKS
0ROPYLENE KG CONTAINED IN CHEMICAL GRADE
3YNTHESIS GAS #/ ( .M
Commercial
plants: 4HE ,0 /XO 3%,%#4/2 4ECHNOLOGY HAS BEEN LICENSED
FOR PLANTS WORLDWIDE AND IS NOW USED TO PRODUCE MORE THAN
OF THE WORLDS BUTYRALDEHYDE CAPACITY 0LANTS RANGE IN SIZE FROM
TO TPY 4HE RHODIUM
BASED CATALYST HAS A LONG SERVICE LIFE AND
)SOMER
SEPARATION
0RODUCT
REMOVAL SECTION
ISO "UTYRALDEHYDE
0ROPYLENE
3YNGAS
2ECYCLE
N "UTYRALDEHYDE
SPENT CATALYSTS CAN BE REACTIVATED ONSITE 4HE TECHNOLOGY IS ALSO PRAC
TICED BY 5NION #ARBIDE #ORP AT ITS 4EXAS #ITY AND 4AFT PLANTS
Licensees: 4WENTY
THREE WORLDWIDE SINCE
Licensor: $AVY 0ROCESS 4ECHNOLOGY ,TD 5+ AND 5NION #ARBIDE #ORP A
SUBSIDIARY OF 4HE $OW #HEMICAL #O 53
Cumene
Application: 4O PRODUCE CUMENE FROM BENZENE AND ANY GRADE OF
PROPYLENEINCLUDING LOWER
QUALITY REl NERY PROPYLENE
PROPANE MIX
TURESUSING THE "ADGER PROCESS AND A NEW GENERATION OF ZEOLITE CATA
LYSTS FROM %XXON-OBIL
Description: 4HE PROCESS INCLUDES A l XED BED ALKYLATION REACTOR A l XED
BED TRANSALKYLATION REACTOR AND A DISTILLATION SECTION ,IQUID PROPYLENE
AND BENZENE ARE PREMIXED AND FED TO THE ALKYLATION REACTOR WHERE
PROPYLENE IS COMPLETELY REACTED 3EPARATELY RECYCLED POLYISOPROPYLBEN
ZENE 0)0" IS PREMIXED WITH BENZENE AND FED TO THE TRANSALKYLATION REAC
TOR WHERE 0)0" REACTS TO FORM ADDITIONAL CUMENE 4HE TRANSALKYLATION
AND ALKYLATION EFm UENTS ARE FED TO THE DISTILLATION SECTION 4HE DISTILLATION
SECTION CONSISTS OF AS MANY AS FOUR COLUMNS IN SERIES 4HE DEPROPANIZER
RECOVERS PROPANE OVERHEAD AS ,0' 4HE BENZENE COLUMN RECOV
ERS EXCESS BENZENE FOR RECYCLE TO THE REACTORS 4HE CUMENE COLUMN
RECOVERS CUMENE PRODUCT OVERHEAD 4HE 0)0" COLUMN RECOVERS 0)0"
OVERHEAD FOR RECYCLE TO THE TRANSALKYLATION REACTOR
Process
features: 4HE PROCESS ALLOWS A SUBSTANTIAL INCREASE IN CAPACITY
FOR EXISTING 30! !L#L OR OTHER ZEOLITE CUMENE PLANTS WHILE IMPROV
ING PRODUCT PURITY FEEDSTOCK CONSUMPTION AND UTILITY CONSUMPTION
4HE NEW CATALYST IS ENVIRONMENTALLY INERT DOES NOT PRODUCE BYPRODUCT
OLIGOMERS OR COKE AND CAN OPERATE AT THE LOWEST BENZENE TO PROPYLENE
RATIOS OF ANY AVAILABLE TECHNOLOGY WITH PROVEN COMMERCIAL CYCLE LENGTHS
OF OVER SEVEN YEARS %XPECTED CATALYST LIFE IS WELL OVER l VE YEARS
"ENZENE
,0'
0ROPYLENE
"ENZENE RECYCLE
#UMENE
0)0"
!LKYLATION
REACTOR
(EAVIES
$EPROPANIZER
4RANSALKYLATION
REACTOR
"ENZENE
COLUMN
#UMENE
COLUMN
0)0"
COLUMN
5TILITY REQUIREMENTS PER TON OF CUMENE PRODUCT
(EAT --KCAL IMPORT
3TEAM TON EXPORT
4HE UTILITIES CAN BE OPTIMIZED FOR SPECIl C SITE CONDITIONSECONOMICS AND
INTEGRATED WITH AN ASSOCIATED PHENOL PLANT
Commercial
plants: 4HE l RST COMMERCIAL APPLICATION OF THIS PROCESS CAME
PRODUCT PURITY ABOVE WEIGHT HAS BEEN REGULARLY ACHIEVED IN
COMMERCIAL OPERATION
ONSTREAM IN !T PRESENT THERE ARE PLANTS OPERATING WITH A COM
BINED CAPACITY EXCEEDING MILLION MTPY )N ADDITION FOUR GRASSROOTS
PLANTS AND AN !L#L REVAMP ARE IN THE DESIGN PHASE &IFTY PERCENT OF THE
WORLDWIDE AND OF ZEOLITE CUMENE PRODUCTION ARE FROM PLANTS USING
THE "ADGER PROCESS
Economics: %STIMATED )3", INVESTMENT FOR A MTPY UNIT ON THE
Licensor: "ADGER ,ICENSING ,,#
Yield
and
product
purity: 4HIS PROCESS IS ESSENTIALLY STOICHIOMETRIC AND
53 'ULF #OAST CONSTRUCTION BASIS IS 53 MILLION
Cumene
Application: !DVANCED TECHNOLOGY TO PRODUCE HIGH
PURITY CUMENE
FROM PROPYLENE AND BENZENE USING PATENTED CATALYTIC DISTILLATION #$
TECHNOLOGY 4HE #$#UMENE PROCESS USES A SPECIALLY FORMULATED ZEOLITE
ALKYLATION CATALYST PACKAGED IN A PROPRIETARY #$ STRUCTURE AND ANOTHER
SPECIALLY FORMULATED ZEOLITE TRANSALKYLATION CATALYST IN LOOSE FORM
Description: 4HE #$ COLUMN COMBINES REACTION AND FRACTIONATION
IN A SINGLE UNIT OPERATION !LKYLATION TAKES PLACE ISOTHERMALLY AND AT
LOW TEMPRATURE #$ ALSO PROMOTES THE CONTINUOUS REMOVAL OF REACTION
PRODUCTS FROM REACTION ZONES 4HESE FACTORS LIMIT BYPRODUCT IMPURITIES
AND ENHANCE PRODUCT PURITY AND YIELD ,OW OPERATING TEMPERATURES AND
PRESSURES ALSO DECREASE CAPITAL INVESTMENT IMPROVE OPERATIONAL SAFETY
AND MINIMIZE FUGITIVE EMISSIONS
)N THE MIXED PHASE #$ REACTION SYSTEM PROPYLENE CONCENTRATION
IN THE LIQUID PHASE IS KEPT EXTREMELY LOW WT DUE TO THE
HIGHER VOLATILITY OF PROPYLENE TO BENZENE 4HIS MINIMIZES PROPYLENE
OLIGOMERIZATION THE PRIMARY CAUSE OF CATALYST DEACTIVATION AND RESULTS IN
CATALYST RUN LENGTHS OF TO YEARS 4HE VAPOR LIQUID EQUILIBRIUM EFFECT
PROVIDES PROPYLENE DILUTION UNACHIEVABLE IN l XED BED SYSTEMS EVEN WITH
EXPENSIVE REACTOR PUMPAROUND ANDOR BENZENE RECYCLE ARRANGEMENTS
/VERHEAD VAPOR FROM THE #$ COLUMN IS CONDENSED AND RETURNED
AS REm UX AFTER REMOVING PROPANE AND LIGHTS 0 4HE #$ COLUMN BOTTOM
SECTION STRIPS BENZENE FROM CUMENE AND HEAVIES 4HE DISTILLATION TRAIN
SEPARATES CUMENE PRODUCT AND RECOVERS POLYISOPROPYLBENZENES 0)0"
AND SOME HEAVY AROMATICS ( FROM THE NET BOTTOMS 0)0" REACTS WITH
BENZENE IN THE TRANSALKYLATOR FOR MAXIMUM CUMENE YIELD /PERATING
CONDITIONS ARE MILD AND NONCORROSIVE STANDARD CARBON STEEL CAN BE USED
FOR ALL EQUIPMENT
Yields: METRIC TONS MT OF CUMENE ARE PRODUCED FROM
MT OF BENZENE AND MT OF PROPYLENE GIVING A PRODUCT YIELD OF
OVER #UMENE PRODUCT IS AT LEAST PURE AND HAS A "RO
MINE )NDEX OF LESS THAN WITHOUT CLAY TREATMENT
"ENZENE
#UMENE
0
0ROPYLENE
(
0)0"
Economics: "ASED ON A MTPY CUMENE PLANT LOCATED IN THE 53
'ULF #OAST THE )3", INVESTMENT IS ABOUT 53 MILLION
4YPICAL OPERATING REQUIREMENTS PER METRIC TON OF CUMENE
0ROPYLENE
"ENZENE
9IELD
5TILITIES
%LECTRICITY K7H
(EAT IMPORT KCAL
3TEAM EXPORT MT
7ATER COOLING M
Cumene, CONTINUED
Commercial
plants: &ORMOSA #HEMICALS &IBRE #ORPORATION 4AIWAN
MTPY
Licensor: #$4%#( A PARTNERSHIP BETWEEN !"" ,UMMUS 'LOBAL AND
#HEMICAL 2ESEARCH ,ICENSING
Cumene
Application: 4O PRODUCE HIGH
QUALITY CUMENE ISOPROPYLBENZENE
BY ALKYLATING BENZENE WITH PROPYLENE TYPICALLY REl NERY OR CHEMICAL
GRADE USING LIQUID
PHASE 1
-AX PROCESS BASED ON ZEOLITIC CATALYST
TECHNOLOGY
Description: "ENZENE IS ALKYLATED TO CUMENE OVER A ZEOLITE CATA
LYST IN A FIXED BED LIQUID PHASE REACTOR &RESH BENZENE IS COMBINED
WITH RECYCLE BENZENE AND FED TO THE ALKYLATION REACTOR 4HE BEN
ZENE FEED FLOWS IN SERIES THROUGH THE BEDS WHILE FRESH PROPYLENE
FEED IS DISTRIBUTED EQUALLY BETWEEN THE BEDS 4HIS REACTION IS HIGHLY
EXOTHERMIC AND HEAT IS REMOVED BY RECYCLING A PORTION OF REACTOR
EFFLUENT TO THE REACTOR INLET AND INJECTING COOLED REACTOR EFFLUENT
BETWEEN THE BEDS
)N THE FRACTIONATION SECTION PROPANE THAT ACCOMPANIES THE
PROPYLENE FEEDSTOCK IS RECOVERED AS ,0' PRODUCT FROM THE OVERHEAD OF
THE DEPROPANIZER COLUMN UNREACTED BENZENE IS RECOVERED FROM THE
OVERHEAD OF THE BENZENE COLUMN AND CUMENE PRODUCT IS TAKEN AS
OVERHEAD FROM THE CUMENE COLUMN $I ISOPROPYLBENZENE $)0" IS
RECOVERED IN THE OVERHEAD OF THE $)0" COLUMN AND RECYCLED TO THE
TRANSALKYLATION REACTOR WHERE IT IS TRANSALKYLATED WITH BENZENE OVER A
SECOND ZEOLITE CATALYST TO PRODUCE ADDITIONAL CUMENE ! SMALL QUANTITY
OF HEAVY BYPRODUCT IS RECOVERED FROM THE BOTTOM OF THE $)0" COLUMN
AND IS TYPICALLY BLENDED TO FUEL OIL 4HE CUMENE PRODUCT HAS A HIGH
PURITY n WT AND CUMENE YIELDS OF WT AND HIGHER
ARE ACHIEVED
4HE ZEOLITE CATALYST IS NONCORROSIVE AND OPERATES AT MILD CONDITIONS
THUS CARBON STEEL CONSTRUCTION IS POSSIBLE #ATALYST CYCLE LENGTHS ARE TWO
YEARS AND LONGER 4HE CATALYST IS FULLY REGENERABLE FOR AN ULTIMATE CATALYST
LIFE OF SIX YEARS AND LONGER %XISTING PLANTS THAT USE 30! OR !L#L CATALYST
CAN BE REVAMPED TO GAIN THE ADVANTAGES OF 1 -AX CUMENE TECHNOLOGY
WHILE INCREASING PLANT CAPACITY
"ENZENE
2ECYCLE BENZENE
#UMENE
$)0"
,0'
0ROPYLENE
(EAVIES
Economics: "ASIS )3", 53 'ULF #OAST
)NVESTMENT 53TPY
2AW MATERIALS UTILITIES PER METRIC TON OF CUMENE
0ROPYLENE TONS
"ENZENE TONS
%LECTRICITY K7
3TEAM TONS IMPORT
7ATER COOLING M
n
4HE 1
-AX DESIGN IS TYPICALLY TAILORED TO PROVIDE OPTIMAL UTILITY
ADVANTAGE FOR THE PLANT SITE SUCH AS MINIMIZING HEAT INPUT FOR STAND
ALONE OPERATION OR RECOVERING HEAT AS STEAM FOR USAGE IN A NEARBY
PHENOL PLANT
Cumene, CONTINUED
Commercial
plants: 3EVEN 1
-AX UNITS ARE IN OPERATION WITH A TOTAL
CUMENE CAPACITY OF MILLION TPY AND TWO ADDITIONAL UNITS ARE EITHER
IN DESIGN OR UNDER CONSTRUCTION
Licensor: 5/0 ,,#
Cyclohexane
Application: 0RODUCE HIGH
PURITY CYCLOHEXANE BY LIQUID
PHASE CATALYTIC
(0 PURGE GAS
HYDROGENATION OF BENZENE
Description: 4HE MAIN REACTOR CONVERTS ESSENTIALLY ALL THE FEED ISOTHER
MALLY IN THE LIQUID PHASE AT A THERMODYNAMICALLY
FAVORABLE LOW TEMPER
ATURE USING A CONTINUOUSLY
INJECTED SOLUBLE CATALYST 4HE CATALYSTS HIGH
ACTIVITY ALLOWS USE OF LOW HYDROGEN PARTIAL PRESSURE WHICH RESULTS IN FEW
ER SIDE REACTIONS EG ISOMERIZATION OR HYDROCRACKING 4HE HEAT OF REAC
TION VAPORIZES CYCLOHEXANE PRODUCT AND USING PUMPAROUND CIRCULATION
THROUGH AN EXCHANGER ALSO GENERATES STEAM 7ITH THE HEAT OF REACTION
BEING IMMEDIATELY REMOVED BY VAPORIZATION ACCURATE TEMPERATURE CON
TROL IS ASSURED ! VAPOR
PHASE l XED
BED l NISHING REACTOR COMPLETES THE
CATALYTIC HYDROGENATION OF ANY RESIDUAL BENZENE 4HIS STEP REDUCES RESID
UAL BENZENE IN THE CYCLOHEXANE PRODUCT TO VERY LOW LEVELS $EPENDING ON
THE PURITY OF THE HYDROGEN MAKE
UP GAS THE STABILIZATION SECTION INCLUDES
EITHER AN ,0 SEPARATOR OR A SMALL STABILIZER TO REMOVE THE LIGHT ENDS
! PRIME ADVANTAGE OF THE LIQUID
PHASE PROCESS IS ITS SUBSTANTIALLY LOWER
COST COMPARED TO VAPOR PHASE PROCESSES INVESTMENT IS PARTICULARLY LOW
BECAUSE A SINGLE INEXPENSIVE MAIN REACTOR CHAMBER IS USED COMPARED TO
MULTIPLE
BED OR TUBULAR REACTORS USED IN VAPOR PHASE PROCESSES 1UENCH
GAS AND UNREACTED BENZENE RECYCLES ARE NOT NECESSARY AND BETTER HEAT
RECOVERY GENERATES BOTH THE CYCLOHEXANE VAPOR FOR THE l NISHING STEP AND
A GREATER AMOUNT OF STEAM 4HESE ADVANTAGES RESULT IN LOWER INVESTMENT
AND OPERATING COSTS /PERATIONAL m EXIBILITY AND RELIABILITY ARE EXCELLENT
CHANGES IN FEEDSTOCK QUALITY AND m OWS ARE EASILY HANDLED 3HOULD THE
CATALYST BE DEACTIVATED BY FEED QUALITY UPSETS FRESH CATALYST CAN BE
INJECTED WITHOUT SHUTTING DOWN
Yield: KG OF CYCLOHEXANE IS PRODUCED FROM KG OF BENZENE
Economics: "ASIS
TPY CYCLOHEXANE COMPLEX )3", 'ULF
#OAST LOCATION WITH 03! HYDROGEN IS 53 MILLION #ATALYST COST IS 53
METRIC TON OF PRODUCT
#ATALYST
(0
SEPARATOR
-AIN
REACTOR
"ENZENE
(YDROGEN
3TEAM
"&7
,0 PURGE GAS
#7
&INISHING
REACTOR
#YCLOHEXANE
(0 SEPARATOR
OR STRIPPER
/PTIONAL
Commercial
plants: 4HIRTY
THREE CYCLOHEXANE UNITS HAVE BEEN LICENSED
Licensor: !XENS !XENS .!
Di-methyl
ether
(DME)
Application: 4O PRODUCE DIMETHYL ETHER $-% FROM METHANOL USING 4OYO
%NGINEERING #ORPS 4%#S $-% SYNTHESIS TECHNOLOGY BASED ON METHA
NOL DEHYDRATION PROCESS &EEDSTOCK CAN BE CRUDE METHANOL AS WELL AS
REl NED METHANOL
Description: )F FEED IS CRUDE METHANOL WATER IS SEPARATED OUT IN THE
METHANOL COLUMN 4HE TREATED FEED METHANOL IS SENT TO A $-% 2EAC
TOR AFTER VAPORIZATION IN 4HE SYNTHESIS PRESSURE IS n -0A'
4HE INLET TEMPERATURE IS n # AND THE OUTLET IS n #
-ETHANOL ONE
PASS CONVERSION TO $-% IS n IN THE REACTOR 4HE
REACTOR EFm UENTS $-% WITH BYPRODUCT WATER AND UNCONVERTED METHA
NOL ARE FED TO A $-% COLUMN AFTER HEAT RECOVERY AND COOLING
)N THE $-% COLUMN $-% IS SEPARATED FROM THE TOP AND CONDENSED
4HE $-% IS COOLED IN A CHILLING UNIT AND STORED IN A $-% TANK AS A
PRODUCT 7ATER AND METHANOL ARE DISCHARGED FROM THE BOTTOM AND FED
TO A METHANOL COLUMN FOR METHANOL RECOVERY 4HE PURIl ED METHANOL
FROM THIS COLUMN IS RECYCLED TO THE REACTOR AFTER MIXING WITH FEEDSTOCK
METHANOL
Economics: 4HE METHANOL CONSUMPTION FOR $-% PRODUCTION IS APPROXI
MATELY TON
METHANOL PER TON
$-%
Commercial
plants: !
TPY UNIT WAS COMMISSIONED IN !UGUST
IN #HINA AND IS THE l RST FUEL $-% FACILITY ! SECOND
TPY
FACILITY IS SCHEDULED TO START UP IN THE THIRD QUARTER OF IN #HINA AND
WILL BE THE LARGEST $-% PLANT
Reference: -II 4 h#OMMERCIAL $-% PLANT FOR FUEL USE v &IRST )NTERNA
TIONAL $-% #ONFERENCE 0ARIS &RANCE /CT n
Licensor: 4OYO %NGINEERING #ORP 4%#
7ATER
#RUDE
METHANOL
$-%
Dimethyl
terephthalate
Application: 4O INCREASE CAPACITY AND REDUCE ENERGY USAGE OF EXISTING
!TM
OR GRASSROOTS DIMETHYL TEREPHTHALATE $-4 PRODUCTION FACILITIES USING
VARIATIONS OF '4 $-4 PROPRIETARY TECHNOLOGY
08
RECOVERY
Description: 4HE COMMON PRODUCTION METHOD OF $-4 FROM PARAXYLENE
AND METHANOL IS THROUGH SUCCESSIVE OXIDATIONS IN FOUR MAJOR STEPS OXI
DATION ESTERIl CATION DISTILLATION AND CRYSTALLIZATION ! MIXTURE OF P
XY
LENE AND METHYL P
TOLUATE -04 IS OXIDIZED WITH AIR USING A HEAVY
METAL
CATALYST !LL ORGANICS ARE RECOVERED FROM THE OFFGAS AND RECYCLED TO THE
SYSTEM 4HE ACID MIXTURE FROM THE OXIDATION IS ESTERIl ED WITH METHANOL
AND PRODUCES A MIXTURE OF ESTERS 4HE CRUDE ESTER MIXTURE IS DISTILLED TO
REMOVE ALL HEAVY BOILERS AND RESIDUE PRODUCED LIGHTER ESTERS ARE RECY
CLED TO THE OXIDATION SECTION 2AW $-4 IS THEN SENT TO THE CRYSTALLIZATION
SECTION TO REMOVE $-4 ISOMERS AND AROMATIC ALDEHYDES
4HE TECHNOLOGY IMPROVEMENTS ENHANCE THE TRADITIONAL PROCESSING IN
EACH SECTION 4HE ADAPTATIONS INCLUDE CHANGES IN PROCESS CONl GURATIONS
AND OPERATING CONDITIONS ALTERATING THE SEPARATION SCHEMES REVISING
THE RECOVERY ARRANGEMENT INCREASING THE VALUE OF THE BYPRODUCTS AND
REDUCING THE OVERALL PLANT RECYCLES
'4# 4ECHNOLOGY OFFERS COMPLETE IMPLEMENTATION OF THE TECHNOLOGY
AND OVERALL PLANT REVIEWS FOR SELECTIVE IMPROVEMENTS TO REDUCE OPERATING
AND OVERALL PRODUCTION COSTS 3OME SEPARATE IMPROVEMENTS AVAILABLE
ARE
/XIDATION OPTIMIZATION REDUCES BYPRODUCT FORMATION THUS LOWERING
P
XYLENE CONSUMPTION
2ECOVERIES OF BYPRODUCTS FOR SALE SUCH AS METHYL BENZOATE -E"Z
AND ACETIC AND FORMIC ACID
)MPROVED ESTERIl ER REACTOR DESIGN ENABLES HIGHER THROUGHPUTS
AND IMPROVES METHANOL USAGE
%NHANCED ISOMER REMOVAL MINIMIZES $-4LOSSES
)MPROVED CRYSTALLIZATION SCHEMES FOR REDUCED ENERGY LOWERS
METHANOL HANDLING AND LOSSES IMPROVES PURITY AND OPERATING m EXIBILITY
)NTEGRATION OF STEAM USAGE IN THE PLANT FOR CONSIDERABLE SAVINGS
-E/(
08
77
-ETHANOL
ACID
RECOVERY
$-4
%STER TO
OXIDATION
-04
!IR
(EAVY
BOILERS
)MPROVED
REACTOR
DESIGN
08-E"Z
REMOVAL
4O
OXIDATION
#RYSTALLIZATION
0URE
$-4
4O FILTRATE
RECOVERY AND
ISOMER REMOVAL
2ESIDUE
TREATMENT
ON OPERATING COSTS
/PERATING REVIEWS TO REDUCE OPERATING DOWNTIME AND EXTEND
ONLINE FACTORS
!DVANCED CONTROL MODELS FOR IMPROVED OPERABILITY
Economics: "ASED ON PROCESS MODIl CATIONS AN EXISTING $-4 PLANT CAN
INCREASE PRODUCTION WITH AN INVESTMENT OF TO TPY OF ADDI
TIONAL CAPACITY ! NEW PLANT WILL HAVE AN INVESTMENT REDUCTION OF ABOUT
EQUIPMENT COST 2AW MATERIAL CONSUMPTION PER TON OF PRODUCT
WITH THE COMPLETE MODIl CATION IS TONS OF PARAXYLENE AND TONS
OF METHANOL
Dimethyl
terephthalate, CONTINUED
Commercial
plants: '4
$-4 TECHNOLOGY IS USED BY SEVEN $-4 PRODUC
ERS
Licensor: '4# 4ECHNOLOGY
Dimethylformamide
Application: 4O PRODUCE DIMETHYLFORMAMIDE $-& FROM DIMETHYLAMINE
3YNTHESIS
$-! AND CARBON MONOXIDE #/
6APORIZATION
Description: !NHYDROUS $-! AND #/ ARE CONTINUOUSLY FED TO A SPE
CIALIZED REACTOR OPERATING AT MODERATE CONDITIONS AND CONTAINING A
CATALYST DISSOLVED IN SOLVENT 4HE REACTOR PRODUCTS ARE SENT TO A SEPARA
TION SYSTEM WHERE CRUDE PRODUCT IS VAPORIZED TO SEPARATE THE SPENT
CATALYST %XCESS $-! AND CATALYST SOLVENT ARE STRIPPED FROM THE CRUDE
PRODUCT AND RECYCLED BACK TO THE REACTION SYSTEM 6ACUUM DISTILLATION
FOLLOWED BY FURTHER PURIl CATION PRODUCES A HIGH
QUALITY SOLVENT
AND l BER
GRADE $-& PRODUCT ! SALEABLE BYPRODUCT STREAM IS ALSO PRO
DUCED
Yields: 'REATER THAN ON RAW MATERIALS #/ YIELD IS A FUNCTION OF ITS
QUALITY
Economics: 4YPICAL PERFORMANCE DATA PER TON OF PRODUCT
$IMETHYLAMINE T
#ARBON MONOXIDE T
3TEAM T
7ATER COOLING M
%LECTRICITY K7H
Commercial
plants: 4HIRTEEN PLANTS IN EIGHT COUNTRIES USE THIS PROCESS
WITH A PRODUCTION CAPACITY EXCEEDING MTPY
Licensor: $AVY 0ROCESS 4ECHNOLOGY 5+
0RODUCT
PURIFICATION
$-! RECOVERY
#ATALYST
$-!
#/
3PENT
CATALYST
"YPRODUCT
$-&
EDC
via
oxygen-lean
oxychlorination
Application: 4HE MODERN 6INNOLIT OXYCHLORINATION PROCESS PRODUCES
ETHYLENE DICHLORIDE %$# BY AN EXOTHERMIC REACTION FROM FEEDSTOCKS
INCLUDING ETHYLENE ANHYDROUS HYDROGEN CHLORIDE (#L AND OXYGEN !N
HYDROUS (#L CAN BE USED FROM THE 6#- PROCESS AS WELL AS FROM OTHER
PROCESSES SUCH AS ISOCYANATES -$) 4$) CHLORINATED METHANES CHLORI
NATED ETHANES EPICHLOROHYDRIN ETC
/XYGEN CAN BE SUPPLIED FROM AN AIR SEPARATION PLANT AS WELL AS FROM
THE COST
EFFECTIVE PRESSURE SWING ADSORPTION 03! PROCESS 4HE 6INNOLIT
OXYCHLORINATION PROCESS IS ALSO ABLE TO HANDLE ETHYLENE ANDOR ANHYDROUS
(#L CONTAINING VENT STREAMS FROM DIRECT CHLORINATION ACETALDEHYDE
MONOCHLOROACETIC ACID AND OTHER PROCESSES
Description: 4HE EXOTHERMIC REACTION IS CATALYZED BY A COPPER CHLORIDE
CATALYST IN A SINGLE
STEP m UIDIZED
BED REACTOR AT TEMPERATURES OF #
(EAT OF REACTION IS RECOVERED BY PRODUCING BAR G STEAM OR HEATING
OTHER HEAT
TRANSFER m UIDS
4HE SMALL AMOUNT OF CATALYST l NES THAT PASS THROUGH THE HIGHLY
EFl CIENT CYCLONE SYSTEM ARE REMOVED BY A NEWLY DEVELOPED HOT
GAS
CATALYST l LTER OR ALTERNATIVELY BY WASTEWATER TREATMENT THAT MEETS EVEN THE
STRICTEST REGULATIONS FOR COPPER DIOXINS AND FURANES 4HE ENVIRONMENTALLY
FRIENDLY PROCESS USES RECYCLE GAS WHICH IS FED BACK TO THE REACTOR AFTER
CONDENSING %$# AND WATER
!FTER REMOVAL OF CARBON DIOXIDE #/ AND CHLORALCHLOROETHANOL
THE CRUDE %$# IS PURIl ED IN THE %$# DISTILLATION UNIT IT CAN BE USED AS
FURNACE FEED OR SALES %$#
Process
features
and
economics ARE
Low
manufacturing
costs: 4HE UNLIMITED CATALYST LIFETIME IS COMBINED
WITH THE LOW LOSSES VIA THE HIGHLY EFl CIENT CYCLONE SYSTEM LESS THAN G
CATALYST PER METRIC TON MTON OF %$# PRODUCED (IGH RAW
MATERIAL YIELDS
ETHYLENE ANHYDROUS (#L AND OXYGEN HIGH CRUDE %$#
PURITY AND THE POSSIBILITY OF USING LOW
COST OXYGEN FROM 03!
UNITS ENSURE A HIGHLY COMPETITIVE PROCESS WITH LOW PRODUCTION COSTS
1UENCH
6ENT TO INCINERATION
(
"OILER
FEEDWATER
3TEAM
(#)
$ECANTER
(#)
/XYGEN
%THYLENE
#OMPRESSOR
(YDROGENATION
REACTOR
/# REACTOR #AT FILTRATION
%$# TO
HEADS
COLUMN
4O WASTEWATER TREATMENT
%$#
CONDENSATION
Safety: 4HE OXYGEN IS MIXED WITH ANHYDROUS (#L OUTSIDE THE REACTOR
AND IS FED INDEPENDENTLY OF THE ETHYLENE INTO THE m UIDIZED BED 4HE
OXYGEN CONCENTRATION IN THE RECYCLE STREAM IS APPROXIMATELY VOL
WHICH IS WELL OUTSIDE THE EXPLOSION RANGE
Environment
friendly: ! HIGHLY EFl CIENT HOT
GAS l LTRATION SYSTEM
SEPARATES THE SMALL QUANTITIES OF CATALYST l NES "ESIDES THE %$# REMOVAL
VIA STEAM STRIPPING NO ADDITIONAL WASTEWATER TREATMENT IS REQUIRED
4HE CHARTER FOR %UROPEAN #OUNCIL FOR 6INYL -ANUFACTURERS %#6-
IS EASILY MET %$# GT OF %$# PURIl CATION CAPACITY COPPER GT
OF OXYCHLORINATION CAPACITY DIOXIN
LIKE COMPONENTS G 4%1T OF
OXYCHLORINATION CAPACITY
EDC
via
oxygen-lean
oxychlorination, CONTINUED
Reliability: ! STABLE TEMPERATURE CONTROL COMBINED WITH AN EXCELLENT
HEAT TRANSFER AND A UNIFORM TEMPERATURE PROlLE NO HOT SPOTS IN THE
mUIDIZED BED EASILY ACHIEVES AN ONSTREAM TIME PER YEAR ! SPECIALLY
DESIGNED RAW
MATERIAL SPARGER SYSTEM ALLOWS OPERATION SPANS OF TWO
YEARS WITHOUT MAINTENANCE ,ARGER HEAT
TRANSFER AREA ALLOWS A HIGHER
STEAM TEMPERATURE AND PRESSURE IN THE COOLING COILS WHICH IMPROVES
THE SAFETY MARGIN TO THE CRITICAL SURFACE TEMPERATURE WHERE HYDROCHLORIC
ACID DEWPOINT CORROSION MAY OCCUR
Flexibility: ! TURNDOWN RATIO AS LOW AS CAPACITY UTILIZATION CAN
BE ACHIEVED AS WELL AS QUICK LOAD CHANGES
Commercial
plants: 4HE PROCESS IS USED IN REACTORS AT SITES WITH
ANNUAL SINGLE REACTOR CAPACITIES UP TO MTONS OF %$# ALONE AS
(#L
CONSUMING PLANT OR AS PART OF THE BALANCED 6#- PROCESS )N SOME
CASES IT HAS REPLACED OTHER OXYCHLORINATION TECHNOLOGIES FROM DIFFERENT
LICENSORS BY REPLACING EXISTING REACTORS OR EXISTING UNITS 4WO NEW OXY
CHLORINATION TRAINS WERE SUCCESSFULLY COMMISSIONED IN 3EPTEMBER
ONE OXYCHLORINATION UNIT IS UNDER DESIGN
Licensor: 6INNOLIT
Contractor: 5HDE 'MB(
EDC
via
high-temperature
chlorination
Application: 6INNOLITS NEW HIGH
TEMPERATURE DIRECT CHLORINATION $# RE
#OLUMN REBOILER
ACTOR PROVIDES AN ENERGY EFl CIENT TECHNOLOGY FOR THE PRODUCTION OF FUR
NACE FEED AND SALES ETHYLENE DICHLORIDE %$# WITHOUT DISTILLATION FROM
CHLORINE AND ETHYLENE
%$# COLUMN
6ENT GAS TO
INCINERATOR OR
OXYCHLORINATION
Description: 4HE LIQUID PHASE REACTION OF ETHYLENE AND CHLORINE RELEASES
APPROXIMATELY K*MOL OF PRODUCED %$#
)N A SIMPLE CARBON STEEL U
SHAPED LOOP REACTOR CHLORINE AND ETHYLENE
ARE SEPARATELY DISSOLVED IN %$# BEFORE THE REACTION TAKES PLACE )N
COMBINATION WITH THE SPECIAL 6INNOLIT CATALYST THIS METHOD SIGNIl CANTLY
MINIMIZES BYPRODUCT FORMATION
$OWNSTREAM OF THE REACTION ZONE THE LOWER STATIC PRESSURE PERMITS
THE REACTOR CONTENT TO BOIL AND APPLIES THE THERMOSYPHON EFFECT FOR
CIRCULATION %$# VAPOR LEAVES THE HORIZONTAL VESSEL AND EITHER ENTERS THE
REBOILER OF A COLUMN EG REBOILER OF HIGH
BOIL
HEADS ANDOR VACUUM
COLUMN OR A HEAT EXCHANGER WHICH CONDENSES THE %$# VAPOR 4HE
REACTION HEAT IS TRANSFERRED TO THE COLUMN INDIRECTLY ! FRACTION OF THE
CONDENSED %$# IS FED BACK TO THE REACTOR AND THE REST IS DIRECTLY SENT TO
THE %$# CRACKER WITHOUT FURTHER DISTILLATION
"ECAUSE OF THE HIGH YIELDS THE 6INNOLIT $# REACTOR CAN BE OPERATED
IN THE STAND
ALONE MODE (OWEVER IF THE REACTOR IS PART OF A COMPLETE
6#- PLANT OFFGAS CAN BE SENT TO THE OXYCHLORINATION REACTOR TO RECOVER
THE REMAINING SMALL QUANTITIES OF ETHYLENE )F SALES
%$# SPECIl CATION IS
THE TARGET ONLY A SMALL STRIPPER COLUMN IS REQUIRED TO ELIMINATE TRACES
OF (#L
Process
features
and
economics ARE
Low
manufacturing
costs: (IGH RAW MATERIAL YIELDS FOR
ETHYLENE AND FOR CHLORINE AND A PRODUCT QUALITY WHICH REQUIRES
NO FURTHER TREATMENT ENSURE A HIGHLY COMPETITIVE PROCESS WITH LOW
PRODUCTION COSTS 4HE (4# HIGH TEMPERATURE CHLORINATION BOILING
REACTOR IS SIMPLE BECAUSE NO %$# WASHING WASTEWATER TREATMENT AND
%$# DISTILLATION FACILITIES ARE NECESSARY
%$# COLUMN
2EACTOR
#HLORINE
%THYLENE
&URNACE FEED %$#
Low
capital
costs: ! SIMPLE DESIGN WITH A MINIMIZED NUMBER OF
EQUIPMENT RESULTS IN LOW UNIT INVESTMENT COSTS
Energy
savings: 6INNOLITS $# PROCESS SIGNIl CANTLY REDUCES THE
STEAM CONSUMPTION IN A BALANCED %$#6#- PLANT 4HE SAVING OF STEAM
IS APPROXIMATELY KG PER METRIC TON MTON OF %$# PRODUCED 4HE
REACTION HEAT CAN PREFERABLY BE USED IN THE %$# DISTILLATION
Simple
process: 4HE (4#
BOILING REACTOR IS SIMPLE DUE TO ELIMINATION
OF WASHING EQUIPMENT WASTEWATER TREATMENT AND %$# DISTILLATION
New
catalyst:
4HE 6INNOLIT $# CATALYST GUARANTEES A FURNACE FEED
%$# QUALITY OF WITHOUT ANY DISTILLATION #ATALYST MAKEUP IS NOT
EDC
via
high-temperature
chlorination, CONTINUED
REQUIRED
Operability
and
maintainability: ! CORROSION INHIBITING CATALYST
SYSTEM AND SIMPLE EQUIPMENT WITHOUT MAJOR MOVING PARTS KEEP THE
MAINTENANCE COSTS LOW
Less
plot
area: 4HE PLOT AREA REQUIREMENT FOR THE $# BOILING REACTOR
UNIT IS VERY SMALL AND CAN BE ACCOMMODATED TO CUSTOMERSg NEEDS
Commercial
plants: 4HE $#
PROCESS ANDOR $#
CATALYST ARE USED FOR THE
ANNUAL PRODUCTION OF MORE THAN MILLION MTONS OF %$# /NE UNIT
WITH AN ANNUAL CAPACITY OF MTONS OF %$# HAS BEEN SUCCESSFULLY
COMMISSIONED IN 3EPTEMBER !NOTHER UNIT WITH THE LATEST PLANT
DESIGN IS CURRENTLY UNDER CONSTRUCTION
Licensor: 6INNOLIT
Contractor: 5HDE 'MB(
Ethanolamines
Application: 4O PRODUCE MONO
-%! DI
$%! AND TRIETHANOLAMINES
$%!
4%! FROM ETHYLENE OXIDE AND AMMONIA
3YNTHESIS
Description: !MMONIA SOLUTION RECYCLED AMINES AND ETHYLENE OXIDE ARE
FED CONTINUOUSLY TO A REACTION SYSTEM THAT OPERATES UNDER MILD CON
DITIONS AND SIMULTANEOUSLY PRODUCES -%! $%! AND 4%! 0RODUCT RATIOS
CAN BE VARIED TO MAXIMIZE -%! $%! OR 4%! PRODUCTION 4HE CORRECT
SELECTION OF THE .( %/ RATIO AND RECYCLING OF AMINES PRODUCES THE DE
SIRED PRODUCT MIX 4HE REACTOR PRODUCTS ARE SENT TO A SEPARATION SYSTEM
WHERE AMMONIA AND WATER ARE SEPARATED AND RECYCLED TO THE REAC
TION SYSTEM 6ACUUM DISTILLATION IS USED TO PRODUCE PURE -%!
$%! AND 4%! ! SALEABLE HEAVIES TAR BYPRODUCT IS ALSO PRODUCED 4ECHNI
CAL GRADE 4%! WT CAN ALSO BE PRODUCED IF REQUIRED
Yields: 'REATER THAN ON RAW MATERIALS
Economics: 4YPICAL PERFORMANCE DATA PER TON AMINES -%!$%!4%!
PRODUCT RATIO OF b b b
%THYLENE OXIDE T
!MMONIA T
3TEAM T
7ATER COOLING M
%LECTRICITY K7H
Commercial
plants: /NE
MTPY ORIGINAL CAPACITY FACILITY
Licensor: $AVY 0ROCESS 4ECHNOLOGY 5+
$EHYDRATION
.(
RECOVERY
0RODUCT
PURIFICATION
-%!
2ECYCLE
AMINES
4%!
!MMONIA
%THYLENE OXIDE
4AR BYPRODUCT
EthersETBE
Application: 4HE 5HDE %DELEANU %4"% PROCESS COMBINES ETHANOL AND
%4"% $EBUTANIZER
REACTOR
ISOBUTENE TO PRODUCE THE HIGH
OCTANE OXYGENATE ETHYL TERTIARY BUTYL
ETHER %4"%
7ATER
WASH
%THANOLWATER
SEPARATION
"" RAFFINATE
Feeds: # CUTS FROM STEAM CRACKER AND &## UNITS WITH ISOBUTENE CON
TENTS RANGING FROM TO
Products: %4"% AND OTHER TERTIARY ALKYL ETHERS ARE PRIMARILY USED IN GAS
%THANOLWATER
AZEOTROPE
OLINE BLENDING AS AN OCTANE ENHANCER TO IMPROVE HYDROCARBON COM
BUSTION EFl CIENCY -OREOVER BLENDING OF %4"% TO THE GASOLINE POOL WILL
LOWER VAPOR PRESSURE 2VP
# FEEDSTOCK
Description: 4HE 5HDE %DELEANU TECHNOLOGY FEATURES A TWO STAGE RE
%THANOL
ACTOR SYSTEM OF WHICH THE l RST REACTOR IS OPERATED IN THE RECYCLE MODE
7ITH THIS METHOD A SLIGHT EXPANSION OF THE CATALYST BED IS ACHIEVED THAT
ENSURES VERY UNIFORM CONCENTRATION PROl LES IN THE REACTOR AND MOST
IMPORTANT AVOIDS HOT SPOT FORMATION 5NDESIRED SIDE REACTIONS SUCH AS
THE FORMATION OF DI
ETHYL ETHER $%% ARE MINIMIZED
4HE REACTOR INLET TEMPERATURE RANGES FROM # AT START
OF
RUN TO
ABOUT # AT END
OF
RUN CONDITIONS /NE IMPORTANT FEATURE OF THE TWO
STAGE SYSTEM IS THAT THE CATALYST CAN BE REPLACED IN EACH REACTOR SEPA
RATELY WITHOUT SHUTTING DOWN THE %4"% UNIT
4HE CATALYST USED IN THIS PROCESS IS A CATION
EXCHANGE RESIN AND IS AVAILABLE
FROM SEVERAL MANUFACTURERS )SOBUTENE CONVERSIONS OF ARE TYPICAL FOR
&## FEEDSTOCKS (IGHER CONVERSIONS ARE ATTAINABLE WHEN PROCESSING STEAM
CRACKER # CUTS THAT CONTAIN ISOBUTENE CONCENTRATIONS OF ABOUT
%4"% IS RECOVERED AS THE BOTTOMS PRODUCT OF THE DISTILLATION UNIT 4HE
ETHANOL
RICH # DISTILLATE IS SENT TO THE ETHANOL RECOVERY SECTION 7ATER IS
USED TO EXTRACT EXCESS ETHANOL AND RECYCLE IT BACK TO PROCESS !T THE TOP
OF THE ETHANOL WATER SEPARATION COLUMN AN ETHANOL WATER AZEOTROPE IS
RECYCLED TO THE REACTOR SECTION 4HE ISOBUTENE
DEPLETED # STREAM MAY
BE SENT TO A RAFl NATE STRIPPER OR TO A MOLSIEVE
BASED UNIT TO REMOVE
OXYGENATES SUCH AS $%% %4"% ETHANOL AND TERT
BUTANOL
%4"% PRODUCT
Utility
requirements: # FEED CONTAINING ISOBUTENE PER METRIC
TON OF %4"%
3TEAM ,0 KG
3TEAM -0 KG
%LECTRICITY K7H
7ATER COOLING M
Commercial
plants: 4HE 5HDE %DELEANU PROPRIETARY %4"% PROCESS HAS
BEEN SUCCESSFULLY APPLIED IN TWO REl NERIES CONVERTING EXISTING -4"%
UNITS !NOTHER -4"% PLANT IS IN THE CONVERSION STAGE
Licensor: 5HDE 'MB(
EthersMTBE
Application: 4HE 5HDE %DELEANU -4"% PROCESS COMBINES METHANOL
-4"% REACTOR
AND ISOBUTENE TO PRODUCE THE HIGH
OCTANE OXYGENATEMETHYL TERTIARY
BUTYL ETHER -4"%
$EBUTANIZER
7ATER
WASH
-ETHANOLWATER
SEPARATION
"" RAFFINATE
Feeds: #
CUTS FROM STEAM CRACKER AND &## UNITS WITH ISOBUTENE CON
TENTS RANGE FROM TO
Products: -4"% AND OTHER TERTIARY ALKYL ETHERS ARE PRIMARILY USED IN GAS
OLINE BLENDING AS AN OCTANE ENHANCER TO IMPROVE HYDROCARBON COMBUS
TION EFl CIENCY
# FEEDSTOCK
Description: 4HE TECHNOLOGY FEATURES A TWO STAGE REACTOR SYSTEM OF
WHICH THE l RST REACTOR IS OPERATED IN THE RECYCLE MODE 7ITH THIS METH
OD A SLIGHT EXPANSION OF THE CATALYST BED IS ACHIEVED WHICH ENSURES VERY
UNIFORM CONCENTRATION PROl LES WITHIN THE REACTOR AND MOST IMPORTANT
AVOIDS HOT SPOT FORMATION 5NDESIRED SIDE REACTIONS SUCH AS THE FORMA
TION OF DIMETHYL ETHER $-% ARE MINIMIZED
4HE REACTOR INLET TEMPERATURE RANGES FROM # AT START OF RUN TO
ABOUT # AT END OF RUN CONDITIONS /NE IMPORTANT FACTOR OF THE TWO
STAGE SYSTEM IS THAT THE CATALYST MAY BE REPLACED IN EACH REACTOR SEPA
RATELY WITHOUT SHUTTING DOWN THE -4"% UNIT
4HE CATALYST USED IN THIS PROCESS IS A CATION EXCHANGE RESIN AND IS
AVAILABLE FROM SEVERAL CATALYST MANUFACTURERS )SOBUTENE CONVERSIONS OF
ARE TYPICAL FOR &## FEEDSTOCKS (IGHER CONVERSIONS ARE ATTAINABLE
WHEN PROCESSING STEAM CRACKER # CUTS THAT CONTAIN ISOBUTENE CONCEN
TRATIONS OF
-4"% IS RECOVERED AS THE BOTTOMS PRODUCT OF THE DISTILLATION UNIT
4HE METHANOL RICH # DISTILLATE IS SENT TO THE METHANOL RECOVERY SECTION
7ATER IS USED TO EXTRACT EXCESS METHANOL AND RECYCLE IT BACK TO PROCESS
4HE ISOBUTENE DEPLETED # STREAM MAY BE SENT TO A RAFl NATE STRIPPER
OR TO A MOLSIEVE BASED UNIT TO REMOVE OTHER OXYGENATES SUCH AS $-%
-4"% METHANOL AND TERT BUTANOL
6ERY HIGH ISOBUTENE CONVERSION IN EXCESS OF CAN BE ACHIEVED
-ETHANOL
-4"% PRODUCT
THROUGH A DEBUTANIZER COLUMN WITH STRUCTURED PACKINGS CONTAINING AD
DITIONAL CATALYST 4HIS REACTIVE DISTILLATION TECHNIQUE IS PARTICULARLY SUITED
WHEN THE RAFl NATE
STREAM FROM THE -4"% UNIT WILL BE USED TO PRODUCE
A HIGH
PURITY BUTENE
PRODUCT
&OR A # CUT CONTAINING ISOBUTENE THE ISOBUTENE CONVERSION
MAY EXCEED AT A SELECTIVITY FOR -4"% OF
Utility
requirements, # FEED CONTAINING ISOBUTENE PER METRIC TON
OF -4"%
3TEAM ,0 KG
3TEAM -0 KG
%LECTRICITY K7H
7ATER COOLING M
EthersMTBE, CONTINUED
Commercial
plants: 4HE 5HDE %DELEANU PROPRIETARY -4"% PROCESS HAS
BEEN SUCCESSFULLY APPLIED IN lVE RElNERIES 4HE ACCUMULATED LICENSED
CAPACITY EXCEEDS --TPY
Licensor: 5HDE 'MB(
Ethyl
acetate
Application: 4O PRODUCE ETHYL ACETATE FROM ETHANOL WITHOUT ACETIC ACID
OR OTHER CO
FEEDS
$EHYDROGENATION
2EFINING
(YDROGEN
Description: %THANOL IS HEATED AND PASSED THROUGH A CATALYTIC DEHYDRO
GENATION REACTOR WHERE PART OF THE ETHANOL IS DEHYDROGENATED TO
FORM ETHYL ACETATE AND HYDROGEN 4HE PRODUCT IS COOLED IN AN INTEGRATED
HEAT
EXCHANGER SYSTEM HYDROGEN IS SEPARATED FROM THE CRUDE PROD
UCT 4HE HYDROGEN IS MAINLY EXPORTED #RUDE PRODUCT IS PASSED THROUGH
A SECOND CATALYTIC REACTOR TO ALLOW hPOLISHINGv AND REMOVE MINOR
BYPRODUCTS SUCH AS CARBONYLS
4HE POLISHED PRODUCT IS PASSED TO A DISTILLATION TRAIN WHERE A
NOVEL DISTILLATION ARRANGEMENT ALLOWS THE ETHANOLETHYL ACETATE WATER
AZEOTROPE TO BE BROKEN 0RODUCTS FROM THIS DISTILLATION SCHEME ARE
UNREACTED ETHANOL WHICH IS RECYCLED AND ETHYL ACETATE PRODUCT
4HE PROCESS IS CHARACTERIZED BY LOW
OPERATING TEMPERATURES AND
PRESSURES WHICH ALLOW ALL EQUIPMENT TO BE CONSTRUCTED FROM EITHER
CARBON STEEL OR LOW
GRADE STAINLESS STEELS )T ALLOWS ETHYL ACETATE TO BE
MADE WITHOUT REQUIRING ACETIC ACID AS A FEED MATERIAL 4HE PROCESS IS
APPROPRIATE FOR BOTH SYNTHETIC ETHANOL AND FERMENTATION ETHANOL AS THE
FEED 4HE SYNTHETIC ETHANOL CAN BE IMPURE ETHANOL WITHOUT SIGNIl CANTLY
AFFECTING THE CONVERSION OR SELECTIVITY 4HE PRODUCT ETHYL ACETATE IS GREATER
THAN
Economics: 4YPICAL PERFORMANCE DATA PER TON OF ETHYL ACETATE PRO
DUCED
&EEDSTOCK
0RODUCT
TONS OF ETHANOL
KG OF HYDROGEN
Commercial
plants: 4HE TECHNOLOGY HAS BEEN DEVELOPED DURING THE MID
TO LATE S 4HE l RST COMMERCIAL PLANT IS A
TPY PLANT IN 3OUTH
!FRICA USING SYNTHETIC ETHANOL
Licensees: /NE SINCE
%THANOL FEED
3ELECTIVE
HYDROGENATION
2ECYCLE ETHANOL
Licensor: $AVY 0ROCESS 4ECHNOLOGY 5+
%THYL ACETATE
PRODUCT
Ethylbenzene
Application: !DVANCED TECHNOLOGY TO PRODUCE HIGH
PURITY ETHYLBENZENE
%" ALKYLATING BENZENE WITH ETHYLENE USING PATENTED CATALYTIC DISTILLA
TION #$ TECHNOLOGY 4HE #$4%#( %" PROCESS USES A SPECIALLY FORMU
LATED ZEOLITE ALKYLATION CATALYST PACKAGED IN A PROPRIETARY #$ STRUCTURE
4HE PROCESS IS ABLE TO HANDLE A WIDE RANGE IN ETHYLENE FEED COMPOSI
TIONFROM TO ETHYLENE
Description: 4HE #$ ALKYLATOR STRIPPER OPERATES AS A DISTILLATION COL
UMN !LKYLATION AND DISTILLATION OCCUR IN THE ALKYLATOR IN THE PRESENCE OF
A ZEOLITE CATALYST PACKAGED IN PATENTED STRUCTURED PACKING 5NREACTED
ETHYLENE AND BENZENE VAPOR FROM THE ALKYLATOR TOP ARE CONDENSED AND
FED TO THE l NISHING REACTOR WHERE THE REMAINING ETHYLENE REACTS OVER
ZEOLITE CATLAYST PELLETS 4HE ALKYLATOR STRIPPER BOTTOMS IS FRACTIONATED
INTO %" PRODUCT POLYETHYLBENZENES AND m UX OIL 4HE POLYETHYLBEN
ZENES ARE TRANSALKYLATED WITH BENZENE OVER ZEOLITE CATALYST PELLETS IN THE
TRANSALKYLATOR TO PRODUCE ADDITIONAL %" 4HE ETHYLENE CAN BE POLYMER
GRADE OR WITH ONLY MINOR DIFFERENCES IN THE PROCESS SCHEME DILUTE ETH
YLENE CONTAINING AS LITTLE AS MOL ETHYLENE AS IN &## OFFGAS 2EACTORS
ARE DESIGNED FOR TO YEARS OF UNINTERRUPTED RUNLENGTH 4HE PROCESS
DOES NOT PRODUCE ANY HAZARDOUS EFm UENT ,OW OPERATING TEMPERATURES
ALLOW USING CARBON STEEL FOR ALL EQUIPMENT
Yields
and
product
quality: "OTH THE ALKYLATION AND TRANS
ALKYLATION REACTIONS
ARE HIGHLY SELECTIVEPRODUCING FEW BYPRODUCTS 4HE %" PRODUCT HAS HIGH
PURITY WT MINIMUM AND IS SUITABLE FOR STYRENE
UNIT FEED 8YLENE
MAKE IS LESS THAN PPM 4HE PROCESS HAS AN OVERALL YIELD OF
Economics: 4HE %" PROCESS FEATURES CONSISTENT PRODUCT YIELDS HIGH
PRODUCT PURITY LOW ENERGY CONSUMPTION LOW INVESTMENT COST AND EASY
RELIABLE OPERATION
)NVESTMENT TPY )3", 'ULF #OAST 53
MILLION
2AW MATERIALS AND UTILITIES BASED ON ONE METRIC TON OF %"
%THYLENE KG
#$ ALKYLATOR
STRIPPER
&INISHING REACTOR
4RANSALKYLATOR
%"
COLUMN
0%"
COLUMN
%THYLBENZENE
"ENZENE
%THYLENE
&LUX OIL
0OLYETHYLBENZENES
"ENZENE KG
%LECTRICITY K7H
7ATER COOLING M
3TEAM MTONS EXPORT
(OT OIL KCAL
Commercial
plants: 4HREE COMMERCIAL PLANTS ARE IN OPERATION IN !RGEN
TINA AND #ANADA WITH CAPACITIES FROM TO MTPY 4HEY
PROCESS ETHYLENE FEEDSTOCKS WITH PURITIES RANGING FROM ETHYLENE TO
POLYMER
GRADE ETHYLENE !N
MTPY UNIT USING DILUTE ETHYLENE IS
CURRRENTLY UNDER CONSTRUCTION
Ethylbenzene, CONTINUED
Licensor: #$4%#( A PARTNERSHIP BETWEEN !"" ,UMMUS 'LOBAL AND
#HEMICAL 2ESEARCH ,ICENSING
Ethylbenzene
Application:
4O PRODUCE ETHYLBENZENE %" FROM BENZENE AND A POLY
MER
GRADE ETHYLENE OR AN ETHYLENEETHANE FEEDSTOCK USING THE "AD
GER %"-AX PROCESS AND PROPRIETARY %XXON-OBIL ALKYLATION AND TRANS
ALKYLATION CATALYSTS 4HE TECHNOLOGY CAN BE APPLIED IN THE DESIGN OF
GRASSROOTS UNITS UPGRADING OF EXISTING VAPOR
PHASE TECHNOLOGY PLANTS
OR CONVERSION OF ALUMINUM CHLORIDE TECHNOLOGY %" PLANTS TO ZEOLITE
TECHNOLOGY
Description: %THYLENE REACTS WITH BENZENE IN EITHER A TOTALLY LIQUID
l LLED
OR MIXED
PHASE ALKYLATION REACTOR CONTAINING MULTIPLE l XED
BEDS OF
%XXON-OBILS PROPRIETARY CATALYST FORMING %" AND VERY SMALL QUANTITIES
OF POLYETHYLBENZENES 0%" )N THE TRANSALKYLATION REACTOR 0%" IS CON
VERTED TO %" BY REACTION WITH BENZENE OVER %XXON-OBILS TRANSALKYLATION
CATALYST 0%" AND BENZENE RECOVERED FROM THE CRUDE %" ENTER THE TRANS
ALKYLATION REACTOR
%Fm UENTS FROM THE ALKYLATION AND TRANSALKYLATION REACTORS ARE FED TO
THE BENZENE COLUMN WHERE UNREACTED BENZENE IS RECOVERED FROM
CRUDE %" 4HE FRESH BENZENE FEEDSTOCK AND A SMALL VENT STREAM FROM
THE BENZENE COLUMN ARE FED TO THE LIGHTS COLUMN TO REJECT LIGHT IM
PURITIES 4HE LIGHTS COLUMN BOTTOMS IS RETURNED TO THE BENZENE COLUMN
4HE BOTTOMS FROM THE BENZENE COLUMN IS FED TO THE %" COLUMN TO
RECOVER %" PRODUCT 4HE BOTTOMS FROM THE %" COLUMN IS FED TO THE 0%"
COLUMN WHERE RECYCLABLE ALKYLBENZENES ARE RECOVERED AS A DISTILLATE
AND DIPHENYL COMPOUNDS ARE REJECTED IN A BOTTOMS STREAM THAT CAN BE
USED AS FUEL
Catalysts: #YCLE LENGTHS IN EXCESS OF FOUR YEARS ARE EXPECTED FOR THE
ALKYLATION AND TRANSALKYLATION CATALYSTS 0ROCESS EQUIPMENT IS FABRI
CATED ENTIRELY FROM CARBON STEEL #APITAL INVESTMENT IS REDUCED AS A
CONSEQUENCE OF THE HIGH ACTIVITY AND EXTRAORDINARY SELECTIVITY OF THE
ALKYLATION CATALYST AND THE ABILITY OF BOTH THE ALKYLATION AND TRANSALKYL
ATION CATALYSTS TO OPERATE WITH VERY LOW QUANTITIES OF EXCESS BENZENE
"ENZENE
6ENT
,IGHT
COLUMN
%THYLENE
%" PRODUCT
!LKYLATION
REACTOR
2ESIDUE
2ECYCLE 0%"
4RANSALKYLATION
REACTOR
"ENZENE
COLUMN
%"
COLUMN
0%"
COLUMN
Product
quality: 4HE %" PRODUCT CONTAINS LESS THAN PPM OF # PLUS
# IMPURITIES 0RODUCT PURITIES OF TO ARE EXPECTED
Economics:
2AW MATERIALS AND STEAM TONS PER TON OF %" PRODUCT
%THYLENE
"ENZENE
3TEAM HIGH
PRESSURE USED
3TEAM MEDIUM
AND LOW
PRESSURED GENERATED
5TILITIES CAN BE OPTIMIZED FOR SPECIl C SITE CONDITIONS
Commercial
plants: 3INCE THE COMMERCIALIZATION OF THE "ADGER %" TECH
NOLOGY IN LICENSES HAVE BEEN GRANTED 4HE TOTAL LICENSED CAPAC
Ethylbenzene, CONTINUED
ITY FOR THE "ADGER %" TECHNOLOGY EXCEEDS MILLION MTPY 4HE CAPACITY
FOR THE %"-AX TECHNOLOGY EXCEEDS MILLION MTPY
Licensor: "ADGER ,ICENSING ,,#
Ethylbenzene
Application: 3TATE
OF
THE
ART TECHNOLOGY TO PRODUCE HIGH
PURITY ETHYLBEN
%THYLBENZENE
ZENE %" BY LIQUID PHASE ALKYLATION OF BENZENE WITH ETHYLENE 4HE ,UM
MUS5/0 %"/NE PROCESS USES SPECIALLY FORMULATED PROPRIETARY ZEOLITE
CATALYST FROM 5/0 4HE PROCESS CAN HANDLE A WIDE RANGE OF ETHYLENE FEED
COMPOSITIONS RANGING FROM CHEMICAL TO POLYMER GRADE
Description: "ENZENE AND ETHYLENE ARE COMBINED OVER A PROPRIETARY ZEO
%THYLENE
LITE CATALYST IN A l XED BED LIQUID PHASE REACTOR &RESH BENZENE IS COMBINED
WITH RECYCLE BENZENE AND FED TO THE ALKYLATION REACTOR 4HE COMBINED
BENZENE FEED m OWS IN SERIES THROUGH THE BEDS WHILE FRESH ETHYLENE FEED
IS DISTRIBUTED EQUALLY BETWEEN THE BEDS 4HE REACTION IS HIGHLY EXOTHERMIC
AND HEAT IS REMOVED BETWEEN THE REACTION STAGES BY GENERATING STEAM
5NREACTED BENZENE IS RECOVERED FROM THE OVERHEAD OF THE BENZENE COL
UMN AND %" PRODUCT IS TAKEN AS OVERHEAD FROM THE %" COLUMN
! SMALL AMOUNT OF POLYETHYLBENZENE 0%" IS RECOVERED IN THE OVER
HEAD OF THE 0%" COLUMN AND RECYCLED BACK TO THE TRANSALKYLATION
REACTOR WHERE IT IS COMBINED WITH BENZENE OVER A SECOND PROPRIETARY
ZEOLITE CATALYST TO PRODUCE ADDITIONAL %" PRODUCT ! SMALL AMOUNT OF m UX
OIL IS RECOVERED FROM THE BOTTOM OF THE 0%" COLUMN AND IS USUALLY
BURNED AS FUEL
4HE CATALYSTS ARE NON CORROSIVE AND OPERATE AT MILD CONDITIONS AL
LOWING FOR ALL CARBON STEEL CONSTRUCTION 4HE REACTORS CAN BE DESIGNED
FOR n YEAR CATALYST CYCLE LENGTH AND THE CATALYST IS FULLY REGENERABLE
4HE PROCESS DOES NOT PRODUCE ANY HAZARDOUS EFm UENT
!DDITIONAL UTILITY SAVINGS CAN BE REALIZED VIA HEAT INTEGRATION WITH
DOWNSTREAM ,UMMUS5/0 #LASSIC 3- OR 3-!24 3- STYRENE UNIT
Yields
and
product
quality: "OTH THE ALKYLATION AND TRANS
ALKYLATION REACTIONS
Commercial
plants: .INETEEN %"/NE UNITS ARE IN OPERATION THROUGHOUT
ARE HIGHLY SELECTIVE PRODUCING FEW BYPRODUCTS 4HE %" PRODUCT HAS A HIGH
PURITY WT MINIMUM AND IS SUITABLE FOR STYRENE
UNIT FEED 8YLENE
MAKE IS LESS THAN PPM 4HE PROCESS HAS AN OVERALL YIELD OF
Economics: 4HE %"/NE PROCESS FEATURES CONSISTENTLY HIGH PRODUCT YIELDS
OVER THE ENTIRE CATALYST LIFE CYCLE HIGH
PRODUCT PURITY LOW
ENERGY CON
SUMPTION LOW INVESTMENT COST AND SIMPLE RELIABLE OPERATION
&LUX OIL
0OLYETHYLBENZENE
"ENZENE
2ECYCLE BENZENE
)NVESTMENT )3", 'ULF #OAST 53MTPY
2AW MATERIAL AND UTILITIES PER METRIC TON OF %"
%THYLENE MTONS
"ENZENE MTONS
5TILITIES 53
n
THE WORLD WITH A TOTAL %" CAPACITY OF MILLION MTPY 5NIT CAPACITIES
RANGE FROM TO MTPY %THYLENE FEEDSTOCK PURITY RANGES
FROM TO .INE ADDITIONAL UNITS ARE EITHER IN DESIGN OR UNDER
CONSTRUCTION THE LARGEST UNIT IS MTPY
Ethylbenzene, CONTINUED
Licensor: !"" ,UMMUS 'LOBAL AND 5/0 ,,#
Ethylene
Application: 4O PRODUCE POLYMER
GRADE ETHYLENE VOL -AJOR
BYPRODUCTS ARE PROPYLENE CHEMICAL OR POLYMER
GRADE A BUTADIENE
RICH
# STREAM # TO # AROMATICS
RICH PYROLYSIS GASOLINE AND HIGH
PURITY
HYDROGEN
3(0
STM
Description: (YDROCARBON FEEDSTOCK IS PREHEATED AND CRACKED IN THE
PRESENCE OF STEAM IN TUBULAR 324 SHORT RESIDENCE TIME PYROLYSIS FURNACES
4HIS APPROACH FEATURES EXTREMELY HIGH OLEl N YIELDS LONG RUNLENGTH
AND MECHANICAL INTEGRITY 4HE PRODUCTS EXIT THE FURNACE AT & TO
& AND ARE RAPIDLY QUENCHED IN THE TRANSFER LINE EXCHANGERS
THAT GENERATE SUPER HIGH PRESSURE 3(0 STEAM 4HE LATEST GENERATION
FURNACE DESIGN IS THE 324 6)
&URNACE EFm UENT AFTER QUENCH m OWS TO THE GASOLINE FRACTIONATOR
WHERE THE HEAVY OIL FRACTION IS REMOVED FROM THE GASOLINE AND LIGHTER
FRACTION LIQUIDS CRACKING ONLY &URTHER COOLING OF FURNACE EFm UENTS IS
ACCOMPLISHED BY A DIRECT WATER QUENCH IN THE QUENCH TOWER 2AW
GAS FROM THE QUENCH TOWER IS COMPRESSED IN A MULTISTAGE CENTRIFUGAL
COMPRESSOR TO GREATER THAN PSIG 4HE COMPRESSED GAS IS THEN
DRIED AND CHILLED (YDROGEN IS RECOVERED IN THE CHILLING TRAIN
WHICH FEEDS THE DEMETHANIZER 4HE DEMETHANIZER OPERATES AT ABOUT
PSIA PROVIDING INCREASED ENERGY EFl CIENCY 4HE BOTTOMS FROM THE
DEMETHANIZER GO TO THE DEETHANIZER
!CETYLENE IN THE DEETHANIZER OVERHEAD IS HYDROGENATED OR
RECOVERED 4HE ETHYLENE ETHANE STREAM IS FRACTIONATED AND POLYMER
GRADE ETHYLENE IS RECOVERED %THANE LEAVING THE BOTTOM OF THE ETHYLENE
FRACTIONATOR IS RECYCLED AND CRACKED TO EXTINCTION
4HE DEETHANIZER BOTTOMS AND CONDENSATE STRIPPER BOTTOMS FROM
THE CHARGE COMPRESSION SYSTEM ARE DEPROPANIZED -ETHYLACETYLENE
AND PROPADIENE ARE HYDROGENATED IN THE DEPROPANIZER USING #$(YDRO
CATALYTIC DISTILLATION HYDROGENATION TECHNOLOGY 4HE DEPROPANIZER BOTTOMS
IS SEPARATED INTO MIXED # AND LIGHT GASOLINE STREAMS 0OLYMER GRADE
PROPYLENE IS RECOVERED IN A PROPYLENE FRACTIONATOR
!CID GAS
324 CRACKING
FURNACE
&EED
3(0
STM
#7
#HARGE GAS COMP
AND ACID GAS
REMOVAL
0YROLYSIS FUEL OIL
%THYLENE
(YDROGEN
-ETHANE
#HILLING
TRAIN AND
HYDROGEN
SEPARATION
(
0ROPYLENE
-IXED #S
(
%THANE
0ROPANE
0YROLYSIS
GASOLINE
! REVISED m OW SCHEME ELIMINATES ^ OF THE EQUIPMENT FROM THIS
CONVENTIONAL m OWSHEET )T USES #$(YDRO HYDROGENATION FOR THE SELECTIVE
HYDROGENATION OF # THROUGH # ACETYLENES AND DIENES IN A SINGLE TOWER
REDUCES THE CRACKED
GAS DISCHARGE PRESSURE TO PSIG USES A SINGLE
REFRIGERATION SYSTEM TO REPLACE THE THREE SEPARATE SYSTEMS AND APPLIES
METATHESIS TO PRODUCE UP TO OF THE PROPYLENE PRODUCT CATALYTICALLY
RATHER THAN BY THERMAL CRACKING THEREBY LOWERING ENERGY CONSUMPTION
BY ^
Energy
consumption: %NERGY CONSUMPTIONS ARE KCALKG OF ETHYLENE
PRODUCED FOR ETHANE CRACKING AND KCALKG OF ETHYLENE FOR NAPHTHA
Ethylene, CONTINUED
FEEDSTOCKS %NERGY CONSUMPTION CAN BE AS LOW AS KCALKG OF ETHYL
ENE FOR NAPHTHA FEEDSTOCKS WITH GAS TURBINE INTEGRATION !S NOTED ABOVE
THE NEW mOW SCHEME REDUCES ENERGY CONSUMPTION BY
Commercial
plants: !PPROXIMATELY OF THE WORLDS ETHYLENE PLANTS
USE ,UMMUS ETHYLENE TECHNOLOGY -ANY EXISTING UNITS HAVE BEEN SIG
NIlCANTLY EXPANDED ABOVE OF NAMEPLATE USING ,UMMUS -#%4
MAXIMUM CAPACITY EXPANSION TECHNOLOGY APPROACH
Licensor: !"" ,UMMUS 'LOBAL
Ethylene
Application: (IGH PERFORMANCE STEAM
CRACKING AND RECOVERY TO PRODUCE
POLYMER
GRADE ETHYLENE AND PROPYLENE BUTADIENE
RICH MIXED #S ARO
MATIC
RICH PYROLYSIS GASOLINE HYDROGEN AND FUEL STREAMS #RACKING FEED
STOCKS RANGE FROM ETHANE THROUGH VACUUM GAS OILS
Description: +ELLOGG "ROWN 2OOTS PROPRIETARY 3ELECTIVE #RACKING
/PTIMUM 2%COVERY 3#/2% OLEl NS TECHNOLOGY REPRESENTS THE INTEGRA
TION OF THE TECHNOLOGIES OF THE FORMER -7 +ELLOGG AND "ROWN 2OOT
COMPANIES COMBINED WITH OLEl NS TECHNOLOGY DEVELOPED BY %XXON-OBIL
#HEMICAL #O THROUGH A LONG TERM WORLDWIDE LICENSING AGREEMENT
%XXON-OBIL BRINGS INNOVATIVE TECHNOLOGY AS WELL AS THE BENEl TS OF EX
TENSIVE OPERATING EXPERIENCE TO FURTHER IMPROVE OPERABILITY RELIABILITY
AND REDUCE PRODUCTION COSTS
4HE 3#/2% PYROLYSIS FURNACE PORTFOLIO FEATURES THE STRAIGHT TUBE 3#
DESIGN WHICH HAS A LOW REACTION TIME IN THE RANGE OF SECONDS AND
LOW OPERATING PRESSURES 4HE DESIGN AND OPERATING CONDITIONS PRODUCE
HIGHER OLEl N YIELDS 4HE PORTFOLIO INCLUDES A RANGE OF DESIGNS TO SATISFY
ANY REQUIREMENTS
4HE PYROLYSIS FURNACE EFm UENT IS PROCESSED FOR HEAT AND PRODUCT
RECOVERY IN AN EFl CIENT RELIABLE LOW COST RECOVERY SECTION 4HE RECOVERY
SECTION DESIGN CAN BE OPTIMIZED FOR SPECIl C APPLICATIONS ANDOR SELECTED
BASED ON OPERATING COMPANY PREFERENCES &LOW SCHEMES BASED ON DE
ETHANIZER l RST DEPROPANIZER l RST AND DEMETHANIZER l RST CONl GURATIONS
ARE AVAILABLE 4HE DEPROPANIZER l RST m OW SCHEME PRIMARILY APPLICABLE TO
LIQUID CRACKERS IS SHOWN ABOVE 4HE SIMILAR BUT SIMPLER DEETHANIZER l RST
SCHEME IS APPROPRIATE FOR ETHANE THROUGH ETHANEPROPANE GAS CRACKERS
4HESE TWO SCHEMES USE FRONT END ACETYLENE CONVERTER SYSTEMS WHICH
MINIMIZE GREEN OIL PRODUCTION AND ALLOW USING LOW PRESSURE RECOVERY
TOWERS +"2 ALSO HAS EXTENSIVE EXPERIENCE WITH THE DEMETHANIZER
l RST m OW SCHEME WHICH CAN BE OFFERED TO CLIENTS PREFERRING THAT
TECHNOLOGY
(0 BOILER
FEEDWATER
0ROCESS STEAM
&UEL GASFUEL OIL
0ROPYLENE
(YDROCARBON
FEEDSTOCK
0YROLYSIS GASOLINE
0ROPANE RECYCLE
%THYLENE
4AIL GAS
&UEL OIL
-IXED #S
(0 SUPERHEATED
STEAM
(YDROGEN
%THANE RECYCLE
#RACKED GASES ARE COOLED AND FRACTIONATED TO REMOVE FUEL OIL AND
WATER
THEN COMPRESSED PROCESSED FOR ACID
GAS REMOVAL
AND DRIED 4HE # AND LIGHTER MATERIAL IS SEPARATED AS AN OVERHEAD
PRODUCT IN THE DEPROPANIZER AND ACETYLENE IS HYDROGENATED IN THE
ACETYLENE CONVERTER 4HE ACETYLENE CONVERTER EFm UENT IS PROCESSED IN
THE DEMETHANIZER SYSTEM
TO SEPARATE THE FUEL GAS AND HYDROGEN
PRODUCTS 4HE DEMETHANIZER BOTTOMS IS SENT TO THE DEETHANIZER FROM
WHICH THE OVERHEAD m OWS TO THE #
SPLITTER WHICH PRODUCES THE
POLYMER
GRADE ETHYLENE PRODUCT AND THE ETHANE STREAM WHICH IS TYPICALLY
RECYCLED TO THE FURNACES AS A FEEDSTOCK 4HE DEETHANIZER BOTTOMS m OWS
TO THE #
SPLITTER WHERE THE POLYMER
GRADE PROPYLENE IS RECOVERED
Ethylene, CONTINUED
AS THE OVERHEAD PRODUCT 4HE #
SPLITTER BOTTOMS PRODUCT PROPANE
IS TYPICALLY RECYCLED TO THE FURNACES AS A FEEDSTOCK 4HE DEPROPANIZER
BOTTOMS PRODUCT #S AND HEAVIER mOW TO THE DEBUTANIZER FOR
RECOVERY OF THE MIXED
# PRODUCT AND AROMATIC
RICH PYROLYSIS GASOLINE
Yields: %THYLENE YIELDS TO FOR ETHANE FOR NAPHTHA AND
FOR GAS OILS MAY BE ACHIEVED DEPENDING UPON FEEDSTOCK CHARACTERISTICS
Commercial
plants: +"2 HAS BEEN INVOLVED IN OVER ETHYLENE PROJECTS
WORLDWIDE WITH SINGLE
TRAIN ETHYLENE CAPACITIES UP TO MILLION TPY IN
CLUDING NEW GRASSROOTS ETHYLENE PLANTS SINCE
Licensor: +ELLOGG "ROWN 2OOT )NC
Ethylene
MAL CRACKING OF HYDROCARBON FRACTIONS FROM ETHANE THROUGH NAPHTHA
UP TO HYDROCRACKER RESIDUE "YPRODUCTS ARE A BUTADIENE
RICH # STREAM
A # n # GASOLINE STREAM RICH IN AROMATICS AND FUEL OIL
Description: &RESH FEEDSTOCK AND RECYCLE STREAMS ARE PREHEATED AND
CRACKED IN THE PRESENCE OF DILUTION STEAM IN HIGHLY SELECTIVE 0YRO#RACK
FURNACES 0YRO#RACK FURNACES ARE OPTIMIZED WITH RESPECT TO RESIDENCE
TIME TEMPERATURE AND PRESSURE PROl LES FOR THE ACTUAL FEEDSTOCK AND THE
REQUIRED FEEDSTOCK m EXIBILITY THUS ACHIEVING THE HIGHEST OLEl N YIELDS
&URNACE EFm UENT IS COOLED IN TRANSFER LINE EXCHANGERS GENERATING (0
STEAM AND BY DIRECT QUENCHING WITH OIL FOR LIQUID FEEDSTOCKS
4HE CRACKED GAS STREAM IS COOLED AND PURIl ED IN THE PRIMARY
FRACTIONATOR AND QUENCH WATER TOWER 7ASTE HEAT IS RECOVERED BY
A CIRCULATING OIL CYCLE GENERATING DILUTION STEAM AND BY A WATER CYCLE
TO PROVIDE HEAT TO REBOILERS AND PROCESS HEATERS 4HE CRACKED GAS
FROM THE QUENCH TOWER IS COMPRESSED IN A OR STAGE COMPRESSOR
AND DRIED IN GAS AND LIQUID ADSORBERS #/ AND (3 ARE REMOVED IN A
CAUSTIC WASH SYSTEM LOCATED BEFORE THE l NAL COMPRESSOR STAGE
4HE COMPRESSED CRACKED GAS IS FURTHER COOLED AND FED TO THE
RECOVERY SECTION FRONT END DEETHANIZER ISOTHERMAL FRONT END #
HYDROGENATION COLD TRAIN DEMETHANIZER AND THE HEAT
PUMPED LOW PRESSURE ETHYLENE FRACTIONATIOR WHICH IS INTEGRATED
WITH THE ETHYLENE REFRIGERATION CYCLE 4HIS WELL PROVEN ,INDE PROCESS IS
HIGHLY OPTIMIZED RESULTING IN HIGH m EXIBILITY EASY OPERATION LOW ENERGY
CONSUMPTION LOW INVESTMENT COSTS AND LONG INTERVALS BETWEEN MAJOR
TURNAROUNDS TYPICALLY l VE YEARS
4HE # FROM THE DEETHANIZER BOTTOMS IS DEPROPANIZED
HYDROGENATED TO REMOVE METHYL ACETYLENE AND PROPADIENE
AND FRACTIONATED TO RECOVER POLYMER GRADE PROPYLENE # COMPONENTS
ARE SEPARATED FROM HEAVIER COMPONENTS IN THE DEBUTANIZER TO
RECOVER A # PRODUCT AND A # STREAM 4HE # TOGETHER WITH THE
&EED
$ILUTION
STEAM
(0 STEAM
Application: 4O PRODUCE POLYMER GRADE ETHYLENE AND PROPYLENE BY THER
#RACKED
GAS
COMP
RESSION
(
3OUR GAS
REMOVAL
#
(
-IXED #S
#(
0ROPYLENE
0YROLYSIS
GASOLINE
#n
&UEL OIL
#
0ROPANE
RECYCLE
%THYLENE
%THANE
RECYCLE
HYDROCARBON CONDENSATES FROM THE HOT SECTION FORMS AN AROMATIC
RICH GASOLINE PRODUCT
Economics: %THYLENE YIELDS VARY BETWEEN AND FOR
GAS OILS NAPHTHA ,0' AND ETHANE RESPECTIVELY 4HE RELATED SPECIl C ENERGY
CONSUMPTION RANGE IS AND KCALKG ETHYLENE
4YPICAL INSTALLATION COSTS FOR A WORLD SCALE )3", GAS NAPHTHA CRACKER ON A
'ULF #OAST BASIS ARE 53TON INSTALLED ETHYLENE CAPACITY
Commercial
plants: /VER MILLION TONS OF ETHYLENE ARE PRODUCED IN
MORE THAN PLANTS WORLDWIDE -ANY PLANTS HAVE BEEN EXPANDED IN
CAPACITY UP TO AND MORE
Ethylene, CONTINUED
2ECENT AWARDS FOR WORLD
SCALE ETHYLENE PLANTS INCLUDE "OROUGE IN
!BU $HABI /PTIMAL IN -ALAYSIA !MIR +ABIR AND -ARUN IN )RAN AND 46+
)) IN (UNGARY 4HE -ARUN PLANT IS ONE OF THE WORLDS LARGEST CRACKERS WITH
A CAPACITY OF
MILLION MTPY ETHYLENE AND
MTPY PROPYLENE
Licensor: ,INDE !'
Ethylene
Application: 4O PRODUCE POLYMER
GRADE ETHYLENE AND PROPYLENE BY THER
MALLY CRACKING PARAFl NIC FEEDSTOCKS ETHANE THROUGH HYDROCRACKED RESI
DUE 4WO MAIN PROCESS TECHNOLOGIES ARE USED
53# ULTRA SELECTIVE CRACKING 0YROLYSIS AND QUENCH SYSTEMS
!23(23 ADVANCED RECOVERY SYSTEM WITH HEAT
INTEGRATED RECTIl ER
SIMPLIl CATION #OLD FRACTIONATION
0LANTS ARE CHARACTERIZED BY HIGH OPERATIONAL RELIABILITY RAPID STARTUPS
AND ABILITY TO MEET ENVIRONMENTAL REQUIREMENTS
Description: &EEDS ARE SENT TO 53# CRACKING FURNACES #ONTAMINANTS
REMOVAL MAY BE INSTALLED UPSTREAM ! PORTION OF THE CRACKING HEAT MAY BE
SUPPLIED BY GAS TURBINE EXHAUST 0YROLYSIS OCCURS WITHIN THE TEMPERATURE
TIME REQUIREMENTS SPECIl C TO THE FEEDSTOCK AND PRODUCT REQUIREMENTS
2APID QUENCHING PRESERVES HIGH
OLEl N YIELD AND THE WASTE HEAT GENER
ATES HIGH
PRESSURE STEAM ,OWER
TEMPERATURE WASTE HEAT IS RECOVERED
AND PYROLYSIS FUEL OIL AND GASOLINE DISTILLATE FRACTIONATED #RACKED GAS
# AND LIGHTER IS THEN COMPRESSED SCRUBBED WITH CAUSTIC TO REMOVE
ACID GASES AND DRIED PRIOR TO FRACTIONATION # AND LIGHTER COMPONENTS
ARE SEPARATED FROM THE # AND HEAVIER COMPONENTS IN THE LOW
FOULING
FRONT
END DUAL PRESSURE DEPROPANIZER /VERHEAD VAPOR IS HYDROGE
NATED TO REMOVE ACETYLENE AND IS ROUTED TO THE !23(23
!23 MINIMIZES REFRIGERATION ENERGY BY USING DISTRIBUTED DISTILLATION
AND SIMULTANEOUS HEAT AND MASS TRANSFER IN THE DEPHLEGMATOR EXCLUSIVE
ARRANGEMENT WITH !IR 0RODUCTS OR (23 SYSTEM 4WO # STREAMS OF VARYING
COMPOSITION ARE PRODUCED (YDROGEN AND METHANE ARE SEPARATED
OVERHEAD
4HE HEAVIER # STREAM IS DEETHANIZED AND # OVERHEAD PASSES TO
THE -0 ETHYLENE
ETHANE FRACTIONATOR INTEGRATED WITH # REFRIGERATION
SYSTEM 4HE LIGHTER # STREAM IS ROUTED DIRECTLY TO THE ETHYLENE
ETHANE
FRACTIONATOR 0OLYMER
GRADE ETHYLENE PRODUCT IS SENT OVERHEAD FROM
THE ETHYLENE
ETHANE FRACTIONATOR !CETYLENE RECOVERY MAY OPTIONALLY BE
INSTALLED UPSTREAM OF THE ETHYLENE
ETHANE FRACTIONATOR
(0
STEAM
&EED
STOCK
# AND HEAVIER
COPRODUCTS
%THYLENE
0ROPYLENE
(-ETHANE
%THANE RECYCLE
0ROPANE RECYCLE
#S ARE COMBINED AND HYDROGENATED TO REMOVE METHYL ACETYLENE
AND PROPADIENE 0OLYMER OR CHEMICAL GRADE PROPYLENE IS THEN
PRODUCED OVERHEAD FROM THE # SUPERFRACTIONATOR
# AND HEAVIER COPRODUCTS ARE FURTHER SEPARATED IN A SEQUENCE
OF DISTILLATION STEPS %THANE AND PROPANE ARE TYPICALLY RECYCLE CRACKED
2EFRIGERATION IS SUPPLIED BY CASCADE ETHYLENEPROPYLENE SYSTEMS
3PECIl C ADVANTAGES OF !23 TECHNOLOGY ARE REDUCED CHILLING
TRAIN REFRIGERATION REQUIREMENTS DUE TO CHILLINGPREFRACTIONATION IN THE
DEPHLEGMATOR OR (23 SYSTEM REDUCED METHANE CONTENT IN FEED TO
DEMETHANIZER PARTIAL DEETHANIZER BYPASSING DUAL FEED ETHYLENE
FRACTIONATOR LOWER REm UX RATIO AND REDUCED REFRIGERATION DEMAND
APPROX
Ethylene, CONTINUED
Economics: %THYLENE YIELDS RANGE FROM ETHANE HIGH CONVERSION
TO HEAVY HYDROGENATED GAS OILS #ORRESPONDING SPECIlC ENERGY
CONSUMPTIONS RANGE FROM KCALKG TO KCALKG
Commercial
plants: /VER ETHYLENE UNITS HAVE BEEN BUILT BY 3TONE
7EBSTER %XPANSION TECHNIQUES BASED ON !23(23 TECHNOLOGY HAVE
INCREASED ORIGINAL CAPACITIES BY AS MUCH AS
Licensor: 3TONE 7EBSTER )NC A 3HAW 'ROUP #O
Ethylene
Application: 4HERMAL CRACKING OF A WIDE RANGE OF FEEDSTOCKS INTO LIGHT
&LUE GAS
OLEl NS AND AROMATICS USING PROPRIETARY CRACKING COILS
#RACKED GAS
Feedstocks: %THANE THROUGH TO HEAVY FEEDS UP TO # %0
Products: #RACKED GAS RICH IN ETHYLENE PROPYLENE BUTADIENE AND "48
Description: 4HERMAL CRACKING OCCURS IN PRESENCE OF STEAM AT HIGH TEM
PERATURES IN CRACKING COILS LOCATED CENTRALLY IN THE l REBOX #OIL OUTLET
TEMPERATURES VARY UP TO # DEPENDING ON FEED QUALITY AND CRACKING
SEVERITY 4HE PROPRIETARY CRACKING COILS ARE THE '+ '+ AND 3-+ COILS
4HEY FEATURE HIGH SELECTIVITY TO ETHYLENE AND PROPYLENE TOGETHER WITH
LOW COKING RATES LONG RUN LENGTHS
#RACKED GASES FROM THE FURNACE PASS THROUGH A TRANSFER
LINE
EXCHANGER 4,% SYSTEM WHERE HEAT IS RECOVERED TO GENERATE HIGH
PRESSURE STEAM 4HE PRIMARY 4,%S ARE LINEAR OR SPECIAL 3 AND 4 TYPE
EXCHANGERS 4HE SELECTED EXCHANGER TYPE ENSURES LOW TO VERY LOW
FOULING RATES AND THUS EXTENDS RUN LENGTHS (EAT FROM THE m UE GASES IS
RECOVERED IN THE CONVECTION SECTION TO PREHEAT FEED AND PROCESS STEAM
AND TO SUPERHEAT GENERATED (0 3TEAM 4HE TECHNOLOGY MAY BE APPLIED
TO RETROl T FURNACES &URNACE PERFORMANCE IS OPTIMIZED USING PROPRIETARY
3092/ PROGRAMS ./X ABATEMENT TECHNOLOGY IS INCORPORATED
0ERFORMANCE DATA
%THANE CONVERSION
.APHTHA CRACKING SEVERITY AS 0%
/VERALL THERMAL EFl CIENCY
#OIL RESIDENCE TIME SEC
'+'+ COILS
3-+ COIL
n
n
n
n
n
/NCE THROUGH ETHYLENE YIELDS DEPEND ON FEED CHARACTERISTICS AND
SEVERITY AND RANGE FROM FOR ETHANE TO FOR LIQUID FEEDS
Commercial
plants: /VER INSTALLATIONS SINCE THE MID
S
Licensor: 4ECHNIP
&EED
"&7
(0 STEAM
0ROCESS STEAM
&0(
%#/
(033(
(4#
'+3-+
COILS
Ethylene
Application: 4O PRODUCE POLYMER
GRADE ETHYLENE AND PROPYLENE A BU
TADIENE
RICH # CUT AN AROMATIC # n # RICH
RAW PYROLYSIS GASOLINE AND
HIGH
PURITY HYDROGEN BY USING THE 4
0!2 PROCESS FOR GAS SEPARATION AND
PRODUCT PURIl CATION FROM RAW CRACKED GAS
Description: %Fm UENTS FROM CRACKING FURNACES ARE COOLED AND PROCESSED
FOR TAR AND HEAVY
GASOLINE REMOVAL
! MULTISTAGE COMPRESSOR DRIVEN BY A STEAM TURBINE COMPRESSES THE
COOLED GAS ,0 AND (0 CONDENSATES ARE STRIPPED IN TWO SEPARATE STRIPPERS
WHERE MEDIUM GASOLINE IS PRODUCED AND PART OF THE # CUT IS RECOVERED
RESPECTIVELY ! CAUSTIC SCRUBBER REMOVES ACID GASES
#OMPRESSED GAS AT PSIG IS DRIED AND THEN CHILLED ! MULTI
STREAM HEAT EXCHANGER CHILLS THE TAIL GAS TO n & ,IQUID CONDENSATES
ARE SEPARATED AT VARIOUS TEMPERATURES SUCH AS n & n & n& AND
n& AND ARE REHEATED AGAINST INCOMING CRACKED GAS 4HE PARTIALLY
VAPORIZED STREAMS ARE SENT TO A DEETHANIZER STRIPPER OPERATING AT ABOUT
PSIG 4HE BOTTOMS # STREAM IS SENT TO PROPYLENE AND HEAVYS
RECOVERY
4HE OVERHEAD IS REHEATED AND ENTERS AN ADIABATIC ACETYLENE
HYDROGENATION REACTOR WHICH TRANSFORMS THE ACETYLENE SELECTIVELY TO
ETHYLENE AND ETHANE !S AN ALTERNATE A SOLVENT
RECOVERY PROCESS CAN BE
APPLIED WITHOUT REHEATING THE GAS
2EACTOR EFm UENT IS CHILLED AND LIGHT
ENDS ARE SEPARATED FROM THE
#
HYDROCARBONS 4HE DEMETHANIZER OVERHEAD IS PROCESSED FOR ETHYLENE
RECOVERY WHILE THE BOTTOMS IS SENT TO ETHYLENEETHANE SEPARATION !N
OPEN HEAT
PUMP SPLITTER IS APPLIED THUS SENDING ETHYLENE PRODUCT TO THE
GAS PIPELINE FROM THE DISCHARGE OF THE ETHYLENE
REFRIGERANT COMPRESSOR
$ILUTE ETHYLENE FOR CHEMICAL APPLICATIONS SUCH AS STYRENE PRODUCTION
CAN BE WITHDRAWN DOWNSTREAM OF THE HYDROGENATION REACTOR 4HE
ETHYLENE CONTENT IS TYPICALLY VOL #ATALYST SUPPLIERS HAVE TESTED THE
HYDROGENATION STEP AND COMMERCIALLY AVAILABLE FRONT
END CATALYSTS ARE
SUITABLE FOR THIS APPLICATION
'AS COMPRESSION ACID
GAS REMOVAL DRYING
#'
#OMPRESSORS
# 2EF
&EED
#RACKING
FURNACES
'AS
COOLING
$EETHANIZER
STRIPPER
(YDROGEN
RICH
FUEL GAS
###
PROCESSING
0ROPYLENE
4AR
GASOLINE
#
BROAD
CUT
!CETYLENE HYDRO
ACETYLENE RECOVERY
!CETYLENE
$EMETHANIZER
STRIPPER
# 2EF
%THYLENE%THANE
&RACTIONATION
/(0
0YGAS
# CUT
%THANE
RECYCLE
%THYLENE
Economics: 4HE ADVANTAGES OF THIS PROCESS ARE LOW EQUIPMENT COSTS
VIZ THE DEETHANIZER SYSTEM AND ETHYLENEETHANE SEPARATION AND RELI
ABILITY OF THE ACETYLENE HYDROGENATION DUE TO LOW EXCESS HYDROGEN AT
THE REACTOR INLET 4HE REFRIGERATION COMPRESSOR BENEl TS FROM LOW SPECIl C
POWER AND SUCTION VOLUME WHILE THE CRACKED
GAS COMPRESSOR PROCESSES
ABOVE
AMBIENT
TEMPERATURE GAS
Commercial
plants: 4ECHNIP IS COMMERCIALIZING THE 4
0!2 PROCESS ON A
CASE
BY
CASE BASIS
Licensor: 4ECHNIP
Ethylene
Application: 4HE -AX%NE PROCESS INCREASES THE ETHYLENE YIELD FROM
NAPHTHA CRACKERS BY RAISING THE CONCENTRATION OF NORMAL PARAFl NS N
PARAFl NS IN THE NAPHTHA
CRACKER FEED 4HE -AX%NE PROCESS IS THE NEW
EST APPLICATION OF 5/0S 3ORBEX TECHNOLOGY 4HE PROCESS USES ADSORPTIVE
SEPARATION TO SEPARATE # n # NAPHTHA INTO A RICH N
PARAFl NS STREAM
AND A STREAM DEPLETED OF N
PARAFl NS
!DSORBENT
CHAMBER
$ESORBENT
2OTARY
VALVE
Economics: #APITAL COSTS AND ECONOMICS DEPEND ON FEED COMPOSITION
AS WELL AS THE DESIRED INCREASE IN ETHYLENE AND PROPYLENE PRODUCTION IN
THE STEAM CRACKER
Licensor: 5/0 ,,#
.ORMAL PARAFFINS TO CRACKER
%XTRACT
Description: 4HE SEPARATION TAKES PLACE IN AN ADSORPTION CHAMBER
THAT IS DIVIDED INTO A NUMBER OF BEDS %ACH BED CONTAINS PROPRIETARY
SHAPE SELECTIVE ADSORBENT !LSO EACH BED IN THE CHAMBER IS CONNECTED
TO A ROTARY VALVE 4HE ROTARY VALVE IS USED ALONG WITH THE SHAPE SE
LECTIVE ADSORBENT TO SIMULATE A COUNTER CURRENT MOVING BED ADSORPTIVE
SEPARATION &OUR STREAMS ARE DISTRIBUTED BY THE ROTARY VALVE TO AND FROM
THE ADSORBENT CHAMBER 4HE STREAMS ARE AS FOLLOWS
s Feed: 4HE NAPHTHA FEED CONTAINS A MIXTURE OF HYDROCARBONS
s Extract: 4HIS STREAM CONTAINS N PARAFl N AND A LIQUID DESORBENT
.APHTHA RICH IN N PARAFl N IS RECOVERED BY FRACTIONATION AND IS SENT
TO THE NAPHTHA CRACKER
s Raffinate: 4HIS STREAM CONTAINS NON NORMAL PARAFl N AND A LIQUID
DESORBENT .APHTHA DEPLETED IN N PARAFl N IS RECOVERED BY FRACTION
ATION AND IS SENT TO A REl NERY OR AN AROMATICS COMPLEX
s Desorbent: 4HIS STREAM CONTAINS A LIQUID DESORBENT THAT IS RECYCLED
FROM THE FRACTIONATION SECTION TO THE CHAMBER
4HE ROTARY VALVE IS USED TO PERIODICALLY SWITCH THE POSITION OF THE
LIQUID FEED AND WITHDRAWAL POINTS IN THE ADSORBENT CHAMBER 4HE PROCESS
OPERATES IN A CONTINUOUS MODE AT LOW TEMPERATURES IN A LIQUID PHASE
&EED
2AFFINATE
&ULL
RANGE NAPHTHA
%XTRACT
COLUMN
$ESORBENT
2AFFINATE
COLUMN
.ON
NORMAL HYDROCARBONS
TO REFORMER FOR GASOLINE
OR AROMATICS PRODUCTION
Ethylene
feed
pretreatment
mercury,
arsenic
and
lead
removal
Application: 5PGRADE NATURAL GAS CONDENSATE AND OTHER CONTAMINATED
STREAMS TO HIGHER
VALUE ETHYLENE PLANT FEEDSTOCKS -ERCURY ARSENIC AND
LEAD CONTAMINATION IN POTENTIAL ETHYLENE PLANT FEEDSTOCKS PRECLUDES
THEIR USE DESPITE ATTRACTIVE YIELD PATTERNS 4HE CONTAMINANTS POISON CAT
ALYSTS CAUSE CORROSION IN EQUIPMENT AND HAVE UNDESIRABLE ENVIRONMEN
TAL IMPLICATIONS &OR EXAMPLE MERCURY COMPOUNDS POISON HYDROTREATING
CATALYSTS AND IF PRESENT IN THE STEAM
CRACKER FEED ARE DISTRIBUTED IN
THE #n # CUTS ! CONDENSATE CONTAINING MERCURY MAY HAVE NEGATIVE
ADDED
VALUE AS A GAS l ELD PRODUCT
Description: 4HREE 2!- PROCESSES ARE AVAILABLE TO REMOVE ARSENIC
2!- ) ARSENIC MERCURY AND LEAD 2!- )) AND ARSENIC MERCURY
AND SULFUR FROM LIQUID HYDROCARBONS 2!- ))) $ESCRIBED ABOVE IS
THE 2!- )) PROCESS &EED IS HEATED BY EXCHANGE WITH REACTOR EFm U
ENT AND STEAM )T IS THEN HYDROLYZED IN THE l RST CATALYTIC REACTOR
IN WHICH ORGANOMETALLIC MERCURY COMPOUNDS ARE CONVERTED TO
ELEMENTAL MERCURY AND ORGANIC ARSENIC COMPOUNDS ARE CONVERTED
TO ARSENIC METAL COMPLEXES AND TRAPPED IN THE BED ,EAD IF ANY IS
ALSO TRAPPED ON THE BED 4HE SECOND REACTOR CONTAINS A SPECIl C
MERCURY TRAPPING MASS 4HERE IS NO RELEASE OF THE CONTAMINANTS TO
THE ENVIRONMENT AND SPENT CATALYST AND TRAPPING MATERIAL CAN BE
DISPOSED OF IN AN ENVIRONMENTALLY ACCEPTABLE MANNER
#ONTAMINANT
-ERCURY PPB
!RSENIC PPB
4YPICAL 2!- )) 0ERFORMANCE
&EEDSTOCK
0RODUCT
PPB IS THE THRESHOLD LIMIT OF THE ANALYTICAL PROCEDURE COMMONLY USED 7ITH PROVISIONS FOR
ELIMINATING SOLID MATTER WATER AND FREE OXYGEN AND USING A MORE SENSITIVE METHOD LEVELS
OF LESS THAN ONE PPB CAN BE ACHIEVED
Economics: 4HE )3", INVESTMENT AT A 'ULF #OAST LOCATION FOR TWO
CONDENSATES EACH CONTAINING
PPB AVERAGE MERCURY CONTENT MAX
!RSENIC AND
MERCURY
FREE
PRODUCT
/RGANOMETALLIC
HYDROGENOLYSIS
AND ARSENIC TRAP
(YDROGEN
$ISTILLED
FEEDSTOCK
#-'
#-'
-ERCURY
TRAP
3TEAM
#7
PPB PPB ARSENIC AND PPB LEAD EXCLUDING BASIC ENGINEERING
DETAILED ENGINEERING OFFSITES CONTRACTOR FEES
)NVESTMENT 53BPD
5TILITIES 53BPD
#ATALYST COST 53BPD
#LEAR OXYGEN FREE
CONDENSATE
!ERATED CONDENSATE
WITH PARTICULATE MATTER
Commercial
plants: &IFTEEN 2!- UNITS HAVE BEEN LICENSED WORLDWIDE
References: $IDILLON " , 3AVARY * #OSYNS 1 $EBUISSCHERT AND 0 4RAV
ERS h-ERCURY AND !RSENIC 2EMOVAL FROM %THYLENE 0LANT &EEDSTOCKS v 3EC
Ethylene
feed
pretreatmentmercury,
arsenic
and
lead
removal, CONTINUED
OND %UROPEAN 0ETROCHEMICALS 4ECHNOLOGY #ONFERENCE 0RAGUE
Licensor: !XENS !XENS .!
Ethylene
glycol,
mono
(MEG)
Application: 4O PRODUCE MONO
ETHYLENE GLYCOL -%' FROM ETHYLENE OX
0URGE
IDE %/
#/ RECYCLE
Description: %/ IN AN AQUEOUS SOLUTION IS REACTED WITH #/ IN THE PRES
ENCE OF A HOMOGENEOUS CATALYST TO FORM ETHYLENE CARBONATE 4HE
ETHYLENE CARBONATE SUBSEQUENTLY IS REACTED WITH WATER TO FORM -%'
AND #/ 4HE NET CONSUMPTION OF #/ IN THE PROCESS IS NIL SINCE ALL
#/ CONVERTED TO ETHYLENE CARBONATE IS RELEASED AGAIN IN THE ETHYLENE
CARBONATE HYDROLYSIS REACTION 5NCONVERTED #/ FROM THE ETHYLENE CAR
BONATE REACTION IS RECOVERED AND RECYCLED TOGETHER WITH #/ RE
LEASED IN THE ETHYLENE CARBONATE HYDROLYSIS REACTION
4HE PRODUCT FROM THE HYDROLYSIS REACTION IS DISTILLED TO REMOVE
RESIDUAL WATER )N SUBSEQUENT DISTILLATION COLUMNS HIGH PURITY -%' IS
RECOVERED AND SMALL AMOUNTS OF CO PRODUCED DI ETHYLENE GLYCOL ARE
REMOVED 4HE HOMOGENEOUS CATALYST USED IN THE PROCESS CONCENTRATES
IN THE BOTTOM OF COLUMN AND IS RECYCLED BACK TO THE REACTION SECTION
4HE PROCESS HAS A -%' YIELD OF #OMPARED TO THE THERMAL
GLYCOL PROCESS STEAM CONSUMPTION AND WASTEWATER PRODUCTION ARE
RELATIVELY LOW THE LATTER BECAUSE NO CONTAMINATED PROCESS STEAM IS
GENERATED
-%' QUALITY AND PERFORMANCE OF THE -%' PRODUCT IN DERIVATIVES
POLYESTERS MANUFACTURING HAVE BEEN DEMONSTRATED TO BE AT LEAST
AS GOOD AS AND FULLY COMPATIBLE WITH -%' PRODUCED VIA THE THERMAL
PROCESS
Commercial
plants: 4HE l RST COMMERCIAL PLANT IS CURRENTLY UNDER CON
STRUCTION IN 4AIWAN 4WO OTHER PROCESS LICENSES HAVE BEEN AWARDED
4HE COMBINATION OF THIS PROCESS WITH THE 3HELL %/ PROCESS IS LICENSED
UNDER THE NAME -i"
PROCESS
Licensor: 3HELL )NTERNATIONAL #HEMICALS "6
Contact: CT
AMSTERDAM SHELLCOM
7ATER
-%'
#/
!QUEOUS %/
#ATALYST RECYCLE
2ESIDUE
Ethylene
glycol
Application: 4O PRODUCE ETHYLENE GLYCOLS -%' $%' 4%' FROM ETHYL
ENE OXIDE %/ USING $OWS -ETEOR PROCESS
Description: )N THE -ETEOR 0ROCESS AN %/WATER MIXTURE IS PREHEATED
AND FED DIRECTLY TO AN ADIABATIC REACTOR WHICH CAN OPERATE WITH OR
WITHOUT A CATALYST !N EXCESS OF WATER IS PROVIDED TO ACHIEVE HIGH SELEC
TIVITIES TO MONOETHYLENE GLYCOL -%' $IETHYLENE $%' AND TRIETHYLENE
4%' GLYCOLS ARE PRODUCED AS COPRODUCTS )N A CATALYZED MODE HIGHER
SELECTIVITIES TO -%' CAN BE OBTAINED THEREBY REDUCING $%' PRODUCTION
TO ONE
HALF THAT PRODUCED IN THE UNCATALYZED MODE 4HE REACTOR IS SPE
CIALLY DESIGNED TO FULLY REACT ALL OF THE %/ AND TO MINIMIZE BACK
MIXING
WHICH PROMOTES ENHANCED SELECTIVITY TO -%'
%XCESS WATER FROM THE REACTOR EFm UENT IS EFl CIENTLY REMOVED IN A
MULTI
EFFECT EVAPORATION SYSTEM 4HE LAST
EFFECT EVAPORATOR OVERHEAD
PRODUCES LOW
PRESSURE STEAM WHICH IS A GOOD LOW
LEVEL ENERGY SOURCE
FOR OTHER CHEMICAL UNITS OR OTHER PARTS OF THE %/-%' PROCESS 4HE
CONCENTRATED WATERGLYCOLS STREAM FROM THE EVAPORATION SYSTEM IS FED
TO THE WATER COLUMN WHERE THE REMAINING WATER AND LIGHT ENDS ARE
STRIPPED FROM THE CRUDE GLYCOLS 4HE WATER
FREE CRUDE GLYCOL STREAM IS FED
TO THE -%' REl NING COLUMN WHERE POLYESTER
GRADE -%' SUITABLE FOR
POLYESTER l BER AND 0%4 PRODUCTION IS RECOVERED $%' AND 4%' EXITING
THE BASE OF THE -%' REl NING COLUMN CAN BE RECOVERED AS HIGH
PURITY
PRODUCTS BY SUBSEQUENT FRACTIONATION
Economics: 4HE CONVERSION OF %/ TO GLYCOLS IS ESSENTIALLY COMPLETE 4HE
REACTION NOT ONLY GENERATES THE DESIRED -%' BUT ALSO PRODUCES $%'
AND 4%' THAT CAN BE RECOVERED AS COPRODUCTS 4HE PRODUCTION OF MORE
$%' AND 4%' MAY BE DESIRABLE IF THE MANUFACTURER HAS A SPECIl C USE FOR
THESE PRODUCTS OR IF MARKET CONDITIONS PROVIDE A GOOD PRICE FOR $%' AND
4%' RELATIVE TO -%' ! CATALYZED PROCESS WILL PRODUCE LESS HEAVY GLYCOLS
4HE ABILITY TO OPERATE IN CATALYZED OR UNCATALYZED MODE PROVIDES m EX
IBILITY TO THE MANUFACTURER TO MEET CHANGING MARKET DEMANDS
3TEAM
2ECYCLED
WATER
-%'
%/WATER
3TEAM
3TEAM
$%' 4%'
Commercial
plants: 3INCE 5##
DESIGNED GLYCOL PLANTS HAVE
BEEN STARTED UP OR ARE UNDER CONSTRUCTION
Licensor: 5NION #ARBIDE #ORP A SUBSIDIARY OF 4HE $OW #HEMICAL #O
Ethylene
glycols
Application: 4O PRODUCE ETHYLENE GLYCOLS -%' $%' AND 4%' FROM ETH
YLENE OXIDE %/
%/ OR AQUEOUS %/
7ATER
Description:
0URIl ED %/ OR A WATER%/ MIXTURE IS COMBINED WITH RE
CYCLE WATER AND HEATED TO REACTION CONDITIONS )N THE TUBULAR REACTOR
ESSENTIALLY ALL %/ IS THERMALLY CONVERTED INTO MONO
ETHYLENE GLYCOL
-%' WITH DI
ETHYLENE GLYCOL $%' AND TRI
ETHYLENE GLYCOL 4%' AS CO
PRODUCTS IN MINOR AMOUNTS %XCESS WATER REQUIRED TO ACHIEVE A HIGH
SELECTIVITY TO -%' IS EVAPORATED IN A MULTI
STAGE EVAPORATOR
4HE LAST EVAPORATOR PRODUCES LOW
PRESSURE STEAM THAT IS USED AS A HEAT
ING MEDIUM AT VARIOUS LOCATIONS IN THE PLANT 4HE RESULTING CRUDE GLYCOLS
MIXTURE IS SUBSEQUENTLY PURIl ED AND FRACTIONATED IN A SERIES OF VACUUM
COLUMNS
4HE SELECTIVITY TO -%' CAN BE INm UENCED BY ADJUSTING THE GLYCOL REACTOR
FEED COMPOSITION
-OST -%' PLANTS ARE INTEGRATED WITH %/ PLANTS )N SUCH AN INTEGRATED
%/-%' FACILITY THE STEAM SYSTEM CAN BE OPTIMIZED TO FULLY EXPLOIT THE
BENEl TS OF HIGH
SELECTIVITY CATALYST APPLIED IN THE %/ PLANT (OWEVER
STANDALONE -%' PLANTS HAVE BEEN DESIGNED AND BUILT
4HE QUALITY OF GLYCOLS MANUFACTURED BY THIS PROCESS RANKS AMONGST THE
HIGHEST IN THE WORLD )T CONSISTENTLY MEETS THE MOST STRINGENT SPECIl CA
TIONS OF POLYESTER l BER AND 0%4 PRODUCERS
Commercial
plants: 3INCE MORE THAN 3HELL
DESIGNED -%'
PLANTS HAVE BEEN COMMISSIONED OR ARE UNDER CONSTRUCTION
Licensor: 3HELL )NTERNATIONAL #HEMICALS "6
4HE COMBINATION OF THIS PROCESS WITH THE 3HELL %/ PROCESS IS LICENSED
UNDER THE NAME -i -/
, PROCESS
3TEAM
7ATER
-%'
$%'
4%'
Ethylene
oxide
2ECLAIM
COMPRESSOR
Application: 4O PRODUCE ETHYLENE OXIDE %/ FROM ETHYLENE USING OXYGEN
AS THE OXIDIZING AGENT
#/
Description: %THYLENE AND OXYGEN IN A DILUENT GAS MADE UP OF A MIXTURE
OF MAINLY METHANE OR NITROGEN ALONG WITH CARBON DIOXIDE AND ARGON
ARE FED TO A TUBULAR CATALYTIC REACTOR 4HE TEMPERATURE OF REACTION IS
CONTROLLED BY ADJUSTING THE PRESSURE OF THE STEAM WHICH IS GENERATED IN
THE SHELL SIDE OF THE REACTOR AND REMOVES THE HEAT OF REACTION 4HE %/
PRODUCED IS REMOVED FROM THE REACTION GAS BY SCRUBBING WITH WATER
AFTER HEAT EXCHANGE WITH THE CIRCULATING REACTOR FEED GAS
"YPRODUCT #/ IS REMOVED FROM THE SCRUBBED REACTION GAS
BEFORE IT IS RECOMPRESSED AND RETURNED TO THE REACTION SYSTEM WHERE
ETHYLENE AND OXYGEN CONCENTRATIONS ARE RESTORED BEFORE RETURNING TO
THE %/ REACTOR
4HE %/ IS STEAM STRIPPED FROM THE SCRUBBING SOLUTION AND RE
COVERED AS A MORE CONCENTRATED WATER SOLUTION FOR FEED TO AN %/
PURIl CATION SYSTEM WHERE PURIl ED PRODUCT IS MADE ALONG WITH A
HIGH ALDEHYDE %/ PRODUCT
Product
quality: 4HE %/ PRODUCT MEETS THE LOW ALDEHYDE SPECIl CATION OF
PPM MAXIMUM WHICH IS REQUIRED FOR %/ DERIVATIVES PRODUCTION
Product
yield:
4HE ETHYLENE YIELD TO PURIl ED %/ IS KG PER KG ETHYLENE
FEED )N ADDITION A SIGNIl CANT AMOUNT OF TECHNICAL
GRADE GLYCOL MAY BE
RECOVERED BY PROCESSING WASTE STREAMS
Commercial
plants: .EARLY PURIl ED %/ PROJECTS HAVE BEEN COMPLETED
OR ARE BEING DESIGNED 4HIS REPRESENTS A TOTAL DESIGN CAPACITY OF ABOUT
MILLION METRIC TONS OF PURIl ED %/ WITH THE LARGEST PLANTS EXCEEDING
MTPY
Licensor: 3CIENTIl C $ESIGN #OMPANY )NC
%THYLENE
3TEAM
2ECYCLE
COMPRESSOR
/
3TEAM
"&7
0URIFIED
%/
3TEAM
3TEAM
3TEAM
(IGH ALDEHYDE
%/ PRODUCT
Ethylene
oxide
Application: 4O PRODUCE ETHYLENE OXIDE %/ FROM ETHYLENE AND OXYGEN
IN A DIRECT OXIDATION PROCESS
Description: )N THE DIRECT OXIDATION PROCESS ETHYLENE AND OXYGEN ARE
MIXED WITH RECYCLE GAS AND PASSED THROUGH A MULTI
TUBULAR CATALYTIC RE
ACTOR TO SELECTIVELY PRODUCE %/ ! SPECIAL SILVER
CONTAINING HIGH
SE
LECTIVITY CATALYST IS USED THAT HAS BEEN IMPROVED SIGNIl CANTLY OVER THE
YEARS -ETHANE IS USED AS BALLAST GAS (EAT GENERATED BY THE REACTION
IS RECOVERED BY BOILING WATER AT ELEVATED PRESSURE ON THE REACTORS SHELL
SIDE THE RESULTING HIGH
PRESSURE STEAM IS USED FOR HEATING PURPOSES AT
VARIOUS LOCATIONS WITHIN THE PROCESS
%/ CONTAINED IN THE REACTOR PRODUCT
GAS IS ABSORBED IN WATER AND
FURTHER CONCENTRATED IN A STRIPPER 3MALL AMOUNTS OF CO
ABSORBED
ETHYLENE AND METHANE ARE RECOVERED FROM THE CRUDE %/ AND RECYCLED
BACK TO THE %/ REACTOR 4HE CRUDE %/ CAN BE FURTHER CONCENTRATED INTO
HIGH
PURITY %/ OR ROUTED TO THE GLYCOLS PLANT AS %/WATER FEED
%/ REACTOR PRODUCT
GAS AFTER %/ RECOVERY IS MIXED WITH FRESH FEED
AND RETURNED TO THE %/ REACTOR 0ART OF THE RECYCLE GAS IS PASSED THROUGH
AN ACTIVATED CARBONATE SOLUTION TO RECOVER #/ A BYPRODUCT OF THE
%/ REACTION THAT HAS VARIOUS COMMERCIAL APPLICATIONS
-OST %/ PLANTS ARE INTEGRATED WITH l BER
GRADE MONO
ETHYLENE
GLYCOL -%' PRODUCTION FACILITIES )N SUCH AN INTEGRATED %/-%' FACILITY
THE STEAM SYSTEM CAN BE OPTIMIZED TO FULLY EXPLOIT THE BENEl TS OF HIGH
SELECTIVITY CATALYST
7HEN ONLY HIGH
PURITY %/ IS REQUIRED AS A PRODUCT A SMALL AMOUNT
OF TECHNICAL
GRADE -%' INEVITABLY IS CO
PRODUCED
Yields: -ODERN PLANTS ARE TYPICALLY DESIGNED FOR AND OPERATE AT A MOLAR
%/ CATALYST SELECTIVITY APPROACHING WITH FRESH CATALYST AND n
AS AN AVERAGE OVER YEARS CATALYST LIFE RESULTING IN AN AVERAGE %/ PRO
DUCTION OF ABOUT TONS PER TON OF ETHYLENE (OWEVER THE TECHNOL
OGY IS m EXIBLE AND THE PLANT CAN BE DESIGNED TAILOR
MADE TO CUSTOMER
REQUIREMENTS OR DIFFERENT OPERATING TIME BETWEEN CATALYST CHANGES
%THYLENE
#/
/XYGEN
3TEAM
3TEAM
%/
7ATER OR
AQUEOUS %/
3TEAM
Commercial
plants: 3INCE MORE THAN 3HELL
DESIGNED PLANTS
HAVE BEEN COMMISSIONED OR ARE UNDER CONSTRUCTION !PPROXIMATELY
OF THE GLOBAL CAPACITY OF %/ EQUIVALENTS IS PRODUCED IN 3HELL
DESIGNED
PLANTS
Licensor: 3HELL )NTERNATIONAL #HEMICALS "6
4HE 3HELL %/ PROCESS IS LICENSED UNDER THE NAME -i -/
, PRO
CESS WHEN COMBINED WITH THE 3HELL ETHYLENE GLYCOLS PROCESS AND UNDER
THE NAME -i"
PROCESS WHEN COMBINED WITH THE 3HELL PROCESS
FOR SELECTIVE -%' PRODUCTION VIA ETHYLENE CARBONATE INTERMEDIATE
Ethylene
oxide
Application: 4O PRODUCE ETHYLENE OXIDE %/ FROM THE DIRECT OXIDATION OF
ETHYLENE USING THE $OW -ETEOR PROCESS
Description: 4HE -ETEOR 0ROCESS A TECHNOLOGY l RST COMMERCIALIZED IN
IS A SIMPLER SAFER PROCESS FOR THE PRODUCTION OF %/ HAVING LOWER
CAPITAL INVESTMENT REQUIREMENTS AND LOWER OPERATING COSTS )N THE -ETEOR
0ROCESS ETHYLENE AND OXYGEN ARE MIXED WITH METHANE BALLAST RECYCLE GAS
AND PASSED THROUGH A SINGLE TRAIN MULTITUBULAR CATALYTIC REACTOR TO SELEC
TIVELY PRODUCE %/ 5SE OF A SINGLE REACTOR IS ONE EXAMPLE OF HOW THE -ETEOR
PROCESS IS A SIMPLER SAFER TECHNOLOGY WITH LOWER FACILITY INVESTMENT COSTS
4HE SPECIAL HIGH PRODUCTIVITY -ETEOR %/ CATALYST PROVIDES VERY
HIGH EFl CIENCIES WHILE OPERATING AT HIGH LOADINGS (EAT GENERATED BY
THE REACTION IS REMOVED AND RECOVERED BY THE DIRECT BOILING OF WATER TO
GENERATE STEAM ON THE SHELL SIDE OF THE REACTOR (EAT IS RECOVERED FROM
THE REACTOR OUTLET GAS BEFORE IT ENTERS THE %/ ABSORBER WHERE %/
IS SCRUBBED FROM THE GAS BY WATER 4HE %/ CONTAINING WATER FROM THE
%/ ABSORBER IS CONCENTRATED BY STRIPPING 4HE CYCLE GAS EXITING THE
ABSORBER IS FED TO THE #/ REMOVAL SECTION WHERE #/ WHICH IS
CO PRODUCED IN THE %/ REACTOR IS REMOVED VIA ACTIVATED HOT POTASSIUM
CARBONATE TREATMENT 4HE #/ LEAN CYCLE GAS IS RECYCLED BY COMPRESSION
BACK TO THE %/ REACTOR
-OST %/ PLANTS ARE INTEGRATED WITH GLYCOL PRODUCTION FACILITIES
7HEN PRODUCING GLYCOLS THE %/ STREAM IS SUITABLE FOR FEEDING DIRECTLY
TO A -ETEOR GLYCOL PROCESS 7HEN %/ IS THE DESIRED l NAL PRODUCT THE
%/ STREAM CAN BE FED TO A SINGLE PURIl CATION COLUMN TO PRODUCE
HIGH PURITY %/ 4HIS PROCESS IS EXTREMELY m EXIBLE AND CAN PROVIDE THE
FULL RANGE OF PRODUCT MIX BETWEEN GLYCOLS AND PURIl ED %/
Economics: 4HE PROCESS REQUIRES A LOWER CAPITAL INVESTMENT AND HAS
LOWER l XED COSTS DUE TO PROCESS SIMPLICITY AND THE NEED FOR FEWER EQUIP
MENT ITEMS ,OWER OPERATING COSTS ARE ALSO ACHIEVED THROUGH THE HIGH
PRODUCTIVITY -ETEOR %/ CATALYST WHICH HAS VERY HIGH EFl CIENCIES AT VERY
HIGH LOADINGS
#ARBON
DIOXIDE
%THYLENE
"OILER
WATER
/XYGEN
3TEAM
3TEAM
%THYLENE
OXIDE
3TEAM
Commercial
plants: 5NION #ARBIDE WAS THE l RST TO COMMERCIALIZE THE
DIRECT OXIDATION PROCESS FOR %/ IN THE S 3INCE 5NION #AR
BIDE
DESIGNED PLANTS HAVE BEEN STARTED UP OR ARE UNDER CONSTRUCTION
4HREE MILLION TONS OF %/ EQUIVALENTS PER YEAR APPROXIMATELY OF
TOTAL WORLD CAPACITY ARE PRODUCED IN 5NION #ARBIDE
DESIGNED PLANTS
Licensor: 5NION #ARBIDE #ORP A SUBSIDIARY OF 4HE $OW #HEMICAL #O
Ethylene
oxide/Ethylene
glycols
2ECLAIM
COMPRESSOR
Application: 4O PRODUCE ETHYLENE GLYCOLS %'S AND ETHYLENE OXIDE %/
FROM ETHYLENE USING OXYGEN AS THE OXIDIZING AGENT
-ODERN %/%' PLANTS ARE HIGHLY INTEGRATED UNITS WHERE %/ PRO
DUCED IN THE %/ REACTION SYSTEM CAN BE RECOVERED AS GLYCOLS -%' $%'
AND 4%' WITH A CO
PRODUCT OF PURIl ED %/ IF DESIRED 0ROCESS INTEGRA
TION ALLOWS FOR A SIGNIl CANT UTILITIES SAVINGS AS WELL AS THE RECOVERY OF ALL
BLEED STREAMS AS HIGH
GRADE PRODUCT WHICH WOULD OTHERWISE HAVE BEEN
RECOVERED AS A LESSER GRADE PRODUCT 4HE INTEGRATED PLANT RECOVERS ALL
-%' AS l BER
GRADE PRODUCT AND %/ PRODUCT AS LOW
ALDEHYDE PRODUCT
4HE TOTAL RECOVERY OF THE %/ FROM THE REACTION SYSTEM IS WITH
ONLY A SMALL LOSS AS HEAVY GLYCOL RESIDUE
Description: %THYLENE AND OXYGEN IN A DILUENT GAS MADE UP OF A MIXTURE
OF MAINLY METHANE OR NITROGEN ALONG WITH CARBON DIOXIDE #/ AND AR
GON ARE FED TO A TUBULAR CATALYTIC REACTOR 4HE TEMPERATURE OF REACTION
IS CONTROLLED BY ADJUSTING THE PRESSURE OF THE STEAM WHICH IS GENERATED
IN THE SHELL SIDE OF THE REACTOR AND REMOVES THE HEAT OF REACTION 4HE %/
PRODUCED IS REMOVED FROM THE REACTION GAS BY SCRUBBING WITH WATER
AFTER HEAT EXCHANGE WITH THE CIRCULATING REACTOR FEED GAS
"YPRODUCT #/ IS REMOVED FROM THE SCRUBBED REACTION GAS
BEFORE IT IS RECOMPRESSED AND RETURNED TO THE REACTION SYSTEM WHERE
ETHYLENE AND OXYGEN CONCENTRATIONS ARE RESTORED BEFORE RETURNING TO
THE %/ REACTOR
4HE %/ IS STEAM STRIPPED FROM THE SCRUBBING SOLUTION AND RECOV
ERED AS A MORE CONCENTRATED WATER SOLUTION THAT IS SUITABLE FOR USE AS
FEED TO A GLYCOL PLANT OR TO AN %/ PURIl CATION SYSTEM 4HE STRIPPED
WATER SOLUTION IS COOLED AND RETURNED TO THE SCRUBBER
4HE GLYCOL PLANT FEED ALONG WITH ANY HIGH ALDEHYDE %/ BLEEDS FROM
THE %/ PURIl CATION SECTION ARE SENT TO THE GLYCOL REACTOR AND THEN TO
A MULTI
EFFECT EVAPORATION TRAIN FOR REMOVAL OF THE BULK OF
THE WATER FROM THE GLYCOLS 4HE GLYCOLS ARE THEN DRIED AND SENT TO
THE GLYCOL DISTILLATION TRAIN WHERE THE -%' $%' AND 4%'
PRODUCTS ARE RECOVERED AND PURIl ED
#/
%THYLENE
0URIFIED
%/
3TEAM
2ECYCLE
COMPRESSOR
/
3TEAM
3TEAM
"&7
3TEAM
3TEAM
%THYLENE OXIDE SECTION
'LYCOL SECTION
4%'
2ESIDUE
4REATING
UNIT
$%'
7ASTE
WATER
-%'
3TEAM
2ECYCLE WATER
Ethylene
oxide/Ethylene
glycols, CONTINUED
Product
quality: 4HE 3$ PROCESS HAS SET THE INDUSTRY STANDARD FOR lBER
GRADE -%' QUALITY 7HEN %/ IS PRODUCED AS A CO
PRODUCT IT MEETS THE
LOW ALDEHYDE SPECIlCATION REQUIREMENT OF
PPM ALDEHYDE MAXIMUM
WHICH IS REQUIRED FOR %/ DERIVATIVE UNITS
Yield: 4HE ETHYLENE YIELD TO GLYCOLS IS KG OF TOTAL GLYCOLS PER KG OF
ETHYLENE 4HE ETHYLENE YIELD FOR THAT PORTION OF THE PRODUCTION GOING TO
PURIlED %/ IS KG OF %/ PRODUCT KG OF ETHYLENE
Commercial
plants: /VER %/%' PLANTS USING 3$ TECHNOLOGY HAVE
BEEN BUILT 4HE WORLDS LARGEST -%' PLANT WITH A CAPACITY OF
MTPY OF -%' IS PRESENTLY IN DESIGN AND FOLLOWS THE STARTUP OF A
MTPY PLANT IN /CTOBER
Licensor: 3CIENTIlC $ESIGN #OMPANY )NC
Formaldehyde
Application: 4O PRODUCE AQUEOUS FORMALDEHYDE !& OR UREA FORMAL
DEHYDE PRECONDENSATE 5&# FROM METHANOL USING THE (ALDOR 4OPSE
&ORMALDEHYDE 32 PROCESS COMPRISING TWO REACTORS IN SERIES
4AIL GAS
2ECYCLE
Description: !IR AND RECYCLE GAS ARE COMPRESSED BY THE BLOWER AND
THEN MIXED WITH LIQUID METHANOL THAT IS INJECTED THROUGH SPRAY NOZZLES
4HE MIXTURE IS PREHEATED TO ABOUT # BY HEAT EXCHANGE WITH HOT CIR
CULATING OIL IN THE HEAT EXCHANGER AFTER WHICH THE GAS IS SUCCESSIVELY
PASSED TO THE TWO SERIES REACTORS AND
!DDITIONAL METHANOL IS INJECTED INTO THE GAS BETWEEN THE TWO
REACTORS 4HE REACTORS CONTAIN MANY TUBES l LLED WITH &+
CATALYST
WHERE METHANOL AND OXYGEN REACT TO MAKE FORMALDEHYDE 2EACTION
HEAT IS REMOVED BY A BATH OF BOILING HEAT
TRANSFER OIL (OT OIL VAPOR IS
CONDENSED IN THE WASTE
HEAT BOILER THUS GENERATING STEAM AT UP
TO BAR PRESSURE "EFORE ENTERING THE ABSORBER THE REACTED GAS
IS COOLED IN THE AFTER COOLER AND REHEATS THE CIRCULATING OIL FROM THE
PROCESS
GAS HEATER
)N THE ABSORBER THE FORMALDEHYDE IS ABSORBED IN WATER OR UREA
SOLUTION (EAT IS REMOVED BY ONE OR TWO COOLING CIRCUITS &ROM THE
LOWER CIRCUIT PRODUCT IN THE FORM OF EITHER !& OR 5&# IS WITHDRAWN
3CRUBBED GAS FROM THE ABSORBER IS SPLIT IN TWO STREAMS RECYCLE GAS AND
TAIL GAS 4HE TAIL GAS IS VENTED AFTER ANY ORGANIC IMPURITIES ARE CATALYTICALLY
INCINERATED IN THE REACTOR 4HUS THE TAIL
GAS PURITY CONFORMS TO THE
ENVIRONMENTAL STANDARDS FOR ANY COUNTRY
7ITH REGARD FOR THE CATALYST THE PERCENTAGE OF METHANOL THAT CAN
BE ADDED TO A FORMALDEHYDE REACTOR IS LIMITED TO ABOUT
VOL 5SING
TWO REACTORS IN SERIES HIGHER PRODUCTION YIELDS ARE ACHIEVABLE WITH THE
SAME GAS m OW THAN WHAT WOULD BE POSSIBLE IN A PLANT WITH ONLY ONE
REACTOR OR A PLANT WITH TWO REACTORS IN PARALLEL
!DVANTAGES OF SERIES REACTORS VS SINGLE OR PARALLEL REACTORS ARE
s ,OWER CAPITAL COST DUE TO REDUCED SIZE OF EQUIPMENT AND PIPING
3TEAM
!IR
-ETHANOL
"&7
#7
!& OR 5&#
#7
s ,ONGER CATALYST LIFE n MONTHS IN REACTOR ) MONTHS IN
REACTOR ))
s ,OWER ELECTRICITY CONSUMPTION AND HIGHER STEAM PRODUCTION
s (IGHER CONVERSION OF METHANOL THEREFORE LESS METHANOL IN
PRODUCT
s 4HE (ALDOR 4OPSE &ORMALDEHYDE 32 PROCESS IS WELL
SUITED TO
EXPAND EXISTING FORMALDEHYDE PLANTS UP TO CAPACITY INCREASE
MAY BE ACHIEVED
Utility
requirements: 0ER KG OF
WT FORMALDEHYDE
Formaldehyde, CONTINUED
0RODUCT
-ETHANOL KG
UREA SOLUTION KG
0ROCESS WATER KG
7ATER COOLING M
%LECTRICITY K7H
WT !&
n
n
WT 5&#
n
Commercial
plants: 4HREE COMMERCIAL 32 UNITS BUILT ALL ARE OPERATING
SUCCESSFULLY 4HREE ADDITIONAL UNITS ARE UNDER CONSTRUCTION
Licensor: (ALDOR 4OPSE !3
Formaldehyde
3TEAM
Application: &ORMALDEHYDE AS A LIQUID SOLUTION OF n WT IS PRIMAR
ILY USED IN THE PRODUCTION OF POLYOXYMETHYLENE 0/- AND HEXAMETHY
LENETETRAMINE AS WELL AS SYNTHETIC RESINS IN THE WOOD INDUSTRY
3TEAM
Description: &ORMALDEHYDE SOLUTIONS ARE PRODUCED BY OXIDATION WITH
$H K*MOL
$H n K*MOL
4HE METHANOL WATER MIXTURE ADJUSTED FOR DENSITY BALANCE AND STORED
IN THE PREPARATION TANK IS CONTINUOUSLY FED BY PUMP TO THE METHANOL
EVAPORATOR 4HE REQUIRED PROCESS AIR IS SUCKED IN BY A BLOWER VIA A
l LTER AND AIR SCRUBBER INTO THE METHANOL EVAPORATOR
&ROM HERE THE METHANOL WATER AIR MIXTURE ENTERS THE REACTOR
WHERE THE CONVERSION OF METHANOL TO FORMALDEHYDE OCCURS "ECAUSE
THE REACTION IS EXOTHERMIC THE REQUIRED TEMPERATURE IS SELF
MAINTAINED
ONCE THE IGNITION HAS BEEN EXECUTED
4HE REACTION GASES EMERGING FROM CATALYSIS CONTAIN FORMALDEHYDE WATER
NITROGEN HYDROGEN AND CARBON DIOXIDE AS WELL AS NONCONVERTED METHANOL
4HEY ARE COOLED TO # IN A WASTE
HEAT BOILER DIRECTLY CONNECTED TO THE
REACTOR 4HE AMOUNT OF HEAT RELEASED IN THE BOILER IS SUFl CIENT FOR HEATING
THE METHANOL EVAPORATOR 4HE REACTION GASES ENTER A
STAGE ABSORPTION
TOWER WHERE ABSORPTION OF FORMALDEHYDE OCCURS IN COUNTER
m OW VIA
AQUEOUS FORMALDEHYDE SOLUTION AND COLD DEMINERALIZED WATER 4HE l NAL
FORMALDEHYDE SOLUTION IS REMOVED FROM THE l RST ABSORPTION STAGE
7ASTE GAS FROM THE ABSORPTION TOWER WITH A HEATING VALUE OF
APPROXIMATELY K*M IS BURNED IN A POST CONNECTED THERMAL
COMBUSTION UNIT 4HE RELEASED HEAT CAN BE USED TO PRODUCE HIGH
PRESSURE
STEAM OR THERMAL OIL HEATING
"Y RECYCLING A PART OF WASTE GAS TO THE REACTOR FORMALDEHYDE
CONCENTRATIONS UP TO WT IN THE l NAL SOLUTION CAN BE REACHED
!BSORPTION WATER
OR UREA SOLUTION
7#4
3TEAM
METHANOL IN THE AIR )N THE 5)& PROCESS THE REACTION OCCURS ON THE SUR
FACE OF A SILVER
CRYSTAL CATALYST AT TEMPERATURES OF #n # WHERE
THE METHANOL IS DEHYDRATED AND PARTLY OXIDIZED
#(/( #(/ (
#(/( / #(/ (/
/FFGAS
3TEAM
7#4
0ROCESS
WATER
7#4
!IR
&ORMALDEHYDE OR
UREA
FORMALDEHYDE
PRECONDENSATE
-ETHANOL
4O PRODUCE UREAFORMALDEHYDE PRECONDENSATE AN AQUEOUS UREA
SOLUTION IN PLACE OF ABSORPTION WATER IS FED INTO THE ABSORPTION TOWER
Economics:
$UE TO THE WASTE
GAS RECYCLING SYSTEM THE METHANOL CONTENT
IN THE FORMALDEHYDE SOLUTION CAN BE REDUCED TO LESS THAN WT AND
FORMIC ACID LESS THAN PPM
4YPICAL CONSUMPTION l GURES PER KG OF FORMALDEHYDE SOLUTION
WT ARE
-ETHANOL KG
7ATER KG
%LECTRICITY K7H
7ATER COOLING M
Licensor: 5HDE )NVENTA &ISCHER
Hydrogen
Application: 0RODUCTION OF HYDROGEN ( FROM HYDROCARBON (# FEED
STOCKS BY STEAM REFORMING
2ECYCLE (
(# FEEDSTOCK
REFINERY OFFGASES
#OMPRESSION
PUMPING
-AKEUP FUEL
Feedstocks: 2ANGING FROM NATURAL GAS TO HEAVY NAPHTHA AS WELL AS PO
REFORMING OPTIONAL STEAM (# REFORMING SHIFT CONVERSION AND HYDRO
GEN PURIl CATION BY PRESSURE SWING ADSORPTION 03! (OWEVER IT IS OFTEN
TAILORED TO SATISFY SPECIl C REQUIREMENTS
&EED PRE TREATMENT NORMALLY INVOLVES REMOVAL OF SULFUR CHLORINE AND
OTHER CATALYST POISONS AFTER PREHEATING TO n #
4HE TREATED FEED GAS MIXED WITH PROCESS STEAM IS REFORMED IN A l RED
REFORMER WITH ADIADATIC PRE REFORMER UPSTREAM IF USED AFTER NECESSARY
SUPER HEATING 4HE NET REFORMING REACTIONS ARE STRONGLY ENDOTHERMIC
(EAT IS SUPPLIED BY COMBUSTING 03! PURGE GAS SUPPLEMENTED BY MAKE
UP FUEL IN MULTIPLE BURNERS IN A TOP l RED FURNACE
2EFORMING SEVERITY IS OPTIMIZED FOR EACH SPECIl C CASE 7ASTE HEAT
FROM REFORMED GAS IS RECOVERED THROUGH STEAM GENERATION BEFORE THE
WATER GAS SHIFT CONVERSION -OST OF THE CARBON MONOXIDE #/ IS FURTHER
CONVERTED TO HYDROGEN 0ROCESS CONDENSATE RESULTING FROM HEAT RECOVERY
AND COOLING IS SEPARATED AND GENERALLY REUSED IN THE STEAM SYSTEM AFTER
NECESSARY TREATMENT 4HE ENTIRE STEAM GENERATION IS USUALLY ON NATURAL
CIRCULATION WHICH ADDS TO HIGHER RELIABILITY 4HE GAS m OWS TO THE 03! UNIT
THAT PROVIDES HIGH PURITY HYDROGEN PRODUCT UP TO PPM #/ AT NEAR
INLET PRESSURES
4YPICAL SPECIl C ENERGY CONSUMPTION BASED ON FEED FUEL n EXPORT
STEAM RANGES BETWEEN 'CAL+.M AND 'CAL+.M n "TU
SCF ,(6 DEPENDING UPON THE FEEDSTOCK PLANT CAPACITY OPTIMIZATION
&EED
PRE
TREATMENT
0RE
REFORMER
OPTIONAL
03! PURGE GAS
3TEAM
SYSTEM
&UEL SYSTEM
TENTIAL REl NERY OFFGASES -ANY RECENT REl NERY HYDROGEN PLANTS HAVE
MULTIPLE FEEDSTOCK m EXIBILITY EITHER IN TERMS OF BACKUP OR ALTERNATIVE
OR MIXED FEED !UTOMATIC FEEDSTOCK CHANGE OVER HAS ALSO SUCCESSFULLY
BEEN APPLIED BY 4ECHNIP IN SEVERAL MODERN PLANTS WITH MULTIPLE FEED
STOCK m EXIBILITY
Description: 4HE GENERIC m OWSHEET CONSISTS OF FEED PRE TREATMENT PRE
0ROCESS STEAM
#ONVECTION
SECTION 2EFORMER
/PTIONAL
#OMB
AIR
PREHEATER
&LUE GAS
STACK
"&7
6ENT STEAM
0' 3TEAM
BOILER
3TEAM
3TEAM
COILS
0ROCESS
COILS
"&7
3HIFT
CONVERSION
!IR
%XPORT STEAM
"&7 PREPARATION
SYSTEM
$OSING
0URGE GAS TO
FUEL SYSTEM
0ROCESS
CONDENSATE
4O STEAM
SYSTEM
#OOLING
TRAIN
$-7
"&7 TO
STEAM SYSTEM
03!
2ECYCLE (
(YDROGEN
PRODUCTS
CRITERIA AND STEAM EXPORT REQUIREMENTS 2ECENT ADVANCES INCLUDE INTE
GRATION OF HYDROGEN RECOVERY AND GENERATION AND RECUPERATIVE POST
REFORMING ALSO FOR CAPACITY RETROl TS
Commercial
plants: 4ECHNIP HAS BEEN INVOLVED IN OVER HYDROGEN
PLANTS WORLDWIDE
Licensor: 4ECHNIP
Maleic
anhydride
Application: 4O PRODUCE MALEIC ANHYDRIDE FROM N
BUTANE USING A m UID
BED REACTOR SYSTEM AND AN ORGANIC SOLVENT FOR CONTINUOUS ANHYDROUS
PRODUCT RECOVERY
(0 STEAM
4AIL GAS TO FUEL USE
OR INCINERATOR WITH
STEAM GENERATION
,IGHT ENDS
Description: . BUTANE AND AIR ARE FED TO A m UID BED CATALYTIC REACTOR
TO PRODUCE MALEIC ANHYDRIDE 4HE m UID BED REACTOR ELIMINATES HOT SPOTS
AND PERMITS OPERATION AT CLOSE TO THE STOICHIOMETRIC REACTION MIXTURE
4HIS RESULTS IN A GREATLY REDUCED AIR RATE RELATIVE TO l XED BED PROCESSES
AND TRANSLATES INTO SAVINGS IN INVESTMENT AND COMPRESSOR POWER AND
LARGE INCREASES IN STEAM GENERATION 4HE m UID BED SYSTEM PERMITS ONLINE
CATALYST ADDITIONREMOVAL TO ADJUST CATALYST ACTIVITY AND REDUCES DOWN
TIME FOR CATALYST CHANGE OUT
4HE RECOVERY AREA USES A PATENTED ORGANIC SOLVENT TO REMOVE THE
MALEIC ANHYDRIDE FROM THE REACTOR EFm UENT GAS ! CONVENTIONAL ABSORPTION
STRIPPING SCHEME OPERATES ON A CONTINUOUS BASIS #RUDE MALEIC
ANHYDRIDE IS DISTILLED TO SEPARATE LIGHT AND HEAVY IMPURITIES !
SLIPSTREAM OF RECYCLE SOLVENT IS TREATED TO ELIMINATE ANY HEAVY BYPRODUCTS
THAT MAY BE FORMED 4HE CONTINUOUS NONAQUEOUS PRODUCT RECOVERY
SYSTEM RESULTS IN SUPERIOR PRODUCT QUALITY AND LARGE SAVINGS IN STEAM
CONSUMPTION )T ALSO REDUCES INVESTMENT PRODUCT DEGRADATION LOSS AND
BYPRODUCT FORMATION AND WASTEWATER
Economics: 4HE !,-! PROCESS PRODUCES HIGH
QUALITY PRODUCT WITH AT
TRACTIVE ECONOMICS 4HE m UID
BED PROCESS IS ESPECIALLY SUITED FOR LARGE
SINGLE
TRAIN PLANTS
Commercial
plants: .INE COMMERCIAL PLANTS HAVE BEEN LICENSED WITH A TO
TAL CAPACITY OF MTPY 4HE LARGEST COMMERCIAL INSTALLATION IS ,ONZAS
MTPY PLANT IN 2AVENNA )TALY 3ECOND GENERATION PROCESS OPTIMIZA
TIONS AND CATALYST HAVE ELEVATED THE PLANT PERFORMANCES SINCE
Licensor: !"" ,UMMUS 'LOBAL,ONZA 'ROUP
"&7
0URE MALEIC
ANHYDRIDE
N
"UTANE
!IR
#RUDE MALEIC
ANHYDRIDE TO
DERIVATIVES
(EAVY BYPRODUCTS
Methanol
steam-methane
reforming
Application: 4O PRODUCE METHANOL FROM NATURAL OR ASSOCIATED GAS FEED
STOCKS USING ADVANCED TUBULAR REFORMING FOLLOWED BY BOILING WATER REAC
TOR SYNTHESIS 4HIS TECHNOLOGY IS AN OPTION FOR CAPACITIES UP TO APPROXI
MATELY MTPD METHANOL FOR CASES WHERE CARBON DIOXIDE #/ IS
AVAILABLE 4OPSE ALSO OFFERS TECHNOLOGY FOR LARGER
SCALE METHANOL FACILI
TIES UP TO MTPD PER PRODUCTION TRAIN AND TECHNOLOGY TO MODIFY
AMMONIA CAPACITY INTO METHANOL PRODUCTION
Description: 4HE GAS FEEDSTOCK IS COMPRESSED IF REQUIRED DESULFURIZED
AND PROCESS STEAM IS ADDED 0ROCESS STEAM USED IS A COMBINATION OF
STEAM FROM THE PROCESS CONDENSATE STRIPPER AND SUPERHEATED MEDIUM
PRESSURE STEAM FROM THE HEADER 4HE MIXTURE OF NATURAL GAS AND STEAM
IS PREHEATED PREREFORMED AND SENT TO THE TUBULAR REFORMER 4HE
PREREFORMER USES WASTE HEAT FROM THE m UE
GAS SECTION OF THE TUBULAR
REFORMER FOR THE REFORMING REACTION THUS REDUCING THE TOTAL LOAD ON
THE TUBULAR REFORMER $UE TO HIGH OUTLET TEMPERATURE EXIT GAS FROM THE
TUBULAR REFORMER HAS A LOW CONCENTRATION OF METHANE WHICH IS AN IN
ERT IN THE SYNTHESIS 4HE SYNTHESIS GAS OBTAINABLE WITH THIS TECHNOLOGY
TYPICALLY CONTAINS SURPLUS HYDROGEN WHICH WILL BE USED AS FUEL IN THE
REFORMER FURNACE )F #/ IS AVAILABLE THE SYNTHESIS GAS COMPOSITION CAN
BE ADJUSTED HEREBY MINIMIZING THE HYDROGEN SURPLUS #ARBON DIOXIDE
CAN PREFERABLY BE ADDED DOWNSTREAM OF THE PREREFORMER
4HE m UE GAS GENERATED IN THE TUBULAR REFORMER IS USED FOR PREHEAT
OF REFORMER AND PREREFORMER FEED NATURAL GAS PREHEAT STEAM SUPERHEAT
AND PREHEAT OF COMBUSTION AIR 4HE SYNTHESIS GAS GENERATED IN THE TUBULAR
REFORMER IS COOLED BY HIGH
PRESSURE STEAM GENERATION PREHEAT OF
BOILER FEED WATER AND REBOILING IN THE DISTILLATION SECTION
!FTER l NAL COOLING BY AIR OR COOLING WATER THE SYNTHESIS GAS IS
COMPRESSED AND SENT TO THE SYNTHESIS LOOP 4HE SYNTHESIS LOOP
IS COMPRISED OF A STRAIGHT
TUBED BOILING WATER REACTOR WHICH IS MORE
EFl CIENT THAN ADIABATIC REACTORS 2EACTION HEAT IS REMOVED FROM THE
REACTOR BY GENERATING -0 STEAM 4HIS STEAM IS USED FOR STRIPPING OF
PROCESS CONDENSATE AND THEREAFTER AS PROCESS STEAM 0REHEATING THE
#/
3TEAM
3ULFUR
REMOVAL
-ETHANOL
REACTOR
3ULFUR
REMOVAL
3TEAM
REFORMER
.ATURAL GAS
0RODUCT METHANOL
7ATER
3TEAM
0RE
REFORMER
-AKEUP
COMPRESSOR
,IGHT ENDS TO FUEL
#ONDENSATE
2AW
METHANOL
2AW
METHANOL
STORAGE
REACTOR FEED COOLS EFm UENT FROM THE SYNTHESIS REACTOR &URTHER COOLING IS
OBTAINED BY AIR OR WATER COOLING 2AW METHANOL IS SEPARATED AND SENT
DIRECTLY TO THE DISTILLATION SECTION FEATURING A VERY EFl CIENT THREE
COLUMN LAYOUT 2ECYCLE GAS IS SENT TO THE RECIRCULATOR COMPRESSOR
AFTER A SMALL PURGE TO REMOVE INERT COMPOUND BUILDUP
4OPSE SUPPLIES A COMPLETE RANGE OF CATALYSTS FOR METHANOL
PRODUCTION 4HE TOTAL ENERGY CONSUMPTION FOR THIS PROCESS SCHEME
IS ABOUT 'CAL TON METHANOL WITHOUT #/ ADDITION 7ITH #/
ADDITION THE TOTAL ENERGY CONSUMPTION CAN BE REDUCED TO 'CAL TON
METHANOL
Methanol
steam-methane
reforming, CONTINUED
Economics: 4UBULAR REFORMING TECHNOLOGY IS ATTRACTIVE AT CAPACITIES
n MTPD METHANOL WHERE THE ECONOMY OF SCALE OF ALTERNA
TIVE TECHNOLOGIES SUCH AS TWO
STEP OR AUTOTHERMAL REFORMING CANNOT BE
FULLY UTILIZED
Commercial
plants: 4HE MOST RECENT PLANT IS A
MTPD METHANOL
FACILITY WITH #/ IMPORT 4HE PLANT WAS COMMISSIONED IN
Licensor: (ALDOR 4OPSE !3
Methanol
autothermal
reforming
(ATR)
/XYGENSTEAM
Application: 4O PRODUCE METHANOL FROM NATURAL OR ASSOCIATED GAS FEED
.ATURAL GAS
STOCKS USING AUTOTHERMAL REFORMING !42 FOLLOWED BY BOILING WATER RE
ACTOR SYNTHESIS 4HIS TECHNOLOGY IS WELL SUITED FOR VERY LARGE
SCALE PLANTS
AS WELL AS FOR THE PRODUCTION OF METHANOL TO OLEl NS OR FUEL
GRADE METH
ANOL 4OPSE ALSO OFFERS TECHNOLOGY FOR SMALLER METHANOL FACILITIES AND
TECHNOLOGY TO MODIFY AMMONIA CAPACITY INTO METHANOL PRODUCTION
Description: 4HE GAS FEEDSTOCK IS COMPRESSED IF REQUIRED DESULFURIZED
AND SENT TO A SATURATOR WHERE THE NATURAL GAS IS SATURATED WITH
PROCESS CONDENSATE AND EXCESS WATER FROM THE DISTILLATION SECTION 2E
CYCLING OF PROCESS CONDENSATE AND EXCESS WATER MINIMIZES THE WATER RE
QUIREMENT ,OW
GRADE MEDIUM
PRESSURE STEAM IS USED IN THE SATURATOR
THUS SAVING HIGH
PRESSURE STEAM 4HE MIXTURE OF NATURAL GAS AND STEAM
IS PREHEATED PREREFORMED AND SENT TO THE AUTOTHERMAL REFORMER
!UTOTHERMAL REFORMING FEATURES A STAND
ALONE OXYGEN
l RED REFORMER
AND THUS THE COST
INTENSIVE PRIMARY TUBULAR REFORMER MAY BE OMITTED
COMPLETELY 4HE AUTOTHERMAL REFORMER CAN OPERATE AT ANY PRESSURE 4HE
OPERATING PRESSURE IS NORMALLY SELECTED BETWEEN AND KG CMG
3YNTHESIS GAS GENERATED IN THE AUTOTHERMAL REFORMER IS COOLED
BY HIGH
PRESSURE STEAM GENERATION PREHEAT OF BOILER FEED WATER
REBOILING IN THE DISTILLATION SECTION AND PREHEAT OF DEMINERALIZED WATER
4HE SYNTHESIS GAS OBTAINABLE WITH THIS TECHNOLOGY IS TYPICALLY DEl CIENT
IN HYDROGEN 4HEREFORE THE SYNTHESIS GAS COMPOSITION MUST BE ADJUSTED
BY RECYCLING RECOVERED HYDROGEN FROM THE SYNTHESIS LOOP !FTER l NAL
COOLING BY AIR OR COOLING WATER THE RECYCLE HYDROGEN IS ADDED TO THE
SYNTHESIS GAS WHICH IS COMPRESSED IN A SINGLE
STEP COMPRESSOR AND
SENT TO THE SYNTHESIS LOOP
4HE SYNTHESIS LOOP IS COMPRISED OF A STRAIGHT
TUBED BOILING WATER
REACTOR WHICH IS MORE EFl CIENT THAN ADIABATIC REACTORS 2EACTION HEAT
IS REMOVED FROM THE REACTOR BY GENERATION OF MEDIUM
PRESSURE STEAM
4HIS STEAM IS USED FOR HEATING IN THE SATURATOR 0REHEATING THE
3ATURATOR
(YDRO
GENATOR
7ATER
3TEAM
!UTOTHERMAL
REFORMER
-ETHANOL
REACTOR
3TEAM
3ULFUR
REMOVAL
0RE
REFORMER
#ONDENSATE
-AKEUP
COMPRESSOR
(YDROGEN
RECOVERY
2ECYLE
COMP
/FF GAS
0URGE
GAS
2AW METHANOL
REACTOR FEED COOLS EFm UENT FROM THE SYNTHESIS REACTOR &URTHER COOLING
IS BY AIR OR WATER COOLING 2AW METHANOL IS SEPARATED AND SENT DIRECTLY
TO THE DISTILLATION SECTION FEATURING A VERY EFl CIENT THREE
COLUMN LAYOUT
2ECYCLE GAS IS SENT TO THE RECIRCULATOR COMPRESSOR AFTER A PURGE
TO REMOVE INERT COMPOUND BUILDUP 4HE PURGE IS SENT TO A HYDROGEN
RECOVERY UNIT WHERE HYDROGEN IS SEPARATED AND RECYCLED TO THE SYNTHESIS
GAS COMPRESSOR
4OPSE SUPPLIES A COMPLETE RANGE OF CATALYSTS FOR METHANOL PRODUC
TION 4HE TOTAL ENERGY CONSUMPTION FOR THIS PROCESS SCHEME IS ABOUT
'CALTON METHANOL 4OTAL ENERGY CONSUMPTION FOR PRODUCTION OF FUEL GRADE
METHANOL IS APPROXIMATELY 'CALTON METHANOL
Methanol
autothermal
reforming
(ATR), CONTINUED
Economics: &OR LARGE
SCALE PLANTS THE TOTAL INVESTMENT INCLUDING AN
OXYGEN PLANT IS APPROXIMATELY LOWER THAN FOR A CONVENTIONAL PLANT
BASED ON TUBULAR STEAM REFORMING
Licensor: (ALDOR 4OPSE !3
Methanol
two-step
reforming
Application: 4O PRODUCE METHANOL FROM NATURAL OR ASSOCIATED GAS FEED
STOCKS USING TWO
STEP REFORMING FOLLOWED BY LOW
PRESSURE SYNTHESIS
4HIS TECHNOLOGY IS WELL SUITED FOR WORLD
SCALE PLANTS 4OPSE ALSO OFFERS
TECHNOLOGY FOR SMALLER AS WELL AS VERY LARGE METHANOL FACILITIES UP TO
TPD AND TECHNOLOGY TO MODIFY AMMONIA CAPACITY INTO METHANOL
PRODUCTION
Description: 4HE GAS FEEDSTOCK IS COMPRESSED IF REQUIRED DESULFURIZED
AND SENT TO A SATURATOR WHERE PROCESS STEAM IS GENERATED !LL
PROCESS CONDENSATE IS REUSED IN THE SATURATOR RESULTING IN A LOWER WATER
REQUIREMENT 4HE MIXTURE OF NATURAL GAS AND STEAM IS PREHEATED AND
SENT TO THE PRIMARY REFORMER %XIT GAS FROM THE PRIMARY REFORMER GOES
DIRECTLY TO AN OXYGEN
BLOWN SECONDARY REFORMER 4HE OXYGEN AMOUNT
AND THE BALANCE BETWEEN PRIMARY AND SECONDARY REFORMER ARE ADJUSTED
SO THAT AN ALMOST STOICHIOMETRIC SYNTHESIS GAS WITH A LOW INERT CONTENT
IS OBTAINED 4HE PRIMARY REFORMER IS RELATIVELY SMALL AND THE REFORMING
SECTION OPERATES AT ABOUT KGCMG
4HE m UE GAS HEAT CONTENT PREHEATS REFORMER FEED ,IKEWISE THE HEAT
CONTENT OF THE PROCESS GAS IS USED TO PRODUCE SUPERHEATED HIGH
PRESSURE
STEAM BOILER FEEDWATER PREHEATING PREHEATING PROCESS CONDENSATE
GOING TO THE SATURATOR AND REBOILING IN THE DISTILLATION SECTION
!FTER l NAL COOLING BY AIR OR COOLING WATER THE SYNTHESIS GAS IS
COMPRESSED IN A ONE
STAGE COMPRESSOR AND SENT TO THE SYNTHESIS LOOP
COMPRISED OF THREE ADIABATIC REACTORS WITH HEAT EXCHANGERS BETWEEN
THE REACTORS 2EACTION HEAT FROM THE LOOP IS USED TO HEAT SATURATOR WATER
3TEAM PROVIDES ADDITIONAL HEAT FOR THE SATURATOR SYSTEM %Fm UENT FROM
THE LAST REACTOR IS COOLED BY PREHEATING FEED TO THE l RST REACTOR BY AIR
OR WATER COOLING 2AW METHANOL IS SEPARATED AND SENT DIRECTLY TO THE
DISTILLATION FEATURING A VERY EFl CIENT THREE
COLUMN LAYOUT 2ECYCLE GAS
IS SENT TO THE RECIRCULATOR COMPRESSOR AFTER A SMALL PURGE TO REMOVE
INERT COMPOUND BUILDUP
4OPSE SUPPLIES A COMPLETE RANGE OF CATALYSTS THAT CAN BE USED IN
THE METHANOL PLANT 4OTAL ENERGY CONSUMPTION FOR THIS PROCESS SCHEME IS
3TEAM
3ATURATOR
0RE
REFORMER
(YDRO
3ULFUR
GENATOR REMOVAL
/XYGEN
3TEAM
REFORMER
.ATURAL GAS
3ECONDARY
REFORMER
3TEAM
3TEAM
-AKEUP
COMPRESSOR
#ONDENSATE
,IGHT ENDS TO FUEL
2AW
METHANOL
0RODUCT METHANOL
7ATER
-ETHANOL
REACTOR
2AW
METHANOL
STORAGE
ABOUT 'CALTON INCLUDING ENERGY FOR OXYGEN PRODUCTION
Economics: 4OTAL INVESTMENTS INCLUDING AN OXYGEN PLANT ARE APPROXI
MATELY LOWER FOR LARGE PLANTS THAN FOR A CONVENTIONAL PLANT BASED
ON STRAIGHT STEAM REFORMING
Commercial
plants: 4HE MOST RECENT LARGE
SCALE PLANT IS A
TPD FA
CILITY IN )RAN 4HIS PLANT WAS COMMISSIONED IN
Licensor: (ALDOR 4OPSE !3
Methanol
Application: 4O PRODUCE METHANOL IN A SINGLE
TRAIN PLANT FROM NATURAL
Description: .ATURAL GAS IS PREHEATED AND DESULFURIZED !FTER DESULFUR
IZATION THE GAS IS SATURATED WITH A MIXTURE OF PREHEATED PROCESS WATER
FROM THE DISTILLATION SECTION AND PROCESS CONDENSATE IN THE SATURATOR
4HE GAS IS FURTHER PREHEATED AND MIXED WITH STEAM AS REQUIRED FOR
THE PRE
REFORMING PROCESS )N THE PRE
REFORMER THE GAS IS CONVERTED TO
( #/ AND #( &INAL PREHEATING OF THE GAS IS ACHIEVED IN THE l RED
HEATER )N THE AUTOTHERMAL REFORMER THE GAS IS REFORMED WITH STEAM
AND / 4HE PRODUCT GAS CONTAINS ( #/ #/ AND A SMALL AMOUNT OF
UNCONVERTED #( AND INERTS TOGETHER WITH UNDERCOMPOSED STEAM 4HE
REFORMED GAS LEAVING THE AUTOTHERMAL REFORMER REPRESENTS A CONSIDER
ABLE AMOUNT OF HEAT WHICH IS RECOVERED AS (0 STEAM FOR PREHEATING
ENERGY AND ENERGY FOR PROVIDING HEAT FOR THE REBOILERS IN THE DISTILLA
TION SECTION
4HE REFORMED GAS IS MIXED WITH HYDROGEN FROM THE PRESSURE SWING
ADSORPTION 03! UNIT TO ADJUST THE SYNTHESIS GAS COMPOSITION 3YNTHESIS
GAS IS PRESSURIZED TO n -0A BY A SINGLE
CASING SYNTHESIS GAS
COMPRESSOR AND IS MIXED WITH RECYCLE GAS FROM THE SYNTHESIS LOOP 4HIS
GAS MIXTURE IS PREHEATED IN THE TRIM HEATER IN THE GAS
COOLED METHANOL
REACTOR )N THE ,URGI WATER
COOLED METHANOL REACTOR THE CATALYST IS l XED
IN VERTICAL TUBES SURROUNDED BY BOILING WATER 4HE REACTION OCCURS UNDER
ALMOST ISOTHERMAL CONDITION WHICH ENSURES A HIGH CONVERSION AND
ELIMINATES THE DANGER OF CATALYST DAMAGE FROM EXCESSIVE TEMPERATURE
%XACT REACTION TEMPERATURE CONTROL IS DONE BY PRESSURE CONTROL OF THE
STEAM DRUM GENERATING (0 STEAM
4HE hPRECONVERTEDv GAS IS ROUTED TO THE SHELL SIDE OF THE GAS
COOLED METHANOL REACTOR WHICH IS l LLED WITH CATALYST 4HE l NAL
CONVERSION TO METHANOL IS ACHIEVED AT REDUCED TEMPERATURES ALONG
&IRED
HEATER
/XYGEN
3ATURATOR
$ESULFURIZATION
GAS OR OIL ASSOCIATED GAS WITH CAPACITIES UP TO MTPD )T IS ALSO
WELL SUITED TO INCREASE CAPACITIES OF EXISTING STEAM REFORMING BASED
METHANOL PLANTS
&UEL
.ATURAL
GAS
0URE
METHANOL
7ATER
COOLED
REACTOR
0RE
REFORMER
0ROCESS
CONDENSATE
!UTO THERMAL
REFORMER
(0 STEAM TO
OXYGEN PLANT
,0 STEAM
'AS
COOLED
REACTOR
"&7
$ISTILLATION
$ISTILLATION
REBOILER
0RESSURE
SWING
ADSORPTION
(
THE OPTIMUM REACTION ROUTE 4HE REACTOR OUTLET GAS IS COOLED TO ABOUT
# TO SEPARATE METHANOL AND WATER FROM THE GASES BY PREHEATING
"&7 AND RECYCLE GAS #ONDENSED RAW METHANOL IS SEPARATED FROM THE
UNREACTED GAS AND ROUTED TO THE DISTILLATION UNIT 4HE MAJOR PORTION
OF THE GAS IS RECYCLED BACK TO THE SYNTHESIS REACTORS TO ACHIEVE A HIGH
OVERALL CONVERSION 4HE EXCELLENT PERFORMANCE OF THE ,URGI COMBINED
CONVERTER ,## METHANOL SYNTHESIS REDUCES THE RECYCLE RATIO TO ABOUT
! SMALL PORTION OF THE RECYCLE GAS IS WITHDRAWN AS PURGE GAS TO
LESSEN INERTS ACCUMULATION IN THE LOOP
)N THE ENERGY
SAVING THREE
COLUMN DISTILLATION SECTION LOW
BOILING
AND HIGH
BOILING BYPRODUCTS ARE REMOVED 0URE METHANOL IS ROUTED TO
Methanol, CONTINUED
THE TANK FARM AND THE PROCESS WATER IS PREHEATED IN THE lRED HEATER
AND USED AS MAKEUP WATER FOR THE SATURATOR
Economics: %NERGY CONSUMPTION FOR A STAND ALONE PLANT INCLUDING UTILI
TIES AND OXYGEN PLANT IS ABOUT '*METRIC TON OF METHANOL 4OTAL IN
STALLED COST FOR A MTPD PLANT INCLUDING UTILITIES AND OXYGEN PLANT
IS ABOUT 53 MILLION DEPENDING ON LOCATION
Commercial
plants: 4HIRTY
lVE METHANOL PLANTS HAVE BEEN BUILT USING
,URGIS ,OW
0RESSURE METHANOL TECHNOLOGY /NE -EGA-ETHANOL PLANT IS
IN OPERATION TWO ARE UNDER CONSTRUCTION AND THREE -EGA-ETHANOL CON
TRACTS HAVE BEEN AWARDED WITH CAPACITIES UP TO MTPD OF METHA
NOL
Licensor: ,URGI !'
Methanol
Application: 4HE /NE 3YNERGY PROCESS IS IMPROVED LOW
PRESSURE METHA
NOL PROCESS TO PRODUCE METHANOL 4HE NEW METHOD PRODUCES METHA
NOL FROM NATURAL OR ASSOCIATED GAS USING TWO
STAGE STEAM REFORMING
FOLLOWED BY COMPRESSION SYNTHESIS AND DISTILLATION #APACITIES RANGING
FROM TO MTPD ARE PRACTICAL IN A SINGLE STREAM #ARBON DI
OXIDE #/ CAN BE USED AS A SUPPLEMENTARY FEEDSTOCK TO ADJUST THE
STOICHIOMETRIC RATIO OF THE SYNTHESIS GAS
Description: 'AS FEEDSTOCK IS COMPRESSED IF REQUIRED DESULFURIZED
AND SENT TO THE OPTIONAL SATURATOR WHERE SOME PROCESS STEAM IS
GENERATED 4HE SATURATOR IS USED WHERE MAXIMUM WATER RECOVERY IS IM
PORTANT &URTHER PROCESS STEAM IS ADDED AND THE MIXTURE IS PREHEATED
AND SENT TO THE PRE REFORMER USING THE #ATALYTIC 2ICH 'AS PROCESS
3TEAM RAISED IN THE METHANOL CONVERTER IS ADDED ALONG WITH AVAIL
ABLE #/ AND THE PARTIALLY REFORMED MIXTURE IS PREHEATED AND SENT TO
THE REFORMER (IGH GRADE HEAT IN THE REFORMED GAS IS RECOVERED AS
HIGH PRESSURE STEAM BOILER FEEDWATER PREHEAT AND FOR REBOIL HEAT
IN THE DISTILLATION SYSTEM 4HE HIGH PRESSURE STEAM IS USED TO DRIVE
THE MAIN COMPRESSORS IN THE PLANT
!FTER l NAL COOLING THE SYNTHESIS GAS IS COMPRESSED AND SENT TO
THE SYNTHESIS LOOP 4HE LOOP CAN OPERATE AT PRESSURES BETWEEN TO
BAR 4HE CONVERTER DESIGN DOES IMPACT THE LOOP PRESSURE WITH RADIAL m OW
DESIGNS ENABLING LOW LOOP PRESSURE EVEN AT THE LARGEST PLANT SIZE ,OW
LOOP PRESSURE REDUCES THE TOTAL ENERGY REQUIREMENTS FOR THE PROCESS
4HE SYNTHESIS LOOP COMPRISES A CIRCULATOR AND THE CONVERTER
OPERATES AROUND # TO # DEPENDING ON THE CONVERTER TYPE
2EACTION HEAT FROM THE LOOP IS RECOVERED AS STEAM AND IS USED DIRECTLY
AS PROCESS STEAM FOR THE REFORMER
! PURGE IS TAKEN FROM THE SYNTHESIS LOOP TO REMOVE INERTS NITROGEN
METHANE AS WELL AS SURPLUS HYDROGEN ASSOCIATED WITH NON STOICHIOMETRIC
OPERATION 4HE PURGE IS USED AS FUEL FOR THE REFORMER #RUDE METHANOL
FROM THE SEPARATOR CONTAINS WATER AS WELL AS TRACES OF ETHANOL AND OTHER
(0 STEAM
"&7
-ETHANOL PRODUCT
$ISTILLATION
.ATURAL
GAS
"&7
3TEAM
7ATER FROM
DISTILLATION
#/ OPTIONAL
&UEL TO
REFORMER
#RUDE
METHANOL
COMPOUNDS 4HESE IMPURITIES ARE REMOVED IN A TWO
COLUMN DISTILLATION
SYSTEM 4HE l RST COLUMN REMOVES THE LIGHT ENDS SUCH AS ETHERS ESTERS
ACETONE AND DISSOLVED NONCONDENSABLE GASES 4HE SECOND COLUMN
REMOVES WATER HIGHER ALCOHOLS AND SIMILAR ORGANIC HEAVY ENDS
Economics: 2ECENT TRENDS HAVE BEEN TO BUILD METHANOL PLANTS IN RE
GIONS OFFERING LOW
COST GAS SUCH AS #HILE 4RINIDAD AND THE !RABIAN
'ULF )N THESE REGIONS TOTAL ECONOMICS FAVOR LOW INVESTMENT RATHER THAN
LOW
ENERGY CONSUMPTION 2ECENT PLANTS HAVE AN ENERGY EFl CIENCY OF
n 'CALTON ! GUIDELINE l GURE TO CONSTRUCT A
MTPD PLANT IS
53 n MILLION
Methanol, CONTINUED
Commercial
plants: 4HIRTEEN PLANTS WITH CAPACITIES RANGING FROM
TO MTPD AS WELL AS SMALLER PLANTS HAVE BEEN BUILT USING THE
3YNETIX ,0- METHANOL TECHNOLOGY 4WO
MTPD PLANTS ARE UNDER
CONSTRUCTION
Licensor: /NE 3YNERGY A CONSORTIUM OF $AVY 0ROCESS 4ECHNOLOGY *OHN
SON -ATTHEY #ATALYSTS AND !KER +VAERNER
Methanol
Application: 4O PRODUCE &EDERAL
'RADE !! REl NED METHANOL FROM NATU
/
RAL GAS
BASED SYNTHESIS GAS AND NAPHTHA USING 4OYO %NGINEERING #ORPS
4%#S 3YNTHESIS 'AS 'ENERATION TECHNOLOGIES AND PROPRIETARY -2&
: RE
ACTOR INCORPORATED IN THE *OHNSON -ATTHEYS *-S PROCESS )N A NATURAL
GAS
BASED PLANT THE SYNTHESIS GAS IS PRODUCED BY REFORMING NATURAL GAS
WITH STEAM ANDOR OXYGEN USING HIGH
ACTIVITY STEAM REFORMING h)3/0v
CATALYST
Description: Syngas
preparation
section. 4HE FEEDSTOCK IS l RST PREHEATED
AND SULFUR COMPOUNDS ARE REMOVED IN A DESULFURIZER 3TEAM IS ADD
ED AND THE FEEDSTOCK
STEAM MIXTURE IS PREHEATED AGAIN ! PART OF THE
FEED IS REFORMED ADIABATICALLY IN PRE
REFORMER 4HE HALF OF FEEDSTOCK
STEAM MIXTURE IS DISTRIBUTED INTO CATALYST TUBES OF THE STEAM REFORMER
AND THE REST IS SENT TO 4%#S PROPRIETARY HEAT EXCHANGER REFORMER
h4!&
8v INSTALLED IN PARALLEL WITH AS THE PRIMARY REFORMING 4HE
HEAT REQUIRED FOR 4!&
8 IS SUPPLIED BY THE EFm UENT STREAM OF SECONDARY
REFORMER $EPENDING ON PLANT CAPACITY THE 4!&
8 AND OR THE SEC
ONDARY REFORMER CAN BE ELIMINATED
Methanol
synthesis
section. 4HE SYNTHESIS LOOP IS COMPRISED OF A CIRCULA
TOR COMBINED WITH COMPRESSOR h-2&
:v REACTOR FEEDEFm UENT
HEAT EXCHANGER METHANOL CONDENSER AND SEPARATOR #UR
RENTLY -2&
: REACTOR IS THE ONLY REACTOR IN THE WORLD CAPABLE OF PRODUC
ING n T D METHANOL IN A SINGLE
REACTOR VESSEL 4HE OPERA
TION PRESSURE IS n -0A 4HE SYNGAS ENTERS THE -2&
: REACTOR AT
n # AND LEAVES AT n # NORMALLY
*- PROPRIETARY METHANOL SYNTHESIS CATALYST IS PACKED IN THE SHELL SIDE
OF THE REACTOR 2EACTION HEAT IS RECOVERED AND USED TO EFl CIENTLY GENER
ATE STEAM IN THE TUBE SIDE 2EACTOR EFm UENT GAS IS COOLED TO CONDENSE
THE CRUDE METHANOL 4HE CRUDE METHANOL IS SEPARATED IN A SEPARATOR
4HE UNREACTED GAS IS CIRCULATED FOR FURTHER CONVERSION ! PURGE IS
TAKEN FROM THE RECYCLING GAS USED AS FUELS IN THE REFORMER
"&7
#7
.ATURAL GAS
NAPHTHA
3TEAM
"&7
(EAT
REC
#RUDE METHANOL
-ETHANOL
"&7
&USEL OIL
0ROCESS WATER
Methanol
purification
section. 4HE CRUDE METHANOL IS FED TO A TWO
COLUMN
DISTILLATION SYSTEM WHICH CONSISTS OF A SMALL TOPPING COLUMN AND A
REl NING COLUMN TO OBTAIN HIGH
PURITY &EDERAL 'RADE !! METHANOL
Economics: )N TYPICAL NATURAL GAS APPLICATIONS APPROXIMATELY '*
TON METHANOL INCLUDING UTILITIES IS REQUIRED
Installations: 4OYO HAS ACCUMULATED EXPERIENCE WITH THE LICENSING OF
METHANOL PLANT PROJECTS
Reference: 53 0ATENT
Licensor: 4OYO %NGINEERING #ORP 4%# *OHNSON -ATTHEY 0,#
Methanol
&EEDSTOCK
Application: 0RODUCTION OF HIGH PURITY METHANOL FROM HYDROCARBON
FEEDSTOCKS SUCH AS NATURAL GAS PROCESS OFFGASES AND ,0' UP TO HEAVY
NAPHTHA 4HE PROCESS USES CONVENTIONAL STEAM REFORMING SYNTHESIS GAS
GENERATION AND A LOW PRESSURE METHANOL SYNTHESIS LOOP TECHNOLOGY )T
IS OPTIMIZED WITH RESPECT TO LOW ENERGY CONSUMPTION AND MAXIMUM
RELIABILITY 4HE LARGEST SINGLE TRAIN PLANT BUILT BY 5HDE HAS A NAMEPLATE
CAPACITY OF MTPD
$ESULFURIZATION
#IRCULATOR
-5' COMPRESSION
3ATURATOR
2EFORMER
COLUMN
DISTILLATION
Description: 4HE METHANOL PLANT CONSISTS OF THE PROCESS STEPS FEED PURI
l CATION STEAM REFORMING SYNGAS COMPRESSION METHANOL SYNTHESIS AND
CRUDE METHANOL DISTILLATION 4HE FEED IS DESULFURIZED AND MIXED WITH PRO
CESS STEAM BEFORE ENTERING THE STEAM REFORMER 4HIS STEAM REFORMER IS A
TOP
l RED BOX TYPE FURNACE WITH A COLD OUTLET HEADER SYSTEM DEVELOPED
BY 5HDE 4HE REFORMING REACTION OCCURS OVER A NICKEL CATALYST /UTLET
REFORMED GAS IS A MIXTURE OF ( #/ #/ AND RESIDUAL METHANE )T IS
COOLED FROM APPROXIMATELY # TO AMBIENT TEMPERATURE -OST OF THE
HEAT FROM THE SYNTHESIS GAS IS RECOVERED BY STEAM GENERATION "&7 PRE
HEATING HEATING OF CRUDE METHANOL DISTILLATION AND DEMINERALIZED WATER
PREHEATING
!LSO HEAT FROM THE m UE GAS IS RECOVERED BY FEEDFEED
STEAM
PREHEATING STEAM GENERATION AND SUPERHEATING AS WELL AS COMBUSTION
AIR PREHEATING !FTER l NAL COOLING THE SYNTHESIS GAS IS COMPRESSED TO
THE SYNTHESIS PRESSURE WHICH RANGES FROM n BARA DEPENDING ON
PLANT CAPACITY BEFORE ENTERING THE SYNTHESIS LOOP
4HE SYNTHESIS LOOP CONSISTS OF A RECYCLE COMPRESSOR FEEDEFm UENT
EXCHANGER METHANOL REACTOR l NAL COOLER AND CRUDE METHANOL SEPARATOR
5HDES METHANOL REACTOR IS AN ISOTHERMAL TUBULAR REACTOR WITH A COPPER
CATALYST CONTAINED IN VERTICAL TUBES AND BOILING WATER ON THE SHELL SIDE
4HE HEAT OF METHANOL REACTION IS REMOVED BY PARTIAL EVAPORATION OF
THE BOILER FEEDWATER THUS GENERATING n METRIC TONS OF -0 STEAM
PER METRIC TON OF METHANOL !DVANTAGES OF THIS REACTOR TYPE ARE LOW
BYPRODUCT FORMATION DUE TO ALMOST ISOTHERMAL REACTION CONDITIONS
HIGH LEVEL HEAT OF REACTION RECOVERY AND EASY TEMPERATURE CONTROL BY
&EED
&UEL
"&7
#ONDENSER
-ETHANOL
REACTOR
0RODUCT
3EPARATOR
)NTERMEDIATE
STORAGE TANK
REGULATING STEAM PRESSURE 4O AVOID INERT BUILDUP IN THE LOOP A PURGE IS
WITHDRAWN FROM THE RECYCLE GAS AND IS USED AS FUEL FOR THE REFORMER
#RUDE METHANOL THAT IS CONDENSED DOWNSTREAM OF THE METHANOL
REACTOR IS SEPARATED FROM UNREACTED GAS IN THE SEPARATOR AND ROUTED
VIA AN EXPANSION DRUM TO THE CRUDE METHANOL DISTILLATION 7ATER AND
SMALL AMOUNT OF BYPRODUCTS FORMED IN THE SYNTHESIS AND CONTAINED IN
THE CRUDE METHANOL ARE REMOVED BY AN ENERGY
SAVING THREE
COLUMN
DISTILLATION SYSTEM
Economics: 4YPICAL CONSUMPTION l GURES FEED FUEL RANGE FROM TO
'CAL PER METRIC TON OF METHANOL AND WILL DEPEND ON THE INDIVIDUAL PLANT
CONCEPT
Methanol, CONTINUED
Commercial
plants: %LEVEN PLANTS HAVE BEEN BUILT AND REVAMPED WORLD
WIDE USING 5HDES METHANOL TECHNOLOGY
Licensor: 5HDE 'MB( IS A LICENSEE OF *OHNSON -ATTHEY #ATALYSTS ,OW
0RESSURE -ETHANOL ,0- 0ROCESS
Methylamines
Application: 4O PRODUCE MONO
--! DI
$-! AND TRIMETHYLAMINES
3YNTHESIS
4-! FROM METHANOL AND AMMONIA
.(
RECOVERY
Description: !NHYDROUS LIQUID AMMONIA RECYCLED AMINES AND METHA
NOL ARE CONTINUOUSLY VAPORIZED SUPERHEATED AND FED TO A CAT
ALYST PACKED CONVERTER 4HE CONVERTER UTILIZING A HIGH ACTIVITY LOW
BYPRODUCT AMINATION CATALYST SIMULTANEOUSLY PRODUCES --! $-!
AND 4-! 0RODUCT RATIOS CAN BE VARIED TO MAXIMIZE --! $-! OR
4-! PRODUCTION 4HE CORRECT SELECTION OF THE .# RATIO AND RECYCLING OF
AMINES PRODUCES THE DESIRED PRODUCT MIX -OST OF THE EXOTHERMIC REAC
TION HEAT IS RECOVERED IN FEED PREHEATING
4HE REACTOR PRODUCTS ARE SENT TO A SEPARATION SYSTEM WHERE THE AM
MONIA IS SEPARATED AND RECYCLED TO THE REACTION SYSTEM 7ATER FROM
THE DEHYDRATION COLUMN IS USED IN EXTRACTIVE DISTILLATION TO BREAK
THE 4-! AZEOTROPES AND PRODUCE PURE ANHYDROUS 4-! 4HE PRODUCT
COLUMN SEPARATES THE WATER FREE AMINES INTO PURE ANHYDROUS --!
AND $-!
-ETHANOL RECOVERY IMPROVES EFl CIENCY AND EXTENDS CATALYST LIFE
BY ALLOWING GREATER METHANOL SLIP EXIT FROM THE CONVERTER !DDITION OF A
METHANOL RECOVERY COLUMN TO EXISTING PLANTS CAN HELP TO INCREASE PRO
DUCTION RATES
!NHYDROUS --! $-! AND 4-! CAN BE USED DIRECTLY IN DOWN
STREAM PROCESSES SUCH AS -$%! $-& $-!# CHOLINE CHLORIDE ANDOR
DILUTED TO ANY COMMERCIAL SPECIl CATION
Yields: 'REATER THAN ON RAW MATERIALS
Economics: 4YPICAL PERFORMANCE DATA PER TON OF PRODUCT AMINES HAVING
--!$-!4-! PRODUCT RATIO OF b b b
-ETHANOL T
!MMONIA T
3TEAM T
7ATER COOLING M
%LECTRICITY K7H
-ETHANOL
RECOVERY
0RODUCT
PURIFICATION
4-!
2ECYCLE
AMINES
--!
$EHYDRATION
!MMONIA
-ETHANOL
6APORIZATION
-ETHANOL
)NERTS
$-!
7ASTE
WATER
Commercial
plants: 4WENTY
SIX COMPANIES IN COUNTRIES USE THIS PRO
CESS WITH A PRODUCTION CAPACITY EXCEEDING MTPY
Licensor: $AVY 0ROCESS 4ECHNOLOGY 5+
Mixed
xylenes
Application: 4O CONVERT # HEAVY AROMATICS ALONE OR IN CONJUNCTION
WITH TOLUENE OR BENZENE CO
FEED PRIMARILY TO MIXED XYLENES USING
%XXON-OBIL #HEMICALS 4RANS0LUS PROCESS
Description: &RESH FEED RANGING FROM #
-AKEUP HYDROGEN
AROMATICS TO MIXTURES OF
# AROMATICS WITH EITHER TOLUENE OR BENZENE ARE CONVERTED PRIMARILY TO
XYLENES IN THE 4RANS0LUS PROCESS #O
BOILING # AROMATICS COMPONENTS
UP TO & ."0 CAN BE INCLUDED IN THE # FEED )N THIS PROCESS LIQUID
FEED ALONG WITH HYDROGEN
RICH RECYCLE GAS ARE SENT TO THE REACTOR
AFTER BEING HEATED TO REACTION TEMPERATURE THROUGH FEEDEFm UENT HEAT
EXCHANGERS AND THE CHARGE HEATER
0RIMARY REACTIONS OCCURRING ARE THE DEALKYLATION OF ALKYLAROMATICS
TRANSALKYLATION AND DISPROPORTIONATION PRODUCING BENZENETOLUENE
AND # AROMATICS CONTAINING OVER XYLENES 4HE THERMODYNAMIC
EQUILIBRIUM OF THE RESULTING PRODUCT AROMATICS IS MAINLY DEPENDENT
ON THE RATIO OF METHYL GROUPS TO AROMATIC RINGS IN THE REACTOR FEED
(YDROGEN
RICH GAS FROM THE HIGH
PRESSURE SEPARATOR IS RECYCLED BACK
TO THE REACTOR WITH MAKEUP HYDROGEN 5NCONVERTED TOLUENE AND #
AROMATICS ARE RECYCLED TO EXTINCTION
4HE ABILITY OF 4RANS0LUS TO PROCESS FEEDS RICH IN # AROMATICS
ENHANCES THE PRODUCT SLATE TOWARD XYLENES /WING TO ITS UNIQUE CATALYST
LONG CYCLE LENGTHS ARE POSSIBLE
Economics: &AVORABLE OPERATING CONDITIONS RELATIVE TO OTHER ALTERNATIVE
TECHNOLOGIES WILL RESULT IN LOWER CAPITAL AND OPERATING COSTS FOR GRASSROOTS
UNITS AND HIGHER THROUGHPUT POTENTIAL IN RETROl T APPLICATIONS
Commercial
plants: 4HE l RST COMMERCIAL UNIT WAS STARTED UP IN 4AIWAN
IN 0ERFORMANCE OF THIS UNIT HAS BEEN EXCELLENT
Licensor: %XXON-OBIL #HEMICAL 4ECHNOLOGY ,ICENSING ,,# RETROl T AP
PLICATIONS !XENS !XENS .! GRASSROOTS APPLICATIONS
/FFGAS TO
FUEL SYSTEM
&RESH TOLUENE
&RESH # AROMATICS
"48 AND
# PRODUCT
4OLUENE AND # RECYCLE
Mixed
xylenes
Application: 4O SELECTIVELY CONVERT TOLUENE TO MIXED XYLENE AND HIGH
PU
RITY BENZENE USING %XXON-OBIL #HEMICALS 4OLUENE $IS0ROPORTIONATION
RD 'ENERATION -4$0
PROCESS
(YDROGEN MAKEUP
(YDROGEN RECYCLE
4O FUEL SYSTEM
#7
Description: $RY TOLUENE FEED AND UP TO WT # AROMATICS ALONG
WITH HYDROGEN
RICH RECYCLE GAS ARE PUMPED THROUGH FEED EFm UENT HEAT
EXCHANGERS AND THE CHARGE HEATER INTO THE -4$0
REACTOR 4OLUENE
DISPROPORTIONATION OCCURS IN THE VAPOR PHASE TO PRODUCE THE MIXED XY
LENE AND BENZENE PRODUCT (YDROGEN
RICH GAS FROM THE HIGH
PRESSURE
SEPARATOR IS RECYCLED BACK TO THE REACTOR TOGETHER WITH MAKEUP HY
DROGEN 5NCONVERTED TOLUENE IS RECYCLED TO EXTINCTION
2EACTOR YIELDS WT
# AND LIGHTER
"ENZENE
4OLUENE
%THYLBENZENE
P
8YLENE
M
8YLENE
O
8YLENE
# AROMATICS
4OLUENE CONVERSION WT
&EED
0RODUCT
Operating
conditions: -4$0
OPERATES AT HIGH SPACE VELOCITY AND LOW
( HYDROCARBON MOLE RATIO 4HESE CONDITIONS COULD POTENTIALLY RESULT IN
INCREASED THROUGHPUT WITHOUT REACTOR ANDOR COMPRESSOR REPLACEMENT
IN RETROl T APPLICATIONS 4HE THIRD
GENERATION CATALYST OFFERS LONG OPERAT
ING CYCLES AND IS REGENERABLE
Economics: %STIMATED ONSITE BATTERY LIMIT INVESTMENT FOR OPEN SHOP
CONSTRUCTION AT 53 'ULF #OAST LOCATION IS PER BPSD CAPACITY
4YPICAL UTILITY REQUIREMENTS PER BBL FEED CONVERTED
%LECTRICITY K7H
&UEL KCALHR
#7
4OLUENE
FEED
3TABILIZER
&URNACE
2EACTOR
0RODUCT
FRACTIONATION
3EPARATOR
7ATER COOLING # RISE CMHR
#ATALYST l LL LBLB FEED CONVERTED
-AINTENANCE PER YEAR AS OF INVESTMENT
Commercial
plants: &OUR -4$0
LICENSEES SINCE
Reference: /IL 'AS *OURNAL /CT PP n
Licensor: %XXON-OBIL #HEMICAL 4ECHNOLOGY ,ICENSING ,,# RETROl T AP
PLICATIONS !XENS !XENS .! GRASSROOTS APPLICATIONS
Mixed
xylenes
Application: 4O CONVERT # HEAVY AROMATICS ALONE OR IN CONJUNCTION
WITH TOLUENE OR BENZENE CO
FEED PRIMARILY TO MIXED XYLENES USING
%XXON-OBIL #HEMICALS 4RANS0LUS PROCESS
Description: &RESH FEED RANGING FROM #
Economics: &AVORABLE OPERATING CONDITIONS RELATIVE TO OTHER ALTERNATIVE
TECHNOLOGIES WILL RESULT IN LOWER CAPITAL AND OPERATING COSTS FOR GRASSROOTS
UNITS AND HIGHER THROUGHPUT POTENTIAL IN RETROl T APPLICATIONS
Commercial
plants: 4HE l RST COMMERCIAL UNIT WAS STARTED UP IN 4AIWAN
IN 4HERE ARE l VE 4RANS0LUS REFERENCES
Licensor: %XXON-OBIL #HEMICAL RETROl T APPLICATIONS !XENS !XENS .!
/FFGAS TO
FUEL SYSTEM
AROMATICS TO MIXTURES
OF # AROMATICS WITH EITHER TOLUENE OR BENZENE ARE CONVERTED PRIMARILY
TO XYLENES IN THE 4RANS0LUS PROCESS #O BOILING # AROMATICS COMPO
NENTS UP TO & ."0 CAN BE INCLUDED IN THE # FEED )N THIS PROCESS
LIQUID FEED ALONG WITH HYDROGEN RICH RECYCLE GAS ARE SENT TO THE REACTOR
AFTER BEING HEATED TO REACTION TEMPERATURE THROUGH FEEDEFm UENT
HEAT EXCHANGERS AND THE CHARGE HEATER
0RIMARY REACTIONS OCCURRING ARE THE DEALKYLATION OF ALKYLAROMATICS
TRANSALKYLATION AND DISPROPORTIONATION PRODUCING BENZENETOLUENE
AND # AROMATICS CONTAINING OVER XYLENES 4HE THERMODYNAMIC
EQUILIBRIUM OF THE RESULTING PRODUCT AROMATICS IS MAINLY DEPENDENT
ON THE RATIO OF METHYL GROUPS TO AROMATIC RINGS IN THE REACTOR FEED
(YDROGEN RICH GAS FROM THE HIGH PRESSURE SEPARATOR IS RECYCLED BACK
TO THE REACTOR WITH MAKE UP HYDROGEN 5NCONVERTED TOLUENE AND #
AROMATICS ARE RECYCLED TO EXTINCTION
4HE ABILITY OF 4RANS0LUS TO PROCESS FEEDS RICH IN # AROMATICS
ENHANCES THE PRODUCT SLATE TOWARD XYLENES /WING TO ITS UNIQUE CATALYST
LONG CYCLE LENGTHS ARE POSSIBLE
GRASSROOTS APPLICATIONS
-AKEUP
HYDROGEN
&RESH TOLUENE
&RESH # AROMATICS
"48 AND
# PRODUCT
4OLUENE AND # RECYCLE
Mixed
xylenes
Application: )N A MODERN 5/0 AROMATICS COMPLEX THE 4!# PROCESS IS
INTEGRATED INTO THE m OW SCHEME TO SELECTIVELY CONVERT #n # AROMAT
ICS INTO XYLENES RATHER THAN SENDING THEM TO THE GASOLINE POOL OR SELLING
THEM AS A SOLVENT
4O FUEL GAS
0URGE GAS
Description: 4HE 4!# PROCESS CONSISTS OF A l XED
BED REACTOR AND PROD
UCT SEPARATION SECTION 4HE FEED IS COMBINED WITH HYDROGEN
RICH RECYCLE
GAS PREHEATED IN A COMBINED FEED EXCHANGER AND HEATED IN A l RED
HEATER 4HE HOT FEED VAPOR GOES TO A REACTOR 4HE REACTOR EFm UENT
IS COOLED IN A COMBINED FEED EXCHANGER AND SENT TO A PRODUCT SEPARA
TOR (YDROGEN
RICH GAS IS TAKEN OFF THE TOP OF THE SEPARATOR MIXED
WITH MAKEUP HYDROGEN GAS AND RECYCLED BACK TO THE REACTOR ,IQUID
FROM THE BOTTOM OF THE SEPARATOR IS SENT TO A STRIPPER COLUMN 4HE
STRIPPER OVERHEAD GAS IS EXPORTED TO THE FUEL GAS SYSTEM 4HE OVERHEAD
LIQUID MAY BE SENT TO A DEBUTANIZER COLUMN OR A STABILIZER 4HE STABILIZED
PRODUCT IS SENT TO THE PRODUCT FRACTIONATION SECTION OF THE 5/0 AROMAT
ICS COMPLEX
Economics: 4HE CURRENT GENERATION OF 4!# CATALYST HAS DEMONSTRATED
THE ABILITY TO OPERATE FOR SEVERAL YEARS WITHOUT REGENERATION )3", COSTS
BASED ON A UNIT PROCESSING MTPY OF FEED CONSISTING OF
WT # n # 53 'ULF #OAST SITE IN
)NVESTMENT 53 MILLION
5TILITIES PER MT OF FEED
%LECTRICITY K7H
3TEAM MT
7ATER COOLING M
&UEL --KCAL
Commercial
plants: 4HREE COMMERCIAL UNITS HAVE BEEN BROUGHT ON
STREAM WITH FEED RATES RANGING FROM MTPY TO MTPY
Licensor: 5/0 ,,#
# AROMATICS
FEED
-AKEUP
HYDROGEN
2ECYCLE GAS
0RODUCT TO
FRACTIONATION
/VERHEAD
LIQUID TO
DEBUTANIZER
Mixed
xylenes
Application: 4HE 4ATORAY PROCESS PRODUCES MIXED XYLENES AND PETRO
CHEMICAL GRADE BENZENE BY DISPROPORTIONATION OF TOLUENE AND TRANSALK
LYATION OF TOLUENE AND # AROMATICS
4O FUEL GAS
0URGE GAS
Description: 4HE 4ATORAY PROCESS CONSISTS OF A l XED
BED REACTOR AND
PRODUCT SEPARATION SECTION 4HE FRESH FEED IS COMBINED WITH HYDROGEN
RICH RECYCLE GAS PREHEATED IN A COMBINED FEED EXCHANGER AND HEATED
IN A l RED HEATER 4HE HOT FEED VAPOR GOES TO THE REACTOR 4HE
REACTOR EFm UENT IS COOLED IN A COMBINED FEED EXCHANGER AND SENT TO A
PRODUCT SEPARATOR
(YDROGEN
RICH GAS IS TAKEN OFF THE TOP OF THE SEPARATOR MIXED WITH
MAKEUP HYDROGEN GAS AND RECYCLED BACK TO THE REACTOR ,IQUID FROM THE
BOTTOM OF THE SEPARATOR IS SENT TO A STRIPPER COLUMN 4HE STRIPPER
OVERHEAD GAS IS EXPORTED TO THE FUEL GAS SYSTEM 4HE OVERHEAD LIQUID
MAY BE SENT TO A DEBUTANIZER COLUMN 4HE PRODUCTS FROM THE BOTTOM
OF THE STRIPPER ARE RECYCLED BACK TO THE "4 FRACTIONATION SECTION OF THE
AROMATICS COMPLEX
4HE 4ATORAY PROCESS UNIT IS CAPABLE OF PROCESSING FEEDSTOCKS RANGING
FROM WT TOLUENE TO WT ! 4HE OPTIMAL CONCENTRATION OF
! IN THE FEED IS TYPICALLY n WT 4HE 4ATORAY PROCESS PROVIDES AN
IDEAL WAY TO PRODUCE ADDITIONAL MIXED XYLENES FROM TOLUENE AND HEAVY
AROMATICS
Economics: 4HE PROCESS IS DESIGNED TO FUNCTION AT A MUCH HIGHER LEVEL
OF CONVERSION PER PASS 4HIS HIGH CONVERSION MINIMIZES THE SIZE OF THE
"4 COLUMNS AND THE SIZE OF 4ATORAY PROCESS UNIT AS WELL AS THE UTILITY
CONSUMPTION OF ALL OF THESE UNITS %STIMATED )3", COSTS BASED ON A UNIT
PROCESSING FEED CAPACITY OF MTPY 53 'ULF #OAST SITE IN
)NVESTMENT 53 MILLION
5TILITIES PER MT OF FEED
%LECTRICITY K7H
3TEAM MT
7ATER COOLING -
&UEL --KCAL
4OULENE AND
# AROMATICS
FEED
/VERHEAD
LIQUID TO
DEBUTANIZER
-AKEUP
HYDROGEN
2ECYCLE GAS
0RODUCT TO "4
FRACTIONATION
Commercial
plants: 5/0 HAS LICENSED A TOTAL OF 4ATORAY UNITS OF
THESE UNITS ARE IN OPERATION AND ARE IN VARIOUS STAGES OF CONSTRUCTION
Licensor: 5/0 ,,#
m-Xylene
Application: 4HE -8 3ORBEX PROCESS RECOVERS META
XYLENE M
XYLENE
FROM MIXED XYLENES 5/0S INNOVATIVE 3ORBEX TECHNOLOGY USES ADSORP
TIVE SEPARATION FOR HIGHLY EFl CIENT AND SELECTIVE RECOVERY AT HIGH PURITY
OF MOLECULAR SPECIES THAT CANNOT BE SEPARATED BY CONVENTIONAL FRAC
TIONATION
!DSORBENT CHAMBER
$ESORBENT
Description: 4HE PROCESS SIMULATES A MOVING BED OF ADSORBENT WITH CON
TINUOUS COUNTER
CURRENT m OW OF LIQUID FEED OVER A SOLID BED OF ADSOR
BENT &EED AND PRODUCTS ENTER AND LEAVE THE ADSORBENT BED CONTINUOUS
LY AT NEARLY CONSTANT COMPOSITIONS ! ROTARY VALVE IS USED TO PERIODICALLY
SWITCH THE POSITIONS OF THE FEED
ENTRY AND PRODUCT
WITHDRAWAL POINTS AS
THE COMPOSITION PROl LE MOVES DOWN THE ADSORBENT BED
4HE FRESH FEED IS PUMPED TO THE ADSORBENT CHAMBER VIA THE RO
TARY VALVE -
XYLENE IS SEPARATED FROM THE FEED IN THE ADSORBENT
CHAMBER AND LEAVES VIA THE ROTARY VALVE TO THE EXTRACT COLUMN 4HE
DILUTE EXTRACT IS THEN FRACTIONATED TO PRODUCE WT M
XYLENE AS A
BOTTOMS PRODUCT 4HE DESORBENT IS TAKEN FROM THE OVERHEAD AND RECIRCU
LATED BACK TO THE ADSORBENT CHAMBER !LL THE OTHER COMPONENTS PRESENT
IN THE FEED ARE REJECTED IN THE ADSORBENT CHAMBER AND REMOVED VIA THE
ROTARY VALVE TO THE RAFl NATE COLUMN 4HE DILUTE RAFl NATE IS THEN FRAC
TIONATED TO RECOVER DESORBENT AS THE OVERHEAD PRODUCT AND RECIRCULATED
BACK TO THE ADSORBENT CHAMBER
Economics: 4HE -8 3ORBEX PROCESS HAS BEEN DEVELOPED TO MEET IN
CREASED DEMAND FOR PURIl ED ISOPHTHALIC ACID 0)! 4HE GROWTH IN DE
MAND FOR 0)! IS LINKED TO THE COPOLYMER REQUIREMENT FOR 0%4 BOTTLE RESIN
APPLICATIONS A MARKET THAT CONTINUES TO RAPIDLY EXPAND 4HE PROCESS HAS
BECOME THE NEW INDUSTRY STANDARD DUE TO ITS SUPERIOR ENVIRONMENTAL
SAFETY AND LOWER COST MATERIALS OF CONSTRUCTION %STIMATED )3", COSTS
BASED ON UNIT PRODUCTION OF MTPY OF M
XYLENE 53 'ULF #OAST
SITE IN
2OTARY VALVE
%XTRACT
&EED
%XTRACT COLUMN
-
XYLENE
$ESORBENT
2AFFINATE
-IXED XYLENES FEED
2AFFINATE COLUMN
2AFFINATE TO STORAGE
)NVESTMENT 53 MILLION
5TILITIES PER MT OF M
XYLENE PRODUCED
%LECTRICITY K7H
3TEAM MT
7ATER COOLING M
Commercial
plants: &IVE -8 3ORBEX UNITS ARE CURRENTLY IN OPERATION AND
ANOTHER UNIT IS IN DESIGN 4HESE UNITS REPRESENT AN AGGREGATE PRODUCTION
OF MTPY OF M
XYLENE
Licensor: 5/0 ,,#
Octenes
Application: 4HE $IMERSOL
8 PROCESS TRANSFORMS BUTENES TO OCTENES
WHICH ARE ULTIMATELY USED IN THE MANUFACTURE OF PLASTICIZERS VIA ISO
NONANOL ISONONYL ALCOHOL AND DIISONONYL PHTHALATE UNITS
2EACTION
SECTION
#ATALYST
REMOVAL
3EPARATION
SECTION
#
Description: "UTENES ENTER THE $IMERSOL 8 PROCESS WHICH COMPRISES
THREE SECTIONS )N THE REACTOR SECTION DIMERIZATION TAKES PLACE IN MULTIPLE
LIQUID PHASE REACTORS USING HOMOGENEOUS CATALYSIS AND AN EFl CIENT
RECYCLE MIXING SYSTEM 4HE CATALYST IS GENERATED IN SITU BY THE REACTION
OF COMPONENTS INJECTED IN THE RECYCLE LOOP 4HE CATALYST IN THE REACTOR
EFm UENT IS DEACTIVATED IN THE NEUTRALIZATION SECTION AND SEPARATED
4HE STABILIZATION SECTION SEPARATES UNREACTED OLEl N MONOMER AND
SATURATES FROM PRODUCT DIMERS WHILE THE SECOND COLUMN SEPARATES
THE OCTENES ! THIRD COLUMN CAN BE ADDED TO SEPARATE DODECENES
/CTENES
#ATALYST
"UTENES
0URGE
WATER
#AUSTIC
0ROCESS
WATER
#
Yields: .EARLY CONVERSION OF N
BUTENES CAN BE ATTAINED AND SE
LECTIVITIES TOWARD OCTENES ARE ABOUT 4HE TYPICAL # PRODUCT IS A
MIXTURE HAVING A MINIMUM OF OCTENE ISOMERS WITH THE FOLLOWING
DISTRIBUTION
N
/CTENES
-ETHYL
HEPTENES
$IMETHYL
HEXENES
$IMERSOL 8 OCTENES EXHIBIT A LOW DEGREE OF BRANCHING RESULTING
IN HIGHER DOWNSTREAM OXONATION REACTION YIELDS AND RATES AND BETTER
PLASTICIZER QUALITY
Economics:
"ASIS )3", FOR A 'ULF #OAST LOCATION USING TPY
OF A RAFl NATE
# CUT CONTAINING N
BUTENES
)NVESTMENT 53 MILLION
4YPICAL OPERATING COST 53
PER METRIC TON OF OCTENES
Commercial
plants:
4HIRTY
l VE $IMERSOL UNITS TREATING VARIOUS OLEl NIC #
AND # CUTS HAVE BEEN LICENSED 4YPICAL OCTENES PRODUCTION CAPACITIES
RANGE FROM TPY UP TO TPY
Reference: #ONVERS ! $ #OMMEREUC AND " 4ORCK h(OMOGENEOUS
#ATALYSIS v )&0 #ONFERENCE
Licensor: !XENS !XENS .!
Olefinsprogressive
separation
for
olefins
recovery
and
raw
cracked-gas
purification
'+ FURNACES
0RIM FRACT AND
QUENCHING
&EED
0YR
GASOLINE
Application: 4O PRODUCE POLYMER GRADE ETHYLENE AND PROPYLENE A BUTA
DIENE RICH # CUT AN AROMATIC # n # RICH RAW PYROLYSIS GASOLINE AND A
HIGH PURITY HYDROGEN BY STEAM PYROLYSIS OF HYDROCARBONS RANGING FROM
ETHANE TO VACUUM GAS OILS
#OMPRESSION
&UEL OIL
(
ABSORBER
Feedstocks: &OR EITHER GASEOUS ETHANEPROPANE OR LIQUID # NAPHTHA
GASOIL FEEDS THIS TECHNOLOGY IS BASED ON 4ECHNIPS PROPRIETARY 0YROLY
SIS &URNACES AND PROGRESSIVE SEPARATION 4HIS METHOD ALLOWS PRODUCING
OLEl NS AT LOW ENERGY CONSUMPTION WITH PARTICULARLY LOW ENVIRONMENTAL
IMPACT
(YDROCARBON FEEDSTOCKS ARE PREHEATED ALSO TO RECOVER HEAT AND
THEN CRACKED BY COMBINING WITH STEAM IN TUBULAR 0YROLYSIS &URNACE
AT AN OUTLET TEMPERATURE RANGING FROM & TO & 4HE FURNACE
TECHNOLOGY CAN BE EITHER AN 3-+ TYPE FOR GAS CRACKING OR '+ TYPE
FOR LIQUID CRACKING 4HE '+ TYPE DESIGN CAN BE ORIENTED TO A HIGH
OLEl NS YIELD WITH VERY m EXIBLE PROPYLENEETHYLENE RATIOS '+ 490% OR
TO A HIGH "48 PRODUCTION '+ TYPE 4HIS SPECIl C APPROACH ALLOWS LONG
RUN LENGTH EXCELLENT MECHANICAL INTEGRITY AND ATTRACTIVE ECONOMICS
4HE HYDROCARBON MIXTURE AT THE FURNACE OUTLET IS QUENCHED RAPIDLY
IN THE TRANSFER LINE EXCHANGERS 4,% OR 3,% GENERATING HIGH
PRESSURE
STEAM )N LIQUID CRACKERS CRACKED GAS m OWS TO A PRIMARY FRACTIONATOR
AFTER DIRECT QUENCH WITH OIL WHERE FUEL OIL IS SEPARATED FROM GASOLINE
AND LIGHTER COMPONENTS AND THEN TO A QUENCH WATER TOWER FOR WA
TER RECOVERY TO BE USED AS DILUTION STEAM AND HEAVY GASOLINE PRODUC
TION END
POINT CONTROL
! MULTISTAGE COMPRESSOR DRIVEN BY A STEAM TURBINE COMPRESSES THE
COOLED GAS ,0 AND (0 CONDENSATE ARE STRIPPED IN TWO SEPARATE STRIPPERS
WHERE MEDIUM GASOLINE IS PRODUCED AND PART OF THE # CUT IS RE
COVERED RESPECTIVELY ! CAUSTIC SCRUBBER REMOVES ACID GASES
&INAL
COMPRESSION
!CID GAS
REMOVAL
ST -0
DEMETHANIZER
STRIPPER
&UEL GAS
%THYLENE
(
# SPLITTER
# HYD
ND -0
DEMETHANIZER
STRIPPER
0ROPYLENE
2EC ETHANE
TO FURNACES
# SPLITTER
$RYING
CHILLING
# HYD
$EETHANIZER
# PRODUCT
#OND STRIPPING
REC 0ROPANE
$EPROPANIZER
$EBUTANIZER
#
#OMPRESSED GAS AT PSIG IS DRIED AND CHILLED ! DOUBLE DEMETHA
NIZING STRIPPING SYSTEM OPERATING AT MEDIUM PRESSURE AND REBOILED
BY CRACKED GAS MINIMIZES THE REFRIGERATION REQUIRED HEAT INTEGRATION
AS WELL AS THE INVESTMENT COST FOR SEPARATING METHANE TOP AND # CUT
BOTTOMS ! DUAL COLUMN CONCEPTABSORBER CONCEPTIS APPLIED
BETWEEN THE SECONDARY DEMETHANIZER OVERHEADS AND THE CHILLED CRACKED
Olefinsprogressive
separation
for
olefins
recovery
and
raw
cracked-gas
purification, CONTINUED
THAT MINIMIZES THE ETHYLENE LOSSES WITH A LOW ENERGY REQUIREMENT (IGH
PURITY HYDROGEN IS PRODUCED IN A COLD BOX
4HE BOTTOMS FROM THE TWO DEMETHANIZERS OF DIFFERENT QUALITY ARE
SENT TO THE DEETHANIZER 4HE 4ECHNIP PROGRESSIVE SEPARATION ALLOWS
THE DEETHANIZER REmUX RATIO TO BE REDUCED 4HE DEETHANIZER OVERHEAD IS
SELECTIVELY HYDROGENATED FOR ACETYLENE CONVERSION PRIOR TO THE ETHYLENE
SPLITTER WHERE ETHYLENE IS SEPARATED FROM ETHANE 4HE RESIDUAL ETH
ANE IS RECYCLED FOR FURTHER CRACKING
4HE (0 STRIPPER AND DEETHANIZER BOTTOMS OF DIFFERENT QUALITY ARE
FED TO A TWO
COLUMN DUAL PRESSURE DEPROPANIZING SYSTEM FOR #
CUT SEPARATION FROM THE # CUT AND HEAVIES THUS GIVING A LOW FOULING
TENDENCY AT MINIMUM ENERGY CONSUMPTION
4HE METHYL
ACETYLENE AND PROPADIENE IN THE # CUT ARE HYDROGE
NATED TO PROPYLENE IN A LIQUID
PHASE REACTOR 0OLYMER
GRADE PROPYLENE
IS SEPARATED FROM PROPANE IN A # SPLITTER 4HE RESIDUAL PROPANE IS
EITHER RECYCLED FOR FURTHER CRACKING OR EXPORTED #S AND LIGHT GASOLINE
ARE SEPARATED IN A DEBUTANIZER
'AS EXPANSION HEAT RECOVERY AND EXTERNAL CASCADE USING ETHYLENE
AND PROPYLENE SYSTEMS SUPPLY REFRIGERATION 4HE MAIN FEATURES OF 4ECH
NIPS PATENTED TECHNOLOGY ARE
s /PTIMIZATION OF OLElNS YIELDS AND SELECTION OF FEEDSTOCKS
s 2EDUCED EXTERNAL REFRIGERATION IN THE SEPARATION SECTIONS
s !UTO
STABLE PROCESS HEAT INTEGRATION ACTS AS FEED FORWARD SYS
TEM
3IMPLE PROCESS CONTROL LARGE USAGE OF STRIPPERABSORBERS TOWERS
SINGLE SPECIlCATION INSTEAD OF DISTILLATION TOWER ANTAGONISTIC TOP
BOTTOM SPECIlCATIONS
Economics: 5LTIMATE RANGE OF ETHYLENE YIELDS VARY FROM ETHANE
TO AROUND VACUUM GAS OILS FOR THE INTERMEDIATE FULL
RANGE
NAPHTHA 4HESE CORRESPOND TO THE RESPECTIVE TOTAL OLElNS YIELDS ETHYLENE
PROPYLENE FROM ETHANE TO VACUUM GAS OILS AND
FOR AN INTERMEDIATE FULL
RANGE NAPHTHA 4HE SPECIlC ENERGY CONSUMP
TION RANGE IS KCAL KG ETHYLENE ETHANE TO KCALKG ETHYL
ENE GAS OIL AND KCAL KG ETHYLENE FOR AN INTERMEDIATE FULL
RANGE
NAPHTHA
Commercial
plants: 4ECHNIP HAS BEEN AWARDED FOUR ETHYLENE PLANTS
RANGING FROM KTY UP TO KTY USING EITHER ETHANE OR LIQUID FEED
STOCKS 7HILE OVER CRACKING FURNACES HAVE BEEN BUILT AND UNITS
OPERATE WORLDWIDE NUMEROUS EXPANSIONS OVER THE NOMINAL CAPACITY
BASED ON PROGRESSIVE SEPARATION TECHNIQUES ARE UNDER WAY WITH UP TO
AN INCREASE IN CAPACITY &OR ETHANE CRACKING FRONT
END HYDROGENA
TION SCHEME IS ALSO AVAILABLE
Licensor: 4ECHNIP
Olefinsbutenes
extractive
distillation
Application: 3EPARATION OF PURE # OLEl NS FROM OLEl NICPARAFl NIC # MIX
# PARAFFINS
TURES VIA EXTRACTIVE DISTILLATION USING A SELECTIVE SOLVENT "54%.%8 IS THE
5HDE TECHNOLOGY TO SEPARATE LIGHT OLEl NS FROM VARIOUS # FEEDSTOCKS
WHICH INCLUDE ETHYLENE CRACKER AND &## SOURCES
Description: )N THE EXTRACTIVE DISTILLATION %$ PROCESS A SINGLE COM
POUND SOLVENT . &ORMYLMORPHOLINE .&- OR .&- IN A MIXTURE WITH
FURTHER MORPHOLINE DERIVATIVES ALTERS THE VAPOR PRESSURE OF THE COM
PONENTS BEING SEPARATED 4HE VAPOR PRESSURE OF THE OLEl NS IS LOWERED
MORE THAN THAT OF THE LESS SOLUBLE PARAFl NS 0ARAFl NIC VAPORS LEAVE THE
TOP OF THE %$ COLUMN AND SOLVENT WITH OLEl NS LEAVES THE BOTTOM OF THE
%$ COLUMN
4HE BOTTOM PRODUCT OF THE %$ COLUMN IS FED TO THE STRIPPER TO
SEPARATE PURE OLEl NS MIXTURES FROM THE SOLVENT !FTER INTENSIVE HEAT
EXCHANGE THE LEAN SOLVENT IS RECYCLED TO THE %$ COLUMN 4HE SOLVENT
WHICH CAN BE EITHER .&- OR A MIXTURE INCLUDING .&- PERFECTLY SATISl ES
THE SOLVENT PROPERTIES NEEDED FOR THIS PROCESS INCLUDING HIGH SELECTIVITY
THERMAL STABILITY AND A SUITABLE BOILING POINT
Economics:
Consumption
per
metric
ton
of
FCC
C4
fraction
feedstock:
3TEAM T T
7ATER COOLING $4 # M T
%LECTRIC POWER K7HT
Product
purity:
N
"UTENE CONTENT
3OLVENT CONTENT
n
WTn MIN
WTn PPM MAX
Commercial
plants: 4WO COMMERCIAL PLANTS FOR THE RECOVERY OF N
BU
TENES HAVE BEEN INSTALLED SINCE
Licensor: 5HDE 'MB(
# OLEFINS
%XTRACTIVE
DISTILLATION
COLUMN
#
FRACTION
3OLVENT
3OLVENT OLEFINS
3TRIPPER
COLUMN
Olefins
by
dehydrogenation
Application: 4HE 5HDE 34EAM !CTIVE 2EFORMING 34!2 PROCESS PRODUCES
(0 STEAM
A PROPYLENE AS FEEDSTOCK FOR POLYPROPYLENE PROPYLENE OXIDE CUMENE
ACRYLONITRILE OR OTHER PROPYLENE DERIVATIVES AND B BUTYLENES AS FEED
STOCK FOR METHYL TERTIARY BUTYL ETHER -4"% ALKYLATE ISOOCTANE POLYBU
TYLENES OR OTHER BUTYLENE DERIVATIVES
!IR
&UEL GAS
Feed: ,IQUEl ED PETROLEUM GAS ,0' FROM GAS l ELDS GAS CONDENSATE
l ELDS AND REl NERIES
Product: 0ROPYLENE POLYMER OR CHEMICAL GRADE ISOBUTYLENE N BUTYLENES
HIGH PURITY HYDROGEN ( MAY ALSO BE PRODUCED AS A BYPRODUCT
Description: 4HE FRESH PARAFl N FEEDSTOCK IS COMBINED WITH PARAFl N RE
CYCLE AND INTERNALLY GENERATED STEAM !FTER PREHEATING THE FEED IS SENT
TO THE REACTION SECTION 4HIS SECTION CONSISTS OF AN EXTERNALLY l RED TUBULAR
l XED
BED REACTOR 5HDE REFORMER CONNECTED IN SERIES WITH AN ADIABAT
IC l XED
BED OXYREACTOR SECONDARY REFORMER TYPE )N THE REFORMER THE
ENDOTHERMIC DEHYDROGENATION REACTION TAKES PLACE OVER A PROPRIETARY
NOBLE METAL CATALYST
)N THE ADIABATIC OXYREACTOR PART OF THE HYDROGEN FROM THE INTERME
DIATE PRODUCT LEAVING THE REFORMER IS SELECTIVELY CONVERTED WITH ADDED
OXYGEN OR AIR THEREBY FORMING STEAM 4HIS IS FOLLOWED BY FURTHER DEHY
DROGENATION OVER THE SAME NOBLE
METAL CATALYST %XOTHERMIC SELECTIVE (
CONVERSION IN THE OXYREACTOR INCREASES OLEl N PRODUCT SPACE
TIME YIELD
AND SUPPLIES HEAT FOR FURTHER ENDOTHERMIC DEHYDROGENATION 4HE REAC
TION TAKES PLACE AT TEMPERATURES BETWEEN #n # AND AT BAR n
BAR
4HE 5HDE REFORMER IS TOP
l RED AND HAS A PROPRIETARY hCOLDv OUT
LET MANIFOLD SYSTEM TO ENHANCE RELIABILITY (EAT RECOVERY UTILIZES PROCESS
HEAT FOR HIGH
PRESSURE STEAM GENERATION FEED PREHEAT AND FOR HEAT RE
QUIRED IN THE FRACTIONATION SECTION
!FTER COOLING AND CONDENSATE SEPARATION THE PRODUCT IS SUBSE
QUENTLY COMPRESSED LIGHT
ENDS ARE SEPARATED AND THE OLEl N PRODUCT IS
3TAR
REFORMER
&EED
PREHEATER
2AW GAS
COMPRESSION
&UEL GAS
/AIR
/XY
REACTOR
'AS
SEPARATION
(EAT
RECOVERY
(YDROCARBON FEED
"OILER FEED WATER
&RACTIONATION
0ROCESS CONDENSATE
0ROCESS STEAM
/LEFIN
PRODUCT
(YDROCARBON
RECYCLE
SEPARATED FROM UNCONVERTED PARAFl NS IN THE FRACTIONATION SECTION
!PART FROM LIGHT
ENDS WHICH ARE INTERNALLY USED AS FUEL GAS THE
OLEl N IS THE ONLY PRODUCT (IGH
PURITY ( MAY OPTIONALLY BE RECOVERD
FROM LIGHT
ENDS IN THE GAS SEPARATION SECTION
Economics: 4YPICAL SPECIl C CONSUMPTION l GURES FOR POLYMER GRADE
PROPYLENE PRODUCTION ARE SHOWN PER METRIC TON OF PROPYLENE PRODUCT
INCLUDING PRODUCTION OF OXYGEN AND ALL STEAM REQUIRED
0ROPANE KGMETRIC TON
&UEL GAS '*METRIC TON
#IRCUL COOLING WATER MMETRIC TON
%LECTRICAL ENERGY K7HMETRIC TON
Olefins
by
dehydrogenation, CONTINUED
Commercial
plants: 4WO COMMERCIAL PLANTS USING THE 34!2 PROCESS FOR
DEHYDROGENATION OF ISOBUTANE TO ISOBUTYLENE HAVE BEEN COMMISSIONED
IN THE 53 AND !RGENTINA -ORE THAN 5HDE REFORMERS AND 5HDE
SECONDARY REFORMERS HAVE BEEN CONSTRUCTED WORLDWIDE
References: (EINRITZ !DRIAN - . 4HIAGARAJAN 3 7ENZEL AND ( 'EHRKE
h34!25HDES DEHYDROGENATION TECHNOLOGY AN ALTERNATIVE ROUTE TO #
AND # OLElNS v %24# 0ETROCHEMICAL 0ARIS &RANCE -ARCH
4HIAGARAJAN . 5 2ANKE AND & %NNENBACH h0ROPANEBUTANE DE
HYDROGENATION BY STEAM ACTIVE REFORMING v !CHEMA &RANKFURT
'ERMANY -AY
Licensor: 5HDE 'MB(
Olefins
Application: 4O PRODUCE ETHYLENE PROPYLENE AND BUTENES FROM NATURAL
2EACTOR
REGENERATION
SECTION
GAS OR EQUIVALENT VIA METHANOL USING THE 5/0(YDRO -4/ METHANOL
TO OLEl NS PROCESS
Description: 4HIS PROCESS CONSISTS OF A REACTOR SECTION A CONTINUOUS CAT
ALYST REGENERATION SECTION AND PRODUCT RECOVERY SECTION /NE OR MORE
m UIDIZED
BED REACTORS ARE USED WITH CONTINUOUS CATALYST TRANSFER TO
AND FROM THE CONTINUOUS CATALYST REGENERATOR 4HE ROBUST REGENER
ABLE -4/
CATALYST IS BASED ON A NONZEOLITIC MOLECULAR SIEVE 2AW
NONDEWATERED METHANOL IS FED TO THE LOW
PRESSURE REACTOR WHICH
OFFERS VERY HIGH CONVERSION OF THE METHANOL WITH VERY HIGH SE
LECTIVITY TO ETHYLENE AND PROPYLENE 4HE RECOVERY SECTION DESIGN DEPENDS
ON PRODUCT USE BUT WILL CONTAIN A PRODUCT WATER RECOVERY AND RECYCLE
SYSTEM A #/ REMOVAL SYSTEM A DRYER A DEETHANIZER AN
ACETYLENE SATURATION UNIT A DEMETHANIZER AND A DEPROPANIZER
4HE PROCESS CAN PRODUCE POLYMER
GRADE ETHYLENE AND PROPYLENE BY
ADDING SIMPLE FRACTIONATION TO THE RECOVERY SECTION
0RODUCT
RECOVERY
SECTION
0RODUCT
&LUE
GAS
7ATER
#(
0URITY
ETHYLENE
0URITY
PROPYLENE
-E/(
!IR
# PRODUCT
Yields: 4HE PROCESS GIVES VERY HIGH TOTAL OLEl NS YIELDS ! TYPICAL PRODUCT
YIELD STRUCTURE IS SHOWN BASED ON MTD RAW METHANOL FEEDRATE TO
AN -4/ PLANT
-ETRIC TPD
%THYLENE
0ROPYLENE
4OTAL LIGHT OLEl NS
"UTENES
#
&UEL GAS
/THER WATER COKE #/X
4HE PROCESS IS m EXIBLE %THYLENE TO PROPYLENE PRODUCT WEIGHT RATIO
CAN BE MODIl ED BETWEEN THE RANGE OF TO BY ALTERING REACTOR
OPERATING SEVERITY 4HE TOTAL YIELD OF OLEl NS VARIES SLIGHTLY THROUGHOUT
THIS RANGE
Economics: 4HE -4/ PROCESS COMPETES FAVORABLY WITH CONVENTIONAL
LIQUID CRACKERS DUE TO LOWER CAPITAL INVESTMENT )T IS ALSO AN IDEAL VE
HICLE TO DEBOTTLENECK EXISTING ETHYLENE PLANTS AND UNLIKE CONVENTIONAL
STEAM CRACKERS THE -4/ PROCESS IS A CONTINUOUS REACTOR SYSTEM WITH
NO l RED HEATERS
Commercial
plants: (YDRO OPERATED A DEMONSTRATION UNIT THAT WAS IN
STALLED IN .ORWAY IN 4HE l RST COMMERCIAL -4/ UNIT IS PLANNED FOR
STARTUP IN IN .IGERIA
Licensor: 5/0 ,,#(YDRO
Olefins
catalytic
Application: 4O SELECTIVELY CONVERT VACUUM GAS OILS AND THE RESULTING
0RODUCT VAPORS
BLENDS OF EACH INTO #n # OLEl NS AROMATIC RICH HIGH OCTANE GASOLINE
AND DISTILLATE USING DEEP CATALYTIC CRACKING $## METHODS
Description: $## IS A m UIDIZED PROCESS TO SELECTIVELY CRACK A WIDE VA
RIETY OF FEEDSTOCKS INTO LIGHT OLEl NS 0ROPYLENE YIELDS OVER WT ARE
ACHIEVABLE WITH PARAFl NIC FEEDS ! TRADITIONAL REACTORREGENERATOR UNIT
DESIGN USES A CATALYST WITH PHYSICAL PROPERTIES SIMILAR TO TRADITIONAL &##
CATALYST 4HE $## UNIT MAY BE OPERATED IN TWO OPERATIONAL MODES MAX
IMUM PROPYLENE 4YPE ) OR MAXIMUM ISO OLEl NS 4YPE )) %ACH OPERA
TIONAL MODE UTILIZES UNIQUE CATALYST AS WELL AS REACTION CONDITIONS $##
MAXIMUM PROPYLENE USES BOTH RISER AND BED CRACKING AT SEVERE REACTOR
CONDITIONS WHILE 4YPE )) UTILIZES ONLY RISER CRACKING LIKE A MODERN &##
UNIT AT MILDER CONDITIONS
4HE OVERALL m OW SCHEME OF $## IS VERY SIMILAR TO A CONVENTIONAL
&## (OWEVER INNOVATIONS IN CATALYST DEVELOPMENT PROCESS VARIABLE
SELECTION AND SEVERITY ENABLES THE $## TO PRODUCE SIGNIl CANTLY MORE
OLEl NS THAN &## IN A MAXIMUM OLEl NS MODE OF OPERATION
0RODUCTS WT &&
%THYLENE
0ROPYLENE
"UTYLENE
IN WHICH )#
!MYLENE
IN WHICH )#
$## 4YPE )
$## 4YPE ))
&##
4HIS TECHNOLOGY IS SUITABLE FOR REVAMPS AS WELL AS GRASSROOT
APPLICATIONS
Commercial
plants: #URRENTLY EIGHT UNITS ARE IN OPERATION SEVEN IN #HI
NA AND ONE IN 4HAILAND !NOTHER PLANT FOR 3AUDI !RAMCO PRESENTLY IN
DESIGN WILL BE THE LARGEST $## UNIT IN THE WORLD
2EACTOR
&LUE GAS
2EGENERATOR
#OMBUSTION AIR
2EGEN CAT STANDPIPE
6APOR AND CATALYST
DISTRIBUTOR
3TRIPPER
2EACTOR RISER
2ISER STEAM
&EED NOZZLES&)4
Reference: $HARRA ET AL h)NCREASE LIGHT OLEl NS PRODUCTION v (YDROCAR
BON 0ROCESSING !PRIL
Licensor: 3TONE 7EBSTER )NC ! 3HAW 'ROUP #O2ESEARCH )NSTITUTE OF
0ETROLEUM 0ROCESSING 3INOPEC
Normal
paraffins,
C10
C13
Application: 4HE -OLEX PROCESS RECOVERS NORMAL # n # PARAFl NS
FROM KEROSINE USING 5/0S INNOVATIVE 3ORBEX ADSORPTIVE SEPARATION
TECHNOLOGY
Description: 3TRAIGHT
RUN KEROSINE IS FED TO A STRIPPER AND A RERUN
COLUMN TO REMOVE LIGHT AND HEAVY MATERIALS 4HE REMAINING HEART
CUT
KEROSINE IS HEATED IN A CHARGE HEATER AND THEN TREATED IN A 5NION
l NING REACTOR TO REMOVE IMPURITIES 4HE REACTOR EFm UENT IS SENT TO A
PRODUCT SEPARATOR TO SEPARATE GAS FOR RECYCLE AND THEN THE LIQUID IS
SENT TO A PRODUCT STRIPPER TO REMOVE LIGHT ENDS 4HE BOTTOMS STREAM
FROM THE PRODUCT STRIPPER IS SENT TO A -OLEX UNIT TO RECOVER NORMAL
PARAFl NS
&EEDSTOCK IS TYPICALLY STRAIGHT
RUN KEROSINE WITH n NORMAL
PARAFl N CONTENT 0RODUCT PURITY IS TYPICALLY GREATER THAN WT
Economics: )NVESTMENT 53 'ULF #OAST BATTERY LIMITS FOR THE PRODUCTION
OF TPY OF NORMAL PARAFl NS TPY
Commercial
plants: 4WENTY
EIGHT -OLEX UNITS HAVE BEEN BUILT
Reference: -C0HEE ! h5PGRADING +EROSENE TO 6ALUABLE 0ETROCHEMI
CALS v TH !NNUAL $E7ITT 7ORLD 0ETROCHEMICAL 2EVIEW (OUSTON 4EXAS
53 -ARCH
Licensor: 5/0 ,,#
,IGHT ENDS
-AKEUP HYDROGEN
2ECYCLE GAS
,IGHT KEROSINE
.ORMAL PARAFFIN
3TRAIGHT
RUN
KEROSINE
2AFFINATE
(EAVY
KEROSINE
Paraffin,
normal
Application: %Fl CIENT LOW
COST RECOVERY AND PURIl CATION PROCESSES FOR
THE PRODUCTION OF ,!"
GRADE ANDOR HIGH
PURITY N
PARAFl N PRODUCTS
FROM KEROSINE
$ESORBENT
-OLECULAR
SIEVE BEDS
Description: 4HE %XXON-OBIL #HEMICAL %-# PROCESS OFFERS COMMER
CIALLY PROVEN TECHNOLOGIES FOR EFl CIENT RECOVERY AND PURIl CATION OF HIGH
PURITY N PARAFl N FROM KEROSINE FEEDSTOCK +EROSINE FEEDSTOCKS ARE IN
TRODUCED TO THE RECOVERY SECTION WHERE THE N PARAFl NS ARE EFl CIENTLY
RECOVERED FROM THE KEROSINE STREAM IN A VAPOR PHASE l XED BED MOLECU
LAR SIEVE ADSORPTION PROCESS )N THE PROCESS THE N PARAFl NS ARE SELEC
TIVELY ADSORBED ON A MOLECULAR SIEVE AND SUBSEQUENTLY DESORBED WITH A
HIGHLY EFFECTIVE DESORBENT
4HE NON N PARAFl N HYDROCARBONS ARE REJECTED AND RETURNED TO THE
REl NERY 4HE PROCESS PROVIDES A UNIQUE ENVIRONMENT ALLOWING THE SOLID
ADSORBENT TO BE VERY TOLERANT OF SULFUR COMPOUNDS WHICH ARE TYPICALLY
PRESENT IN KEROSINE FEEDSTOCK 4HE ADSORBENT IS THEREFORE ABLE TO LAST LONG
CYCLE LENGTHS WITH A TOTAL LIFE UP TO YEARS AS COMMERCIALLY DEMONSTRATED
BY %XXON-OBIL )N MOST CASES DUE TO THE HIGH SULFUR TOLERANCE THE
KEROSINE FEEDSTOCK WILL NOT REQUIRE HYDROTREATING PRETREATMENT WHICH
SIGNIl CANTLY REDUCES CAPITAL INVESTMENT AND OPERATING COST 4HE RECOVERY
SECTION PRODUCES ,!" GRADE N PARAFl N PRODUCT
(IGH PURITY SPECIALTY GRADE N PARAFl N PRODUCTS ARE PRODUCED IN
THE %XXON-OBIL 0URIl CATION PROCESS 4HE ,!" GRADE PRODUCT FROM THE
RECOVERY PROCESS IS FURTHER PROCESSED IN A PURIl CATION SECTION WHERE
RESIDUAL AROMATICS AND OTHER IMPURITIES ARE FURTHER REDUCED 0URIl CATION
IS ACCOMPLISHED IN A LIQUID PHASE l XED BED ADSORPTION SYSTEM 4HE
IMPURITIES ARE SELECTIVELY ADSORBED ON A MOLECULAR SIEVE AND SUBSEQUENTLY
REMOVED WITH A HYDROCARBON DESORBENT 4HE HIGH PURITY N PARAFl NS
PRODUCT IS THE HIGHEST QUALITY AVAILABLE IN THE MARKET %XXON-OBIL
COMMERCIALLY PRODUCES AND MARKETS N PARAFl N PRODUCT WITH AROMATICS
CONTENT BELOW WTPPM 4HE %XXON-OBIL N PARAFl N TECHNOLOGIES
OFFER THE INDUSTRYS LOWEST CAPITAL AND OPERATING COST SOLUTIONS AND
HIGHEST PURITY PRODUCTS FOR N PARAFl N PRODUCERS
,!" GRADE N PARAFFINS PRODUCT
!MMONIA
*ET FUEL
TO REFINERY
!DSORPTION
$ESORPTION
$ESORPTION
*ET FUEL
TO REFINERY
!DSORPTION
-OLECULAR
SIEVE BEDS
+EROSINE FEED
2ECOVERY
SECTION
0URIFICATION
SECTION
(IGH
PURITY
N
PARAFFINS
PRODUCT
Product
quality: 4YPICAL PROPERTIES OF HIGH
PURITY N
PARAFl N PRODUCT
0URITY WT
!ROMATICS WT PPM
"ROMINE )NDEX MGG
3ULFUR WT PPM
Yield: 4YPICALLY OVER OF THE N
PARAFl N CONTAINED IN THE KEROSINE
STREAM IS RECOVERED
Commercial
plants: %XXON-OBIL #HEMICAL HAS YEARS OF EXPERIENCE IN
THE PRODUCTION OF N
PARAFl NS AND IS THE SECOND LARGEST PRODUCER IN THE
Paraffin,
normal, CONTINUED
WORLD %XXON-OBILS N
PARAFlN PLANT AT "AYTOWN 4EXAS PRODUCES HIGH
PURITY PRODUCT IN A SINGLE TRAIN AT A NAMEPLATE CAPACITY OF TPY
Licensor: +ELLOGG "ROWN 2OOT )NC
Paraxylene
Application: 3UITE OF ADVANCED AROMATICS TECHNOLOGIES COMBINED IN THE
MOST EFFECTIVE MANNER TO MEET CUSTOMERS INVESTMENT AND PRODUCTION
OBJECTIVES FOR PARAXYLENE AND BENZENE AND ARE LICENSED UNDER THE NAME
0ARAMA8
-OBIL AND
5HDE TECHNOLOGIES LICENSED BY !XENS FOR GRASSROOTS APPLICATIONS
Production: 4YPICAL PARAXYLENE SINGLE TRAIN COMPLEX FROM NAPHTHA TO
PARAXYLENE FEATURING !ROMIZING %LUXYL 8Y-AX AND 4RANS0LUS UNITS
&EED n !RAB LIGHT NAPHTHA
0ARAXYLENE
"ENZENE
.ET PRODUCER OF HYDROGEN
4HOUSAND TPY
Economics: 4HE )3", 'ULF #OAST LOCATION ERECTED COST INCLUDING
l RST LOAD OF CATALYSTS AND CHEMICALS WITH ALLOWANCE FOR OFFSITES
"ENZENE
"4
EXTRACTION
0ARAXYLENE
#n
Description: !ROMATICS ARE PRODUCED FROM NAPHTHA IN THE !ROMIZING
SECTION AND SEPARATED BY CONVENTIONAL DISTILLATION 4HE XYLENE FRAC
TION IS SENT TO THE %LUXYL UNIT WHICH PRODUCES PARAXYLENE
VIA SIMULATED COUNTERCURRENT ADSORPTION 4HE 08 DEPLETED RAFl NATE IS
ISOMERIZED BACK TO EQUILIBRIUM IN THE ISOMERIZATION SECTION WITH EI
THER %" DEALKYLATION TYPE 8Y-AX PROCESSES OR %" ISOMERIZATION TYPE
/PARIS CATALYSTS (IGH PURITY BENZENE AND TOLUENE ARE SEPARATED FROM
NON AROMATIC COMPOUNDS WITH EXTRACTIVE DISTILLATION -ORPHYLANE
PROCESSES 4OLUENE AND # TO # AROMATICS ARE CONVERTED TO MORE
VALUED BENZENE AND MIXED XYLENES IN THE 4RANS0LUS
PROCESS LEADING
TO INCREMENTAL PARAXYLENE PRODUCTION
%LUXYL TECHNOLOGY HAS THE INDUSTRIALLY PROVEN ABILITY TO MEET ULTIMATE
SINGLE TRAIN 08 PURITY AND CAPACITIES AS HIGH AS MTPY 0ROPRIETARY
HYBRID %LUXYL CONl GURATIONS INTEGRATE AN INTERMEDIATE PURITY ADSORPTION
SECTION WITH A SINGLE
STAGE CRYSTALLIZATION IDEAL FOR RETROl TS !XENS IS THE
LICENSOR OF ALL THE TECHNOLOGIES INVOLVED IN THE 0ARAMA8 SUITE
2AFFINATE
4OLUENE
#
(
.APHTHA
08
EXTRACTION
4OL
#
TRANSALKYLATION
#
2EFORMING
#
ISOM
#
# #
#
#
)NVESTMENT MILLION 53
!NNUAL UTILITIES CATALYST AND CHEMICAL
OPERATING COST MILLION 53YR
#
(EAVY
AROMATICS
Commercial
plants: %IGHT %LUXYL UNITS HAVE BEEN LICENSED ACCOUNTING
FOR MILLION TPY OF PARAXYLENE AND THREE UNITS THAT ARE IN OPERATION 3IX
ISOMERIZATION UNITS USE THE /PARIS CATALYST AND %XXON-OBIL %" DEAL
KYLATING UNITS HAVE BEEN PUT INTO OPERATION 4HREE 4RANS0LUS UNITS ARE
CURRENTLY IN OPERATION
Reference: $UPRAZ # ET AL h-AXIMIZING PARAXYLENE PRODUCTION WITH
0ARAMA8v (OTIER ' AND -ETHIVIER ! h0ARAXYLENE 0RODUCTION WITH
Paraxylene, CONTINUED
THE %LUXYL 0ROCESSv !)#H% 3PRING -EETING .EW /RLEANS -ARCH
Licensor: !XENS !XENS .!
Paraxylene
Application: 4O SELECTIVELY CONVERT TOLUENE TO HIGH
PURITY PARA
XYLENE
RICH 08 XYLENES AND BENZENE USING %XXON-OBIL #HEMICALS TECH
NOLOGIES 0X-AX AND !34$0
(YDROGEN MAKEUP
(YDROGEN RECYCLE
4O FUEL SYSTEM
#7
Description: $RY TOLUENE FEED AND HYDROGEN
RICH RECYCLE GAS ARE PUMPED
THROUGH FEEDEFm UENT EXCHANGERS AND CHARGE HEATER AND INTO THE REAC
TOR 3ELECTIVE TOLUENE DISPROPORTIONATION 34$0 OCCURS IN THE VAPOR
PHASE TO PRODUCE THE PARAXYLENE
RICH XYLENE AND BENZENE CO
PRODUCT
"YPRODUCT YIELDS ARE SMALL 2EACTOR EFm UENT IS COOLED BY HEAT EXCHANGE
AND LIQUID PRODUCTS ARE SEPARATED FROM THE RECYCLE GAS (YDROGEN
RICH
GAS FROM THE SEPARATOR IS RECYCLED BACK TO THE REACTOR TOGETHER WITH
MAKEUP HYDROGEN ,IQUID PRODUCT IS STRIPPED OF REMAINING LIGHT GAS IN
THE STABILIZER AND SENT TO PRODUCT FRACTIONATION 5NCONVERTED TOLUENE
IS RECYCLED TO EXTINCTION
4HE 0X-AX TECHNOLOGY USES CATALYST WHICH IS EX
SITU SELECTIVATED BY
PRETREATMENT DURING CATALYST MANUFACTURE 4HE !34$0 TECHNOLOGY USES
CATALYST WHICH IS IN
SITU COKE SELECTIVATED "OTH TECHNOLOGIES PROVIDE
SIGNIl CANTLY HIGHER SELECTIVITY AND LONGER OPERATING CYCLES THAN OTHER 34$0
TECHNOLOGIES /PERATING COSTS ASSOCIATED WITH DOWNSTREAM RECOVERY ARE
ALSO REDUCED BY THE HIGH PARAXYLENE PURITY FROM 0X-AX AND !34$0
Operating
conditions: 0X-AX OPERATES AT LOWER START
OF
CYCLE TEMPERATURES
AND LOWER HYDROGEN TO HYDROCARBON RECYCLE RATIOS THAN OTHER 34$0
TECHNOLOGIES RESULTING IN LONGER CYCLES AND LOWER UTILITIES "Y ELIMINATING
THE IN
SITU SELECTIVATION STEP THE 0X-AX VERSION OF THIS TECHNOLOGY RESULTS
IN SIMPLIl ED OPERATION AND LOWER CAPITAL COSTS "OTH CATALYSTS OFFER LONG
OPERATING CYCLES AND ARE REGENERABLE
Commercial
plants: 4HERE ARE SEVEN -34$0 UNITS PREDECESSOR TECHNOLOGY
TO 0X-AX AND !34$0 AND FOUR UNITS USING 0X-AX TECHNOLOGY 4HE l RST
TWO 0X-AX UNITS STARTED UP IN AND AT #HALMETTE 2El NINGS
,OUISIANA 2El NERY AND -OBIL #HEMICALS "EAUMONT PLANT RESPECTIVELY
#7
4OLUENE
FEED
2EACTOR
3EPARATOR
3TABILIZER
&URNACE
0RODUCT
FRACTIONATION
Licensor:
%XXON-OBIL #HEMICAL RETROl T APPLICATIONS !XENS !XENS .!
GRASSROOTS APPLICATIONS
Paraxylene
Application: 4O SELECTIVELY CONVERT TOLUENE TO HIGH
PURITY PARA
XYLENE
RICH 08 XYLENES AND BENZENE USING %XXON-OBIL #HEMICALS TECH
NOLOGIES 0X-AX AND !34$0
(YDROGEN MAKEUP
(YDROGEN RECYCLE
4O FUEL SYSTEM
#7
Description: $RY TOLUENE FEED AND HYDROGEN
RICH RECYCLE GAS ARE PUMPED
THROUGH FEEDEFm UENT EXCHANGERS AND CHARGE HEATER AND INTO THE REAC
TOR 3ELECTIVE TOLUENE DISPROPORTIONATION 34$0 OCCURS IN THE VAPOR
PHASE TO PRODUCE THE PARAXYLENE
RICH XYLENE AND BENZENE CO
PRODUCT
"YPRODUCT YIELDS ARE SMALL 2EACTOR EFm UENT IS COOLED BY HEAT EXCHANGE
AND LIQUID PRODUCTS ARE SEPARATED FROM THE RECYCLE GAS (YDROGEN
RICH
GAS FROM THE SEPARATOR IS RECYCLED BACK TO THE REACTOR TOGETHER WITH
MAKEUP HYDROGEN ,IQUID PRODUCT IS STRIPPED OF REMAINING LIGHT GAS IN
THE STABILIZER AND SENT TO PRODUCT FRACTIONATION 5NCONVERTED TOLUENE
IS RECYCLED TO EXTINCTION
4HE 0X-AX TECHNOLOGY USES CATALYST WHICH IS EX
SITU SELECTIVATED BY
PRETREATMENT DURING CATALYST MANUFACTURE 4HE !34$0 TECHNOLOGY USES
CATALYST WHICH IS IN
SITU COKE SELECTIVATED "OTH TECHNOLOGIES PROVIDE
SIGNIl CANTLY HIGHER SELECTIVITY AND LONGER OPERATING CYCLES THAN OTHER 34$0
TECHNOLOGIES /PERATING COSTS ASSOCIATED WITH DOWNSTREAM RECOVERY ARE
ALSO REDUCED BY THE HIGH PARAXYLENE PURITY FROM 0X-AX AND !34$0
Operating
conditions: 0X-AX OPERATES AT LOWER START
OF
CYCLE TEMPERA
TURES AND LOWER HYDROGEN TO HYDROCARBON RECYCLE RATIOS THAN OTHER 34$0
TECHNOLOGIES RESULTING IN LONGER CYCLES AND LOWER UTILITIES "Y ELIMINATING
THE IN
SITU SELECTIVATION STEP THE 0X-AX VERSION OF THIS TECHNOLOGY RE
SULTS IN SIMPLIl ED OPERATION AND LOWER CAPITAL COSTS "OTH CATALYSTS OFFER
LONG OPERATING CYCLES AND ARE REGENERABLE
Commercial
plants: 4HERE ARE SEVEN -34$0 UNITS PREDECESSOR TECH
NOLOGY TO 0X-AX AND !34$0 AND FOUR UNITS USING 0X-AX TECHNOLOGY
4HE l RST TWO 0X-AX UNITS STARTED UP IN AND AT #HALMETTE
2El NINGS ,OUISIANA 2El NERY AND -OBIL #HEMICALS "EAUMONT PLANT
RESPECTIVELY
#7
4OLUENE
FEED
2EACTOR
3EPARATOR
3TABILIZER
&URNACE
0RODUCT
FRACTIONATION
Licensor: %XXON-OBIL #HEMICAL 4ECHNOLOGY ,ICENSING ,,# RETROl T AP
PLICATIONS !XENS !XENS .! GRASSROOTS APPLICATIONS
Paraxylene
Application: ! 5/0 AROMATICS COMPLEX IS A COMBINATION OF PROCESS UNITS
WHICH ARE USED TO CONVERT PETROLEUM NAPHTHA AND PYROLYSIS GASOLINE
INTO THE BASIC PETROCHEMICAL INTERMEDIATES BENZENE TOLUENE PARAXY
LENE ANDOR ORTHO
XYLENE
Description: 4HE CONl GURATION OF AN AROMATICS COMPLEX DEPENDS UPON
THE AVAILABLE FEEDSTOCK THE DESIRED PRODUCT SLATE AND THE BALANCE BE
TWEEN PERFORMANCE AND CAPITAL INVESTMENT ! FULLY INTEGRATED MODERN
COMPLEX CONTAINS A NUMBER OF 5/0 PROCESS TECHNOLOGIES
4HE NAPHTHA FEED IS l RST SENT TO A 5/0 NAPHTHA HYDROTREATING UNIT
TO REMOVE SULFUR AND NITROGEN COMPOUNDS AND THEN SENT TO A ##2
0LATFORMING UNIT TO REFORM PARAFl NS AND NAPHTHENES TO AROMATICS
4HE REFORMATE PRODUCED IN THE ##2 0LATFORMING UNIT IS SENT TO A
DEBUTANIZER COLUMN WHICH STRIPS OFF THE LIGHT ENDS 4HE DEBUTANIZER
BOTTOMS ARE SENT TO A REFORMATE SPLITTER 4HE # FRACTION FROM THE
OVERHEAD OF THE REFORMATE SPLITTER IS SENT TO A 3ULFOLANE UNIT 4HE
# FRACTION FROM THE BOTTOM OF THE REFORMATE SPLITTER IS SENT TO A XYLENE
FRACTIONATION SECTION 4HE 3ULFOLANE UNIT EXTRACTS THE AROMATICS AND THEN
INDIVIDUAL HIGH
PURITY BENZENE AND TOLUENE PRODUCTS ARE RECOVERED IN A
"4 FRACTIONATION SECTION
4OLUENE IS USUALLY BLENDED WITH # AROMATICS ! FROM THE
OVERHEAD OF THE HEAVY AROMATICS COLUMN AND CHARGED TO A 4ATORAY
UNIT FOR PRODUCTION OF ADDITIONAL XYLENES AND BENZENE 4OLUENE AND
HEAVY AROMATICS CAN ALSO BE CHARGED TO A 4($! UNIT FOR PRODUCTION
OF ADDITIONAL BENZENE
4HE # FRACTION FROM THE BOTTOM OF THE REFORMATE SPLITTER IS
CHARGED TO A XYLENE SPLITTER COLUMN 4HE BOTTOM OF THE XYLENE
SPLITTER COLUMN IS SENT TO THE O
XYLENE COLUMN TO SEPARATE HIGH
PURITY O
XYLENE PRODUCT AND THE BOTTOMS ARE SENT TO THE HEAVY AROMATICS
COLUMN
4HE XYLENE SPLITTER OVERHEAD IS SENT DIRECTLY TO A 0AREX UNIT
WHERE WT PURE PARAXYLENE IS RECOVERED BY ADSORPTIVE SEPARATION
2AFFINATE
"ENZENE
4OLUENE
3ULFOLANE
(YDROGEN
##2
PLATFORMING
4ATORAY
4($!
.APHTHA
HYDROTREATING
!ROMATICS #
0ARAXYLENE
.APHTHA
0AREX
,IGHT ENDS
)SOMAR
/
XYLENE
AT VERY HIGH RECOVERY 4HE RAFl NATE FROM THE 0AREX UNIT IS ALMOST
ENTIRELY DEPLETED OF PARAXYLENE AND IS SENT TO AN )SOMAR UNIT )N
THE )SOMAR UNIT ADDITIONAL PARAXYLENE IS PRODUCED BY RE
ESTABLISHING
AN EQUILIBRIUM DISTRIBUTION OF XYLENE ISOMERS 4HE EFm UENT FROM THE
)SOMAR UNIT IS SENT TO A DEHEPTANIZER COLUMN 4HE BOTTOMS FROM
THE DEHEPTANIZER ARE RECYCLED BACK TO THE XYLENE SPLITTER COLUMN
Economics: ! SUMMARY OF THE INVESTMENT COST AND THE UTILITY CONSUMP
TION FOR A TYPICAL PARA
XYLENE AROMATICS COMPLEX TO PROCESS MILLION
MTPY OF NAPHTHA FEED IS INDICATED BELOW 4HE ESTIMATED )3", ERECTED
Paraxylene, CONTINUED
COST FOR THE UNIT ASSUMES CONSTRUCTION ON A 53 'ULF COAST SITE IN
)NVESTMENT 53 MILLION
0RODUCTS MTPY
"ENZENE
PARAXYLENE
0URE HYDROGEN
5TILITIES PER MT OF FEED
%LECTRICITY K7H
3TEAM MT
7ATER COOLING M
&UEL 'CAL
Commercial
plants: 5/0 IS THE WORLDS LEADING LICENSOR OF PROCESS TECH
NOLOGY FOR AROMATICS PRODUCTION 5/0 HAS LICENSED MORE THAN SEPA
RATE PROCESS UNITS FOR AROMATICS PRODUCTION INCLUDING OVER ##2
0LATFORMING UNITS 3ULFOLANE UNITS 0AREX UNITS )SOMAR UNITS
4ATORAY UNITS AND 4($! UNITS
5/0 HAS DESIGNED INTEGRATED AROMATICS COMPLEXES WHICH PRODUCE
BOTH BENZENE AND PARAXYLENE 4HESE COMPLEXES RANGE IN PARAXYLENE
PRODUCTION CAPACITY FROM TO MILLION MTPY
Licensor: 5/0 ,,#
Paraxylene
Application: 4O PRODUCE A DESIRED XYLENE ISOMER OR ISOMERS FROM A MIX
TURE OF # AROMATICS USING THE 5/0 )SOMAR AND 0AREX PROCESSES
#n
( MAKEUP
Description: &RESH FEED CONTAINING AN EQUILIBRIUM MIXTURE OF # AROMATIC
ISOMERS IS FED TO A XYLENE SPLITTER "OTTOMS FROM THE SPLITTER ARE THEN
SEPARATED INTO AN OVERHEAD PRODUCT OF O
XYLENE AND A BYPRODUCT OF
# AROMATICS /VERHEAD FROM THE SPLITTER IS SENT TO A 5/0 0AREX PROCESS
UNIT TO RECOVER ULTRA
HIGH
PURITY P
XYLENE )F DESIRED HIGH
PURITY M
XYLENE MAY ALSO BE RECOVERED USING THE -8 3ORBEX PROCESS 2EMAINING
COMPONENTS ARE RECYCLED TO THE 5/0 )SOMAR PROCESS UNIT REACTOR
WHERE THEY ARE CATALYTICALLY CONVERTED BACK TOWARD AN EQUILIBRIUM MIX
TURE OF # AROMATIC ISOMERS (YDROGEN
RICH RECYCLE GAS IS SEPARATED
FROM THE REACTOR EFm UENT BEFORE FRACTIONATION TO REMOVE LIGHT
CRACKED
BYPRODUCTS OVERHEAD 4HE REMAINING # AROMATICS ARE THEN COMBINED
WITH THE FRESH FEED AND SENT TO THE XYLENE SPLITTER
4HE FEEDSTOCK CONSISTS OF A MIXTURE OF # AROMATICS TYPICALLY DERIVED
FROM CATALYTICALLY REFORMED NAPHTHA HYDROTREATED PYROLYSIS GASOLINE OR AN
,0' AROMATIZATION UNIT 4HE FEED MAY CONTAIN UP TO ETHYLBENZENE
WHICH IS CONVERTED EITHER TO XYLENES OR BENZENE BY THE )SOMAR REACTOR AT
A HIGH
CONVERSION RATE PER PASS &EEDSTOCKS MAY BE PURE SOLVENT EXTRACTS
OR FRACTIONAL HEARTCUTS CONTAINING UP TO NONAROMATICS (YDROGEN
MAY BE SUPPLIED FROM A CATALYTIC REFORMING UNIT OR ANY SUITABLE SOURCE
#HEMICAL HYDROGEN CONSUMPTION IS MINIMAL
O
8YLENE PRODUCT PURITY OF UP TO IS POSSIBLE DEPENDING ON
THE COMPOSITION OF THE FEED AND FRACTIONATION EFl CIENCY 4HE 0AREX UNIT
IS CAPABLE OF PRODUCING PURE P
XYLENE WITH PER PASS RECOVERY
GREATER THAN
Operating
conditions: -ODERATE TEMPERATURE AND PRESSURE REQUIREMENTS
PERMIT USING CARBON AND LOW
ALLOY STEEL AND CONVENTIONAL PROCESS EQUIP
MENT
Yields: 4YPICAL MASS BALANCE FOR THE 0AREX )SOMAR COMPLEX
# AROMATICS
P
8YLENE
O
8YLENE
# AROMATICS
#OMPOSITION
%THYLBENZENE
P
8YLENE
M
8YLENE
O
8YLENE
&RESH FEED WT UNITS
0RODUCT WT UNITS
n
n
Economics: %STIMATED INSIDE BATTERY LIMITS )3", ERECTED AND UTILITY COSTS
ARE GIVEN FOR A 0AREX
)SOMAR COMPLEX WHICH INCLUDES THE XYLENE SPLITTER
COLUMN AND THE O
XYLENE COLUMN 53 'ULF #OAST FOURTH QUARTER
)NVESTMENT 53 PER MT OF FEED
5TILITIES 53 PER MT OF P
XYLENE PRODUCT
n
Paraxylene, CONTINUED
Commercial
plants: 3INCE 5/0 HAS LICENSED 0AREX UNITS AND
)SOMAR UNITS
Licensor: 5/0 ,,#
Paraxylene
Application: 4HE 08
0LUS 80 0ROCESS CONVERTS TOLUENE TO PARAXYLENE AND
BENZENE 4HE PARAXYLENE IS PURIl ED TO WT VIA SINGLE
STAGE CRYS
TALLIZATION AND A WASH COLUMN 4HE BENZENE PURITY IS
GRADE BY FRAC
TIONATION
,IGHT ENDS
"ENZENE
(YDROGEN
0ARAXYLENE
Description: 4HE 08
0LUS 80 0ROCESS IS COMPOSED OF THREE PROCESSING
STEPS
3ELECTIVE TOLUENE DISPROPORTIONATION VIA THE 08
0LUS 0ROCESS
&RACTIONATION FOR RECOVERY OF RECYCLE TOLUENE AND BENZENE
PRODUCT
4HE "ADGER.IRO PARAXYLENE CRYSTALLIZATION PROCESS WHERE SINGLE
STAGE CRYSTALLIZATION AND CRYSTAL WASH COLUMNS ARE USED
)N THE 08
0LUS TECHNOLOGY FRESH TOLUENE IS COMBINED WITH RECYCLE
GAS HEATED AND FED TO A l XED
BED REACTOR 4HE PARA
SELECTIVE CATALYST
PRODUCES XYLENE PRODUCT WITH PARAXYLENE IN THE XYLENES 2EACTOR
EFm UENT m OWS TO A SEPARATOR WHERE THE RECYCLE GAS IS RECOVERED AND THE
LIQUID PRODUCT IS SENT TO A STRIPPER
)N THE FRACTIONATION SECTION STRIPPER BOTTOMS ARE FED TO A BENZENE
COLUMN WHERE THE BENZENE PRODUCT IS RECOVERED AND THE UNCONVERTED
TOLUENE IS FRACTIONATED FOR RECYCLE 4HE TOLUENE COLUMN BOTTOMS ARE SENT
TO A RERUN COLUMN WHERE THE PARAXYLENE CONCENTRATED FRACTION IS TAKEN
OVERHEAD
)N THE "ADGER.IRO CRYSTALLIZATION UNIT THE XYLENES ARE FED TO A
SINGLE
STAGE CRYSTALLIZATION SECTION THAT USES CONTINUOUS SUSPENSION
CRYSTALLIZATION )N THIS SECTION THE PARAXYLENE IS PURIl ED WITH A SINGLE
REFRIGERANT COMPRESSOR SYSTEM AND THE MOTHER LIQUOR REJECTED 4HE
PURIl ED PARAXYLENE IS FED TO A .IRO WASH COLUMN SECTION WHERE
ULTRA
HIGH
PURITY PARAXYLENE IS PRODUCED BY COUNTERCURRENT CRYSTAL
WASHING
#OMPONENTS OF THIS m EXIBLE TECHNOLOGY ARE ESPECIALLY SUITED FOR
CAPACITY EXPANSION OF EXISTING PARAXYLENE PRODUCTION FACILITIES
4OLUENE
2ECYCLE TOLUENE
Yields:
4OLUENE CONVERSION PER PASS
0ARAXYLENE YIELD WT
"ENZENE YIELD WT
,IGHT ENDS WT
0ARAXYLENE RECOVERY
0ARAXYLENE PURITY WT
(EAVIES
-OTHER LIQUOR
Economics: #APITAL INVESTMENT PER MTY OF PARAXYLENE PRODUCT
%%# 53
5TILITIES PER MT OF PARAXYLENE PRODUCT
%LECTRICITY K7H
3TEAM (0 MT
3TEAM ,0 MT
7ATER COOLING M
&UEL --KCAL
Paraxylene, CONTINUED
Commercial
plants: 4WO 08
0LUS UNITS ARE IN OPERATION ANOTHER UNIT IS
IN DESIGN AND CONSTRUCTION 4WO "ADGER.IRO LICENSED AND PROCESS PACK
AGES WERE PRODUCED FOR THREE "ADGER.IRO CRYSTALLIZATION PROJECTS
Licensor: 5/0 ,,# 3TONE 7EBSTER )NC AND .IRO 0ROCESS 4ECHNOLOGY
"6
Paraxylene
crystallization
Application: #RYST08 IS SUSPENSION CRYSTALLIZATION TECHNOLOGY TO IMPROVE
(IGH
PURITY PARAXYLENE
PRODUCTION SECTION
PRODUCTION OF PARAXYLENE INCREASING CAPACITIES INCREASING PURITY LEVELS
ACHIEVABLE SIMPLIFYING OPERATION SCHEME AND SIGNIl CANTLY LOWERING
CAPITAL INVESTMENT 4HE TECHNOLOGY OPTIMIZES CURRENT EQUIPMENT AND
DESIGN TECHNIQUES TO DELIVER EFl CIENT AND RELIABLE PRODUCTION UTILIZING
m EXIBLE ATTAINABLE EQUIPMENT AND FEED STREAMS
Description: 3USPENSION CRYSTALLIZATION OF PARAXYLENE 08 IN THE XYLENE
ISOMER MIXTURE IS USED TO PRODUCE PARAXYLENE CRYSTALS 4HE TECHNOLOGY
USES AN OPTIMIZED ARRANGEMENT OF EQUIPMENT TO OBTAIN THE REQUIRED
RECOVERY AND PRODUCT PURITY 7ASHING THE PARAXYLENE CRYSTAL WITH THE
l NAL PRODUCT IN A HIGH EFl CIENCY PUSHER
CENTRIFUGE SYSTEM PRODUCES THE
PARAXYLENE PRODUCT
7HEN PARAXYLENE CONTENT IN THE FEED IS ENRICHED ABOVE EQUILIBRIUM
FOR EXAMPLE STREAMS ORIGINATING FROM SELECTIVE TOLUENE CONVERSION PRO
CESSES THE PROPRIETARY CRYSTALLIZATION PROCESS TECHNOLOGY IS EVEN MORE
ECONOMICAL TO PRODUCE HIGH
PURITY PARAXYLENE PRODUCT AT HIGH RECOVER
IES 4HE PROCESS TECHNOLOGY TAKES ADVANTAGE OF RECENT ADVANCES IN CRYS
TALLIZATION TECHNIQUES AND IMPROVEMENTS IN EQUIPMENT TO CREATE THIS EC
ONOMICALLY ATTRACTIVE METHOD FOR PARAXYLENE RECOVERY AND PURIl CATION
$ESIGN USES ONLY CRYSTALLIZERS AND CENTRIFUGES IN THE PRIMARY OPERA
TION 4HIS SIMPLICITY OF EQUIPMENT PROMOTES LOW MAINTENANCE COSTS EASY
INCREMENTAL EXPANSIONS AND CONTROLLED m EXIBILITY (IGH
PURITY PARAXYLENE
IS PRODUCED IN THE FRONT SECTION OF THE PROCESS AT WARM TEMPERATURES
TAKING ADVANTAGE OF THE HIGH CONCENTRATION OF PARAXYLENE ALREADY IN
THE FEED !T THE BACK END OF THE PROCESS HIGH PARAXYLENE RECOVERY IS
OBTAINED THROUGH A SERIES OF CRYSTALLIZERS OPERATED SUCCESSIVELY AT COLDER
TEMPERATURES 4HIS SCHEME MINIMIZES THE NEED FOR RECYCLING EXCESSIVE
AMOUNTS OF l LTRATE THUS REDUCING OVERALL ENERGY REQUIREMENTS
Process
advantages INCLUDE
s (IGH PARAXYLENE PURITY AND RECOVERY WT PURITY AT UP TO
RECOVERY
0ARAXYLENE CRYSTALLIZATION
RECOVERY SECTION
&ILTRATE RECYCLE
3CRAPED
SURFACE
CRYSTALLIZER
3CRAPED
SURFACE CRYSTALLIZERS
3ECONDARY
CENTRIFUGE
0RIMARY
CENTRIFUGE
0ARAXYLENE
RICH FEED
08 LEAN
FILTRATE
#RYSTALS TO FEED DRUM
&EED
DRUM
08 MELT
DRUM
08 PRODUCT
0ARAXYLENE WASH
s #RYSTALLIZATION EQUIPMENT IS SIMPLE EASY TO PROCURE AND OPERA
TIONALLY TROUBLE FREE
s #OMPACT DESIGN REQUIRES SMALL PLOT SIZE AND LOWEST CAPITAL INVEST
MENT
s 3YSTEM IS m EXIBLE TO MEET MARKET REQUIREMENTS FOR PARAXYLENE PU
RITY
s 3YSTEM IS EASILY AMENABLE TO FUTURE REQUIREMENT FOR INCREMENTAL
CAPACITY INCREASES
s &EED CONCENTRATION OF PARAXYLENE IS USED EFl CIENTLY
s 4ECHNOLOGY IS m EXIBLE TO PROCESS A RANGE OF FEED CONCENTRATIONS
n WT PARAXYLENE IN A STAGE REFRIGERATION SYSTEM
Paraxylene
crystallization, CONTINUED
s $ESIGN VARIATIONS ARE USED TO RECOVER PARAXYLENE EFlCIENTLY FROM
FEEDSTOCKS ^ 08 IN A MULTI
STAGE SYSTEM COMPETITIVE WITH ADSORP
TION
BASED SYSTEMS
Economics: 4ECHNO ECONOMIC COMPARISON OF #RYST08 TO CONVENTIONAL
TECHNOLOGIES BASIS 08 FEED PURITY TPY OF WT 08
#RYST08 /THER CRYSTALLIZATION
TECHNOLOGIES
)NVESTMENT COST --
0ARAXYLENE RECOVERY
%LECTRICITY CONSUMPTION K7HTON 08
/PERATION MODE
#ONTINUOUS
"ATCH
Licensor: '4# 4ECHNOLOGY IN ALLIANCE WITH ,YONDELL #HEMICAL #O
Phenol
Application: )MPROVED TECHNOLOGY TO PRODUCE HIGHEST QUALITY PHENOL
AND ACETONE FROM CUMENE 2El NED ALPHA METHYL STYRENE !-3 PRODUC
TION IS OPTIONAL (IGH YIELD IS ACHIEVED AT LOW OPERATING AND CAPITAL COSTS
WITHOUT TAR CRACKING
&RESH
CUMENE
2ECYCLE
CUMENE
Description: &RESH AND RECYCLE CUMENE IS OXIDIZED WITH AIR TO FORM
CUMENE HYDROPEROXIDE #(0 USING NEW OXIDIZER TREATMENT TECHNOLOGY
TO REDUCE ORGANIC ACID FORMATION AND IMPROVE SELECTIVITY /VERHEAD VA
PORS ARE COOLED AND CONDENSED TO RECOVER CUMENE 3PENT AIR IS TREATED
TO ABSORB AND RECOVER RESIDUAL HYDROCARBONS
/XIDATE IS CONCENTRATED IN A MULTISTAGE CUMENE STRIPPING SYSTEM
#ONCENTRATED #(0 m OWS DIRECTLY TO THE CLEAVAGE UNIT WHERE IT IS
DECOMPOSED UNDER PRECISELY CONTROLLED CONDITIONS USING NEW TWO
STAGE !DVANCED #LEAVAGE 4ECHNOLOGY A AND B #LEAVAGE CONDITIONS
ARE OPTIMIZED TO PERMIT #(0 DECOMPOSITION WITHOUT PRODUCING HEAVY
BYPRODUCTS #LEAVAGE EFm UENT IS NEUTRALIZED BEFORE THE MIXTURE IS
FRACTIONATED
.EUTRALIZED CLEAVAGE EFm UENT IS l RST SPLIT INTO SEPARATE ACETONE
CUMENE!-3WATER AND PHENOLHEAVIER FRACTIONS /VERHEADS FROM
THE SPLITTER ARE THEN FRACTIONATED TO REMOVE ALDEHYDES AND CUMENE
!-3WATER TO PRODUCE HIGH
PURITY ACETONE WT 3PLITTER
BOTTOMS IS FRACTIONATED UNDER VACUUM TO PRODUCE A CRUDE PHENOL DISTILLATE
AND A HEAVY WASTE HYDROCARBON STREAM (YDROCARBON IMPURITIES
ARE REMOVED FROM THE CRUDE PHENOL BY HYDROEXTRACTIVE DISTILLATION
FOLLOWED BY CATALYTIC PHENOL TREATMENT AND VACUUM DISTILLATION
TO PRODUCE ULTRA
HIGH
PURITY PHENOL WT
0HENOL IS RECOVERED FROM THE ACETONE l NISHING COLUMN BOTTOMS
BY EXTRACTION WITH CAUSTIC !-3 IN THE RAFl NATE IS THEN CONCENTRATED
HYDROGENATED AND RECOVERED AS CUMENE FOR RECYCLE TO OXIDATION
2El NED !-3 PRODUCTION IS OPTIONAL
Yields: TONS OF PHENOL AND TONS OF ACETONE ARE PRODUCED
FROM TONS OF CUMENE GIVING A PRODUCT YIELD OF OVER
3PENT AIR
!LDEHYDE
PURGE
2ECYCLED
ACETONE
!CETONE
PRODUCT
.A/(
3OLVENT
(
!IR
2ECYCLE CUMENE
,IGHT WASTE
HYDROCARBON
3PENT SULFATE
2ECOVERED
PHENOL
0HENOL
PRODUCT
B
A
#ATALYST
#ATALYST
(EAVY WASTE
HYDROCARBON
Commercial
plants: '% 0LASTICS -T 6ERNON )NDIANA METRIC
TONSYR ;MTPY= REVAMPED IN &ORMOSA #HEMICALS &IBRE #ORPORA
TION 4AIWAN MTPY REVAMPED IN TO DOUBLE THE ORIGINAL
PLANT CAPACITY ,UMMUS HAS MORE THAN YEARS OF PHENOL
PLANT DESIGN
EXPERIENCE
Licensor: !"" ,UMMUS 'LOBAL'% 0LASTICS )LLA )NTERNATIONAL
Phenol
Application: ! HIGH
YIELD PROCESS TO PRODUCE HIGH
PURITY PHENOL AND AC
!CETONE
ETONE FROM CUMENE WITH OPTIONAL BYPRODUCT RECOVERY OF ALPHA METHYL
STYRENE !-3 AND ACETOPHENONE !0
Description: #UMENE IS OXIDIZED WITH AIR AT HIGH EFl CIENCY
TO PRODUCE CUMENE HYDROPEROXIDE #(0 WHICH IS CONCENTRATED
AND CLEAVED UNDER HIGH YIELD CONDITIONS TO PHENOL AND AC
ETONE IN THE PRESENCE OF AN ACID CATALYST 4HE CATALYST IS REMOVED AND
THE CLEAVAGE MIXTURE IS FRACTIONATED TO PRODUCE HIGH PURITY PRODUCTS
n SUITABLE FOR ALL APPLICATIONS !-3 IS HYDROGENATED TO CUMENE
AND RECYCLED TO OXIDATION OR OPTIONALLY RECOVERED AS A PURE BYPRODUCT
0HENOL AND ACETONE ARE PURIl ED ! SMALL AQUEOUS EFm UENT IS PRETREAT
ED TO ALLOW EFl CIENT BIOTREATMENT OF PLANT WASTEWATER 7ITH !-3 HY
DROGENATION TONS OF CUMENE WILL PRODUCE TON OF PHENOL AND
TONS OF ACETONE 4HIS HIGH YIELD PROCESS PRODUCES VERY HIGH
QUALITY PHENOL AND ACETONE PRODUCTS WITH VERY LITTLE HEAVY AND LIGHT
END BYPRODUCTS 7ITH OVER YEARS OF CONTINUOUS TECHNOLOGICAL DEVEL
OPMENT THE +ELLOGG "ROWN 2OOT +"2 PHENOL PROCESS FEATURES LOW
CUMENE AND ENERGY CONSUMPTIONS COUPLED WITH UNSURPASSED SAFETY
AND ENVIRONMENTAL SYSTEMS
Commercial
plants: 4HIRTY PLANTS WORLDWIDE HAVE BEEN BUILT OR ARE NOW
UNDER CONSTRUCTION WITH A TOTAL PHENOL CAPACITY OF OVER --TPY +"2
HAS LICENSED GRASSROOTS PLANTS IN YEARS WITH A TOTAL CAPACITY OF
--TPY 4HREE NEW LICENSES WERE AWARDED IN WITH TWO STARTUPS
SCHEDULED FOR -ORE THAN OF THE WORLDS PHENOL IS PRODUCED
VIA THE +"2 PROCESS
Reference: (YDROCARBON %NGINEERING $ECEMBER*ANUARY
Licensor: +ELLOGG "ROWN 2OOT )NC
!IR
#ATALYST
#UMENE
(YDRO
CARBON
RECOVERY
0HENOL
0HENOL
RECOVERY
7ASTE OILS TO FUEL
%FFLUENT
TREATMENT
7ASTEWATER
!-3 OPTIONAL
Phenol
Application: 4HE 3UNOCO5/0 PHENOL PROCESS PRODUCES HIGH
QUALITY
PHENOL AND ACETONE BY LIQUID
PHASE PEROXIDATION OF CUMENE
3PENT AIR
Description: +EY PROCESS STEPS
Oxidation
and
concentration
(1): #UMENE IS OXIDIZED TO CUMENE
HYDROPEROXIDE #(0 ! SMALL AMOUNT OF DIMETHYLPHENYLCARBINOL $-0#
IS ALSO FORMED BUT LOW
PRESSURE AND LOW
TEMPERATURE OXIDATION RESULTS
IN VERY HIGH SELECTIVITY OF #(0 #(0 IS THEN CONCENTRATED AND UNREACTED
CUMENE IS RECYCLED BACK TO THE OXIDATION SECTION
Decomposition
and
neutralization
(2): #(0 IS DECOMPOSED TO PHENOL
AND ACETONE ACCOMPANIED BY DEHYDRATION OF $-0# TO ALPHAMETHYLSTYRENE
!-3 CATALYZED BY MINERAL ACID 4HIS UNIQUE DESIGN ACHIEVES A VERY HIGH
SELECTIVITY TO PHENOL ACETONE AND !-3 WITHOUT USING RECYCLE ACETONE 4HE
HIGH TOTAL YIELDS FROM OXIDATION AND DECOMPOSITION COMBINE TO ACHIEVE
WT CUMENEWT PHENOL WITHOUT TAR CRACKING $ECOMPOSED CATALYST IS
NEUTRALIZED
Phenol
and
acetone
purification
(3): 0HENOL AND ACETONE ARE
SEPARATED AND PURIl ED ! SMALL AMOUNT OF BYPRODUCT IS REJECTED AS
HEAVY RESIDUE
AMS
hydrogenation
or
AMS
refining
(4): !-3 IS HYDROGENATED BACK
TO CUMENE AND RECYCLED TO OXIDATION OR !-3 IS REl NED FOR SALE
#UMENE PEROXIDATION IS THE PREFERRED ROUTE TO PHENOL ACCOUNTING
FOR MORE THAN OF WORLD PRODUCTION 4HE 3UNOCO5/0 0HENOL PROCESS
FEATURES LOW FEEDSTOCK CONSUMPTION WT CUMENEWT PHENOL
WITHOUT TAR CRACKING AVOIDING THE EXPENSE AND IMPURITIES ASSOCIATED
WITH TAR CRACKING (IGH PHENOL AND ACETONE PRODUCT QUALITIES ARE ACHIEVED
THROUGH A COMBINATION OF MINIMIZING IMPURITY FORMATION AND EFl CIENT
PURIl CATION TECHNIQUES /PTIMIZED DESIGN RESULTS IN LOW INVESTMENT
COST ALONG WITH LOW UTILITY AND CHEMICALS CONSUMPTION FOR LOW VARIABLE
COST OF PRODUCTION $ESIGN OPTIONS FOR BYPRODUCT ALPHAMETHYLSTYRENE
!-3 ALLOW PRODUCERS TO SELECT THE BEST ALTERNATIVE FOR THEIR MARKET
HYDROGENATE !-3 BACK TO CUMENE OR REl NE !-3 FOR SALE .O ACETONE
#UMENE
!IR
/XIDATION
CONCENTRATION
$ECOMPOSITION
AND
NEUTRALIZATION
0HENOL AND
ACETONE
PURIFICATION
!CETONE
0HENOL
2ESIDUE
(
!-3
HYDROGENATION
OR !-3 REFINING
!-3
RECYCLE TO THE DECOMPOSITION CLEAVAGE SECTION SIMPLIl ED NEUTRALIZATION
AND NO TAR CRACKING MAKE THE 3UNOCO5/0 0HENOL PROCESS EASIER TO
OPERATE
Commercial
plants: 4HE 3UNOCO5/0 0HENOL PROCESS IS CURRENTLY USED IN
PLANTS WORLDWIDE HAVING TOTAL PHENOL CAPACITY OF MORE THAN MIL
LION MTPY &OUR ADDITIONAL PROCESS UNITS WITH A TOTAL DESIGN CAPACITY OF
MTPY ARE IN DESIGN AND CONSTRUCTION
Licensor: 3UNOCO AND 5/0 ,,#
Phthalic
anhydride
Application: 4O PRODUCE PHTHALIC ANHYDRIDE 0! FROM O
XYLENE NAPH
THALENE OR MIXTURES OF BOTH FEEDSTOCKS USING A l XED
BED VAPOR PHASE
PROCESS ORIGINALLY KNOWN AS THE VON (EYDEN 0ROCESS
3UPERHEATED (0 STEAM
(0 STEAM
"OILER FEEDWATER
Description: !IR IS HEATED AND LOADED WITH EVAPORATED O
XYLENE AND
OR NAPHTHALENE 4HE HYDROCARBONAIR MIXTURE ENTERS A MULTITUBULAR RE
ACTOR CONTAINING CATALYST !N AGITATED SALT MELT REMOVES THE HEAT OF
REACTION AND MAINTAINS CONSTANT TEMPERATURE CONDITIONS 2EACTION HEAT
GENERATES HIGH
PRESSURE STEAM
-ODERN PLANTS OPERATE WITH O
XYLENE FEEDSTOCK LOADINGS OF n
G.M AIR 4HE LOADINGS OF G.M AIR IN AN ADIABACTIC POST
REACTOR
IS RECOMMENDED WHICH IS INSTALLED IN THE ENLARGED GAS COOLER CASING
2EACTOR EFm UENT GAS IS PRECOOLED IN A GAS COOLER BEFORE PART
OF THE 0! VAPOR IS CONDENSED TO A LIQUID IN THE PRECONDENSOR AND
IS CONTINUOUSLY DISCHARGED TO THE CRUDE 0! TANK 4HE REMAINDER OF
ABOUT G 0!M IN THE REACTION GAS IS CONDENSED AS SOLID SUBLIMATE IN
SWITCH CONDENSORS ON SPECIALLY DESIGNED l NNED TUBES 4HE SWITCH
CONDENSORS ARE PERIODICALLY COOLED AND HEATED IN A DISCONTINUOUS
OPERATION OF AN AUTOMATED SWITCHING CYCLE USING HEAT TRANSFER OIL CIRCUITS
$URING THE HEATING PHASE SOLID 0! IS MELTED FROM THE CONDENSOR TUBES
AND DISCHARGED AS A LIQUID TO CRUDE 0! TANK %Fm UENT GAS IS VENTED TO THE
ATMOSPHERE AFTER WATER SCRUBBING ANDOR INCINERATION
4HE CRUDE 0! IS THERMALLY PRETREATED AND THEN FED TO THE VACUUM
DISTILLATION SYSTEM ,OW BOILING ," IMPURITIES ARE REMOVED IN THE LIGHTS
COLUMN AS ," RESIDUES 4HE HIGH
BOILING (" RESIDUE FROM THE PURE
0! COLUMN IS SENT TO THE RESIDUE BOIL
OUT VESSEL FOR 0! RECOVERY 0URE
0! OBTAINED AS A DISTILLATE CAN BE STORED EITHER IN THE MOLTEN STATE OR
m AKED AND BAGGED
Catalyst: 3PECIAL HIGH PERFORMANCE CATALYSTS OXIDIZE O XYLENE AS WELL AS
NAPHTHALENE AND MIXTURES OF BOTH FEEDSTOCKS IN ANY PROPORTIONS !LL
CATALYSTS ARE RING SHAPED
,0 STEAM
7ASTE GAS
TO INCINERATION
6ACUUM
UNIT
#ATALYTIC
OXIDATION
REACTOR
(0
3TEAM
,0
!IR
3TEAM
HOT OIL
O
8YLENE
.APHTHALENE
(OT
OIL
-ELTED
0!
(4
OIL
3TEAM
#RUDE ,IGHTS
,IQUID
GENERATOR
0! COLUMN
PRECONDENSER
"&7
0URE 0!
PRODUCT
"&7
(OT
OIL
(" RESIDUE
," RESIDUE
Yield: n KG 0! FROM KG OF PURE O
XYLENE n KG 0! FROM
KG OF PURE NAPHTHALENE
Economics: %XCELLENT ENERGY UTILIZATION AND MINIMIZED OFFGAS VOLUME
ARE DUE TO HIGH HYDROCARBON AIR RATIO 0LANTS CAN BE DESIGNED TO OPERATE
INDEPENDENTLY OF EXTERNAL POWER SUPPLY AND EXPORT ELECTRIC ENERGY OR
(0 STEAM
Commercial
plants: -ORE THAN PLANTS WITH TYPICAL PRODUCTION CA
PACITIES OF n TPY WITH A MAXIMUM CAPACITY OF
TPY HAVE BEEN DESIGNED AND BUILT BY ,URGI
Licensor: "!3& !' AND ,URGI !'
Polyalkylene
terephthalates(PET,
PBT,
PTT,
PEN)
#ATALYST $IOL
(/4(&-E/(
0ROCESS COLUMN
Application: .EW PROCESS TO PRODUCE POLYESTERS FROM THE POLYALKYLENE
TEREPHTHALATE FAMILY FROM TEREPHTHALIC ACID 04! OR DIMETHYL TEREPHTHAL
ATE $-4 AND DIOLS USING THE 5)& PROPRIETARY TWO
REACTOR 2 PROCESS
CONSISTING OF TOWER REACTOR %302%% AND $)3#!'% l NISHER OR ALTERNA
TIVELY A SOLID
STATE l NISHING
%302%%
TOWER REACTOR
#ATALYST
Description: ! SLURRY COMPOSED OF A DICARBOXYLIC ACID AND A DIOL IS PRE
PARED AT A LOW MOLE RATIO 4HE SLURRY IS FED TO THE TOWER REACTORS BOTTOM
WHERE THE MAIN ESTERIl CATION OCCURS UNDER PRESSURE OR UNDER VACUUM AT
TEMPERATURES RANGING BETWEEN # TO # 4HIS REACTION MAY BE
CATALYZED OR AUTOCATALYZED
-ONOMER IS TRANSFERRED VIA A PRESSURIZED PIPE TO THE REACTOR TOP
WHERE REACTION SIDE PRODUCTS ARE m ASHED OUT (IGHER CONVERSION RATES
n ARE ACHIEVED BY A CASCADE OF FOUR TO SIX REACTION CUPS AT
DECREASING PRESSURES AND INCREASING TEMPERATURES
3TIRRING AND INTERMIX ARE DONE BY REACTION VAPORS WHILE PASSING
THROUGH THE CUPS ! PRECONDENSATE WITH I6S OF TO IS OBTAINED
AFTER SURFACE
ACTIVE l LM EVAPORATION DONE AS A TWIN ASSEMBLY UNDER
VACUUM AND HIGHER TEMPERATURE
4HE PREPOLYMER MAY BE l NISHED IN THE MELT PHASE WITH 5)&S
$)3#!'% REACTOR OR IN A SOLID
STATING UNIT TO OBTAIN THE REQUIRED END
PRODUCT FEATURES
! PROCESS COLUMN SEPARATES SIDE REACTION LOW BOILERS FROM THE
DIOL WHICH IS THEN RECYCLED BACK TO THE REACTION 3PRAY CONDENSERS AND
VACUUM UNITS RECOVER UNREACTED FEEDSTOCK AND RECYCLE THE DIOL THUS
IMPROVING THE ECONOMICS OF THIS PROCESS
Economics: 4HIS NEW PROCESS REDUCES CONVERSION COST BY MORE THAN
AS COMPARED TO CONVENTIONALHISTORICAL PROCESSES BY ITS COMPACT
DESIGN LOW ENERGY INPUT SHORT
TERM REACTION AND AGITATOR
LESS DESIGN
! PRODUCT YIELD OF MORE THAN IS ATTAINABLE
$IOL
$)3#!'%
04!DIOL
OR $-4DIOL
3OLID
STATE
FINISHING
- -ELT
PHASE
FINISHER
)6 n
0OLYESTERS
)6 n
%NERGY COST CAN BE REDUCED BY MORE THAN !DDITIONALLY THE END
PRODUCTS QUALITY IS IMPROVED DUE TO ELIMINATING INTERMEDIATE PRODUCT
LINES IT OFFERS NARROW RESIDENCE TIME DISTRIBUTION AS WELL AS INTENSIVE
SURFACE RENEWAL AND FAST REACTION
Commercial
plants:
&OUR COMMERCIAL UNITS WITH A TOTAL OPERATING CAPAC
ITY OF MTPD AND ONE PILOT UNIT OF MTPD
References: h#OMPACT CONTINUOUS PROCESS FOR HIGH VISCOSITY 0"4 v 0OLY
ESTER &IFTH 7ORLD #ONGRESS :RICH
Polyalkylene
terephthalates(PET,
PBT,
PTT,
PEN),
CONTINUED
h2 SINGLE
STREAM 0%4 PROCESS ! NEW HIGHLY ECONOMIC POLYESTER TECH
NOLOGY v )NTERNATIONAL &IBRE *OURNAL VOL ISSUE PP n
Licensor: 5HDE )NVENTA &ISCHER
Polycaproamide
Application:
5HDE )NVENTA
&ISCHERS 6+
TUBE PROCESS POLYMERIZES d
CAP
ROLACTAM ,# MONOMER TO PRODUCE POLYCAPROAMIDE NYLON
CHIPS
Description: ,IQUID ,# IS CONTINUOUSLY POLYMERIZED IN A 6+ TUBE IN
THE PRESENCE OF WATER STABILIZER AND MODIFYING ADDITIVES AT ELEVATED
TEMPERATURES 4HE POLYMERIZATION PROCESS HAS PROVEN TO BE VERY RELIABLE
EASY TO OPERATE AND ECONOMICAL 0REPOLYMERIZATION IS AVAILABLE TO REDUCE
REACTOR VOLUME FOR LARGE CAPACITY UNITS 4HE POLYCAPROAMIDE CHIPS ARE
FORMED FROM THE MELT USING STRAND CUTTERS AND ARE CONVEYED TO THE EX
TRACTION COLUMN
4HE CHIPS CONTAINING ABOUT OF MONOMER AND CYCLIC
OLIGOMERS ARE TREATED WITH HOT WATER IN THE EXTRACTION COLUMN 4HE
EXTRACTABLES ARE REMOVED TO A VERY LARGE EXTENT TO ACHIEVE A GOOD
POLYMER QUALITY AND HIGH PERFORMANCE WHEN PROCESSED FURTHER
7ET CHIPS ARE SENT TO THE CENTRIFUGE AND DRIED BY HOT DRY NITROGEN
IN A TWO ZONE DRYER 4HE NITROGEN GAS IS REGENERATED IN SEPARATE
CYCLES )N THE BOTTOM ZONE OF THE DRYER THE CHIPS ARE COOLED VIA A HEAT
EXCHANGER
4HE DRYING UNIT CAN BE EXTENDED TO A SOLID STATE POSTCONDENSATION
IE DRYING AND SOLID STATE POSTCONDENSATION OCCURS IN ONE PROCESS STAGE
4HUS HIGH VISCOSITY CHIPS FOR INDUSTRIAL YARNS l LMS AND EXTRUSION MOLDED
PARTS CAN BE PRODUCED
,OW UTILITY AND ENERGY CONSUMPTION ARE ACHIEVED BY USING CLOSED
CIRCUITS OF WATER AND NITROGEN AS WELL AS BY RECOVERING HEAT 4HE RECOVERY
PROCESS FOR THE RECYCLING OF THE EXTRACTABLES REDUCES RAW MATERIAL COST
%XTRACT WATER IS CONCENTRATED AND DIRECTLY RE FED TO THE POLYMERIZATION
UNIT !LTERNATIVELY THE CONCENTRATED EXTRACT IS FED TO A SEPARATE SPECIALLY
DESIGNED CONTINUOUS REPOLYMERIZATION UNIT
"ATCH AND CONTINUOUS PROCESS UNITS ARE AVAILABLE TO MEET ALL POTENTIAL
REQUIREMENTS REGARDING POLYMER GRADES AS WELL AS REGARDING m EXIBILITY IN
OUTPUT RATES AND CAPACITIES 3PECIAL ATTENTION IS DEVOTED DURING PLANT
DESIGN TO ATTAIN MINIMAL OPERATING EXPENSES FOR RAW MATERIAL UTILITIES
AND PERSONNEL
!DDITIVE
PREPARATION
0OLYMERIZATION
$RYING
%XTRACTION
#APROLACTAM
2EFEEDING
6+
TUBE
#HIPS
PRODUCTION
.
(
.
%XTRACTABLES
RECOVERY
Licensor: 5HDE )NVENTA &ISCHER
&INAL 0! CHIPS
Polyesters
(polyethylene
terephthalate)
2EACTION VAPORS
Application: 4O PRODUCE POLYESTERS FOR RESIN AND TEXTILE APPLICATIONS FROM
TEREPHTHALIC ACID 04! OR DIMETHYL TEREPHTHALATE $-4 AND DIOLS ;ETH
YLENE GLYCOL %' OR OTHERS= USING THE 5)&
PROPRIETARY FOUR
REACTOR2
PROCESS INCLUDING $)3#!'%
l NISHER
#ATALYST4I/
04! n )0! n
DIOL SLURRY
Description: ! SLURRY COMPOSED OF 04! AND %' OR MOLTEN $-4 AND %'
IS FED TO THE l RST ESTERIl CATIONESTER
INTERCHANGE REACTOR IN WHICH
MAIN REACTION OCCURS AT ELEVATED PRESSURE AND TEMPERATURES #n
# 2EACTION VAPORSWATER OR METHANOL ARE SENT TO A LOWHIGH
BOILER SEPARATION COLUMN (IGH BOILERS ARE REUSED AS FEEDSTOCK
4HE OLIGOMER IS SENT TO A SECOND CASCADED STIRRED REACTOR
OPERATING AT A LOWER PRESSURE AND A HIGHER TEMPERATURE 4HE REACTION
CONVERSION CONTINUES TO MORE THAN #ATALYST AND ADDITIVES MAY BE
ADDED 2EACTION VAPORS ARE SENT TO THE PROCESS COLUMN 4HE OLIGOMER
IS THEN PREPOLYMERIZED BY A THIRD CASCADED REACTOR UNDER SUB
ATMOSPHERIC PRESSURE AND INCREASED TEMPERATURE TO OBTAIN A DEGREE OF
POLYCONDENSATION &INAL POLYCONDENSATION UP TO INTRINSIC VISCOSITIES
OF I 6 IS DONE IN THE $)3#!'%
l NISHER 0ELLETIZING OR DIRECT
MELT CONVERSION USAGE IS OPTIONAL
%' IS RECOVERED BY CONDENSING PROCESS VAPORS AT VACUUM CONDITIONS
6ACUUM GENERATION MAY BE DONE EITHER BY WATER VAPOR AS A MOTIVE
STREAM OR BY THE DIOL %' 4HE AVERAGE PRODUCT YIELD EXCEEDS
Economics: 4YPICAL UTILITY REQUIREMENTS PER METRIC TON OF 0%4 ARE
%LECTRICITY K7H
&UEL OIL KG
.ITROGEN .M
!IR .M
Commerical
plants: 4HIRTEEN LINES WITH PROCESSING CAPACITIES RANGING
FROM TO MTPD ARE OPERATING MORE THAN POLYESTER #0 PLANTS
(/ TO
STRIPPER
#ATALYST
ADDITIVES
$)3#!'%
FINISHER
$-4
DIOL
-
-
0%4 MELT
CHIPS
$IOL RECYCLING
%STERIFICATION
0REPOLYCONDENSATION
0OLYCONDENSATION
HAVE BEEN BUILT WORLDWIDE 0RESENTLY MTPD LINES ARE IN OPERATION AS
SINGLE
TRAIN LINES INCLUDING A SINGLE l NISHER
Licensor: 5HDE )NVENTA &ISCHER
Polyethylene,
HDPE
Application: 4O PRODUCE HIGH
DENSITY POLYETHYLENE ($0% USING THE
Products: 4HE CASCADE TECHNOLOGY ENABLES THE MANUFACTURING OF TAI
LOR MADE PRODUCTS WITH A DEl NITE -7$ FROM NARROW TO BROAD -7$
4HE MELT m OW INDEX MAY VARY FROM BIMODAL PRODUCT TO OVER
UNIMODAL PRODUCT (OMOPOLYMERS AND COPOLYMERS ARE USED IN VARIOUS
4O SCRUBBER
#ATALYST
COMPONENTS
0OST
REACTOR
2EACTORS
#ATALYST
STORAGE
VESSEL
2ECEIVER
&ROM REFRIGERANT
Description: 4HE (OSTALEN PROCESS IS A SLURRY POLYMERIZATION METHOD WITH
TWO REACTORS PARALLEL OR IN SERIES 3WITCHING FROM A SINGLE REACTION TO A RE
ACTION IN CASCADE ENABLES PRODUCING TOP QUALITY UNIMODAL AND BIMODAL
POLYETHYLENE 0% FROM NARROW TO BROAD MOLECULAR WEIGHT DISTRIBUTION
-7$ WITH THE SAME CATALYST
0OLYMERIZATION OCCURS IN A DISPERSING MEDIUM SUCH AS N
HEXANE
USING A VERY HIGH
ACTIVITY :IEGLER CATALYST .O DEACTIVATION AND CATALYST
REMOVAL IS NECESSARY BECAUSE A VERY LOW LEVEL OF CATALYST RESIDUE REMAINS
IN THE POLYMER &OR UNIMODAL
GRADE PRODUCTION THE CATALYST THE DISPERS
ING MEDIUM MONOMER AND HYDROGEN ARE FED TO THE REACTOR WHERE
POLYMERIZATION OCCURS )N THE CASE OF BIMODAL GRADE PRODUCTION THE
CATALYST IS ONLY FED TO THE l RST REACTOR THE SECOND STEP POLYMERIZATION
OCCURS UNDER DIFFERENT REACTION CONDITIONS WITH RESPECT TO THE l RST REAC
TOR !LSO ETHYLENE BUTENE AND FURTHER DISPERSING MEDIUM ARE FED TO THE
SECOND REACTOR 2EACTOR CONDITIONS ARE CONTROLLED CONTINUOUSLY THUS
A VERY HIGH
QUALITY 0% IS MANUFACTURED
&INALLY THE ($0% SLURRY FROM THE SECOND REACTOR IS SENT TO THE POST
REACTOR TO REDUCE DISSOLVED MONOMER AND NO MONOMER RECYCLING IS
NEEDED )N THE DECANTER THE POLYMER IS SEPARATED FROM THE DISPERS
ING MEDIUM 4HE POLYMER CONTAINING THE REMAINING HEXANE IS DRIED IN A
m UIDIZED BED DRYER AND THEN PELLETIZED IN THE EXTRUSION SECTION 4HE
SEPARATED AND COLLECTED DISPERSING MEDIUM OF THE m UID SEPARATION STEP
WITH THE DISSOLVED CO
CATALYST AND COMONOMER IS RECYCLED TO THE PO
LYMERIZATION REACTORS ! SMALL PART OF THE DISPERSING MEDIUM IS DISTILLED
TO MAINTAIN THE COMPOSITION OF THE DILUENT
4O BUTENE RECOVERY
&ROM SCRUBBER
STIRRED TANK HEAVY DILUENT (OSTALEN PROCESS
#YCLONE
%THYLENE #OMONOMER (YDROGEN
#OOLER
-AKEUP COCATALYST
0URIFIED HEXANE
(EATER
#OLLECTING VESSEL
&LUID
BED
DRYER
#OARSE
GRAIN
/"3,
3CREEN
'RANULATION
#YCLE NITROGEN
4O TANK FARM
&ROM BUTENE
RECOVERY
APPLICATIONS SUCH AS BLOW MOLDING LARGE CONTAINERS SMALL BOTTLES EX
TRUSION MOLDING l LM PIPES TAPES AND MONOl LAMENTS FUNCTIONAL PACK
AGING AND INJECTION MOLDING CRATES WASTE BINS TRANSPORT CONTAINERS
Economics: #ONSUMPTION PER METRIC TON OF 0% BASED ON GIVEN PRODUCT
MIX
%THYLENE AND COMONOMER T
%LECTRICITY K7H
3TEAM KG
7ATER COOLING WATER $4 # MT
Commercial
plants: 4HERE ARE (OSTALEN PLANTS IN OPERATION OR UNDER
Polyethylene,
HDPE, CONTINUED
CONSTRUCTION WITH A TOTAL LICENSED CAPACITY OF NEARLY MILLION TPY )NDI
VIDUAL CAPACITY CAN RANGE UP TO TPY FOR A SINGLE
LINE INSTALLATION
Licensor: "ASELL 0OLYOLElNS
Polyethylene,
LDPE
Application: 4HE HIGH
PRESSURE ,UPOTECH 43 OR 4- TUBULAR REACTOR PRO
,OW PRESSURE RECYCLE
CESS IS USED TO PRODUCE LOW DENSITY POLYETHYLENE ,$0% HOMOPOLYMERS
AND %6! COPOLYMERS 3INGLE TRAIN CAPACITY OF UP TO TPY CAN BE
PROVIDED
(IGH
PRESSURE RECYCLE
2EACTOR
Description: %THYLENE INITIATOR AND IF APPLICABLE COMONOMERS ARE FED TO
THE PROCESS AND COMPRESSED TO PRESSURES UP TO BAR BEFORE ENTERING
THE TUBULAR REACTOR )N THE 43 MODE THE COMPLETE FEED ENTERS THE REACTOR
AT THE INLET AFTER THE PREHEATER IN THE 4- MODE PART OF THE GAS IS COOLED
AND QUENCHES THE REACTOR CONTENTS AT VARIOUS POINTS OF INJECTION
4HE POLYMER PROPERTIES -) R -7$ ARE CONTROLLED BY THE INITIATOR
PRESSURE TEMPERATURE PROl LE AND COMONOMER CONTENT !FTER THE REAC
TOR EXCESS ETHYLENE IS RECOVERED AND RECYCLED TO THE REACTOR FEED STREAM
4HE POLYMER MELT IS MIXED WITH ADDITIVES IN AN EXTRUDER TO YIELD THE l NAL
PRODUCT
! RANGE OF PRODUCTS CAN BE OBTAINED USING THE ,UPOTECH 4 PROCESS
RANGING FROM STANDARD ,$0% GRADES TO %6! COPOLYMERS OR . BUTYL AC
RYLATE MODIl ED COPOLYMER 4HE PRODUCTS CAN BE APPLIED IN SHRINK l LM
EXTRUSION INJECTION MOLDING EXTRUSION BLOW MOLDING PIPE EXTRUSION
PIPE COATING TAPES AND MONOl LAMENTS
4HERE IS NO LIMIT TO THE NUMBER OF REACTOR GRADES THAT CAN BE PRO
DUCED 4HE PRODUCT MIX CAN BE ADJUSTED TO MATCH MARKET DEMAND AND
ECONOMICAL PRODUCT RANGES !DVANTAGES FOR THE TUBULAR REACTOR DESIGN
WITH LOW RESIDENCE TIME ARE EASY AND QUICK TRANSITIONS STARTUP AND SHUT
DOWN
2EACTOR GRADES FROM -) TO AND FROM DENSITY TO
GCM WITH COMONOMER CONTENT UP TO CAN BE PREPARED
Economics: #ONSUMPTION PER METRIC TON OF 0%
%THYLENE T
%LECTRICITY K7H
3TEAM T
.ITROGEN .M
n
n EXPORT CREDIT
%THYLENE
#OMONOMER
%XTRUDER
Commercial
plants: -ANY ,UPOTECH 4 PLANTS HAVE BEEN INSTALLED AFTER
THE l RST PLANT IN WITH A TOTAL LICENSED CAPACITY OF MILLION TONS
"ASELL OPERATES ,$0% PLANTS IN %UROPE WITH A TOTAL CAPACITY OF CLOSE TO
MILLION TPY 4HE NEWEST STATE
OF
THE
ART ,UPOTECH 43 UNIT AT "ASELLS SITE
IN !UBETTE &RANCE WAS COMMISSIONED IN WITH A CAPACITY OF
THOUSAND TONS IT IS THE LARGEST SINGLE
LINE ,$0% PLANT
Licensor: "ASELL 0OLYOLEl NS
Polyethylene
Application: .EW GENERATION 3PHERILENE GAS
PHASE TECHNOLOGY WITH SIM
-ONOMERS
RECOVERY
Description: #ATALYST COMPONENTS ARE MIXED AND FED DIRECTLY TO A PRE
CONTACT VESSEL WHERE THE CATALYST IS ACTIVATED UNDER CONTROLLED CONDI
TIONS 4HE ACTIVATED CATALYST SYSTEM m OWS CONTINUOUSLY INTO THE l RST GAS
PHASE REACTOR '02 ! COOLER ON THE CIRCULATION GAS LOOP REMOVES
THE REACTION HEAT
0RODUCT CONTAINING STILL ACTIVE CATALYST IS CONTINUOUSLY DISCHARGED
FROM THE l RST '02 VIA A PROPRIETARY DEVICE TO A SECOND '02 WITH SIMI
LAR CONl GURATION 2ESULTANT DISCHARGED GAS IS RECOVERED AND NO GAS FROM
THE l RST '02 ENTERS THE SECOND '02 DUE TO A PROPRIETARY hLOCK
HOPPERv
SYSTEM 4HE SECOND '02 IS INDEPENDENTLY SUPPLIED WITH NECESSARY
MONOMER COMONOMER AND HYDROGEN TO MAINTAIN REACTION CONDITIONS
TRULY INDEPENDENT FROM THE l RST '02 4HIS GIVES 3PHERILENE PROCESS THE
ABILITY TO PRODUCE TRULY BIMODAL ($0% GRADES AND THE ADDED FREEDOM TO
OBTAIN hINVERSEv COMONOMER DISTRIBUTION IN THE l NAL PRODUCT BY SELEC
TIVELY FEEDING COMONOMER ONLY WHERE NECESSARY 0RESSURE AND TEMPERA
TURE IN THE '02S ARE ALSO INDEPENDENTLY CONTROLLED WHILE NO ADDITIONAL
FEED OF CATALYTIC COMPONENTS TO THE SECOND '02 IS REQUIRED
4HE POLYMER IN SPHERICAL FORM WITH PARTICLE SIZE RANGING FROM AP
PROXIMATELY MM TO MM IS THEN DISCHARGED IN A RECEIVER RECOVERING
THE RESULTANT GAS AND TO A PROPRIETARY UNIT FOR MONOMER STRIPPING
AND NEUTRALIZATION OF ANY REMAINING CATALYST ACTIVITY 2ESIDUAL HYDRO
CARBONS IN THE POLYMER ARE STRIPPED OUT AND RECYCLED BACK TO REACTION
4HE POLYMER IS DRIED BY A CLOSED
LOOP NITROGEN SYSTEM AND WITH NO
VOLATILE SUBSTANCES IS SENT TO LIQUID ANDOR SOLID ADDITIVES INCORPORATION
STEP BEFORE EXTRUSION
-ONOMERS
RECOVERY
#7
#ATALYST
COCATALYST
-ONOMERS #OMONOMERS
(YDROGEN
#ATALYST ACTIVATION
!DDITIVES
3TEAM
%XTRUSION
PLIl ED PROCESS m OW SCHEME TO PRODUCE LINEAR LOW DENSITY POLYETHYLENE
,,$0% MEDIUM DENSITY POLYETHYLENE -$0% AND HIGH DENSITY POLYETH
YLENE ($0% OF NARROW UNIMODAL MOLECULAR WEIGHT DISTRIBUTION AS WELL
AS BIMODAL MOLECULAR WEIGHT DISTRIBUTION USING ONLY A SINGLE :IEGLER
.ATTA TITANIUM BASED CATALYST FAMILY WITH FULL ONLINE SWING CAPABILITY
WITHOUT SHUTDOWNS
0%
PELLETS
.ITROGEN
'AS PHASE
POLYMERIZATION
TWO GAS
PHASE REACTORS SET
UP
&INISHING
3TEAMING DRYING
ADDITIVATION
Products: 0RODUCT DENSITY RANGE IS VERY WIDE FROM APPROXIMATELY
GCC ,,$0% TO GCC ($0% INCLUDING FULL ACCESS TO THE -$0%
RANGE TO GCC -ELT INDEX -) CAPABILITY RANGES FROM
TO G MIN "ECAUSE OF THE DUAL '02 SET
UP 3PHERILENE TECHNOL
OGY ENABLES PRODUCTION OF PREMIUM BIMODAL GRADES -) DENSITY IN GAS
PHASE WITH hINVERSEv COMONOMER DISTRIBUTION HITHERTO AVAILABLE ONLY
VIA MORE INVESTMENT
INTENSIVE SLURRY TECHNOLOGIES #OMMERCIALLY PROVEN
GRADES INCLUDE BIMODAL ($0% FOR PRESSURE PIPE MARKETS WITH 0% CER
TIl CATION AND BIMODAL ($0% GRADES FOR HIGH
STRENGTH l LM MARKETS 4RA
DITIONAL ($0% GRADES FOR INJECTION MOLDING AND EXTRUSION APPLICATIONS A
Polyethylene, CONTINUED
FULL RANGE OF ,,$0% PRODUCTS FOR CAST AND BLOWN lLM EXTRUSION COATING
AND INJECTION MOLDING APPLICATIONS AS WELL AS -$0% PRODUCTS FOR ROTO
MOLDING GEOMEMBRANES TEXTILE AND RAFlA ARE AVAILABLE
Economics: #ONSUMPTION PER METRIC TON OF ,,$0%
%THYLENE AND COMONOMER T
%LECTRICITY K7H
3TEAM KG
7ATER COOLING $4 # MT
Commercial
plants: ,ICENSED FROM NINE PLANTS USING 3PHERILENE
PROCESS AND TECHNOLOGY HAVE BEEN LICENSED WITH A TOTAL CAPACITY OF
MILLION TPY 3INGLE
LINE CAPACITIES IN OPERATION RANGE FROM
TO TPY WITH CURRENT PROCESS DESIGN AVAILABLE FOR PLANTS UP TO
TPY IN SINGLE
LINE CAPACITY
Licensor: "ASELL 0OLYOLElNS
Polyethylene
Application: 4HE )NNOVENE ' GAS PHASE PROCESS PRODUCES LINEAR
LOW
DENSITY POLYETHYLENE ,,$0% AND HIGH
DENSITY POLYETHYLENE ($0% US
ING EITHER :IEGLER
.ATTA CHROMIUM OR METALLOCENE CATALYSTS
#YCLONE
Description: :IEGLER
.ATTA AND METALLOCENE CATALYSTS ARE DIRECTLY INJECTED
INTO THE REACTOR FROM STORAGE WHEREAS CHROMIUM CATALYSTS ARE INJECTED
FOLLOWING ACTIVATION OF THE CATALYST VIA "0 PROPRIETARY TECHNOLOGY 4HE "0
CATALYST PORTFOLIO ENABLES THE PRODUCTION OF A FULL
RANGE OF 0% PRODUCTS
WITH THE SAME SWING REACTOR USING THESE THREE MAIN CATALYST FAMILIES
!CCURATE CONTROL OF ALL THE PRODUCT PROPERTIES SUCH AS DENSITY AND
MELT INDEX IS ACHIEVED BY CONTINUOUS AND AUTOMATIC ADJUSTMENT OF THE
PROCESS GAS COMPOSITION AND OPERATING CONDITIONS 4HE REACTOR IS
DESIGNED TO ENSURE GOOD MIXING AND A UNIFORM TEMPERATURE /PERATING
CONDITIONS WITHIN THE BED ARE MILD THE PRESSURE IS ABOUT BAR G AND
THE TEMPERATURE BETWEEN # AND # 0OLYMER PARTICLES GROW IN THE
m UIDIZED BED REACTOR WHERE THE m UIDIZATION GAS IS A MIXTURE OF ETHYLENE
COMONOMER HYDROGEN AND NITROGEN &INE PARTICLES LEAVING THE REACTOR
WITH THE EXIT GAS ARE COLLECTED BY CYCLONES WHICH ARE UNIQUE TO THE
)NNOVENE GAS
PHASE TECHNOLOGY AND RECYCLED TO THE REACTOR 4HIS FEATURE
ENSURES THAT l NE PARTICLES DO NOT CIRCULATE IN THE REACTION LOOP WHERE
THEY COULD FOUL THE COMPRESSOR EXCHANGER AND REACTOR GRID 4HE CYCLONES
ALSO PREVENT PRODUCT CONTAMINATION DURING TRANSITIONS 5NREACTED GAS IS
COOLED AND SEPARATED FROM ANY LIQUID COMPRESSED AND RETURNED
TO THE REACTOR MAINTAINING THE GROWING POLYMER PARTICLES AT THE DESIRED
TEMPERATURE #ATALYSTS ARE INCORPORATED INTO THE l NAL PRODUCT WITHOUT
ANY CATALYST REMOVAL STEP
4HE REACTOR AND ALMOST ALL OTHER EQUIPMENT IS MADE FROM CARBON
STEEL 0OLYMER POWDER IS WITHDRAWN FROM THE REACTOR VIA A PROPRIETARY
LATERAL DISCHARGE SYSTEM AND SEPARATED FROM ASSOCIATED PROCESS GAS IN
A SIMPLE DEGASSING STAGE USING HOT RECIRCULATING NITROGEN 4HE POWDER
IS THEN PNEUMATICALLY CONVEYED TO THE l NISHING SECTION WHERE ADDITIVES
ARE INCORPORATED BEFORE PELLETIZATION AND STORAGE
%XCHANGER
0OLYMER
FINISHING
2EACTOR
%THYLENE
#OMONOMER
(YDROGEN
#OMPRESSOR
)NJECTION
NOZZLE
3EPARATOR
0UMP
Economics: 4HE LOW
PRESSURE TECHNOLOGY AND EASE OF OPERATION ENSURES
THAT THE )NNOVENE PROCESS IS INHERENTLY SAFE BEST
IN
CLASS ENVIRONMEN
TALLY AND ECONOMICALLY ATTRACTIVE WITH REGARD TO BOTH INVESTMENT CAPEX
AND OPEX
Products: ! WIDE RANGE OF ,,$0% AND ($0% PRODUCTS CAN BE PRODUCED
WITHIN THE SAME REACTOR ,,$0% IS USED IN l LM INJECTION MOLDING AND
EXTRUSION APPLICATIONS AND CAN BE MADE USING EITHER BUTENE OR HEXENE
AS THE COMONOMER .ARROW MOLECULAR WEIGHT ($0% PROVIDES SUPERIOR IN
JECTION MOLDING AND ROTATIONAL MOLDING GRADES WHEREAS BROAD MOLECULAR
WEIGHT ($0% IS USED FOR BLOW MOLDING PIPE l LM AND OTHER EXTRUSION
APPLICATIONS
Polyethylene, CONTINUED
Commercial
plants: 4HIRTY
lVE REACTOR LINES ARE OPERATING IN DESIGN OR
UNDER CONSTRUCTION WORLDWIDE REPRESENTING AROUND --TPY PRODUC
TION WITH CAPACITIES RANGING FROM TPY TO TPY $ESIGNS UP
TO TPY ARE ALSO AVAILABLE
Licensor: "0
Polyethylene
Application: 4O PRODUCE LOW
DENSITY POLYETHYLENE ,$0% HOMOPOLYMERS
AND %6! COPOLYMERS USING THE HIGH
PRESSURE FREE RADICAL PROCESS ,ARGE
SCALE TUBULAR REACTORS WITH A CAPACITY IN THE RANGE OF n -TPY AS WELL
AS STIRRED AUTOCLAVE REACTORS WITH CAPACITY AROUND -TPY CAN BE USED
-ODIFIER
COMONOMERS
Description: ! VARIETY OF ,$0% HOMOPOLYMERS AND COPOLYMERS CAN BE
#
PRODUCED ON THESE LARGE REACTORS FOR VARIOUS APPLICATIONS INCLUDING l LMS
MOLDING AND EXTRUSION COATING 4HE MELT INDEX POLYMER DENSITY AND
MOLECULAR WEIGHT DISTRIBUTION ARE CONTROLLED WITH TEMPERATURE PROl LE
PRESSURE INITIATOR AND COMONOMER CONCENTRATION !UTOCLAVE REACTORS
CAN GIVE NARROW OR BROAD MOLECULAR WEIGHT DISTRIBUTION DEPENDING ON
THE SELECTED REACTOR CONDITIONS WHEREAS TUBULAR REACTORS ARE TYPICALLY
USED TO PRODUCE NARROW MOLECULAR WEIGHT DISTRIBUTION POLYMERS
'ASEOUS ETHYLENE IS SUPPLIED TO THE BATTERY LIMITS AND BOOSTED TO
BAR BY THE PRIMARY COMPRESSOR 4HIS MAKEUP GAS TOGETHER WITH THE
RECYCLE GAS STREAM IS COMPRESSED TO REACTOR PRESSURE IN THE SECONDARY
COMPRESSOR 4HE TUBULAR REACTORS OPERATE AT PRESSURES UP TO BAR
WHEREAS AUTOCLAVES NORMALLY OPERATE BELOW BAR 4HE POLYMER
IS SEPARATED IN A HIGH
AND LOW
PRESSURE SEPARATOR NONREACTED GAS IS
RECYCLED FROM BOTH SEPARATORS -OLTEN POLYMER FROM THE LOW
PRESSURE
SEPARATOR IS FED INTO THE EXTRUDER POLYMER PELLETS ARE THEN TRANSFERRED
TO STORAGE SILOS
4HE MAIN ADVANTAGES FOR THE HIGH
PRESSURE PROCESS COMPARED TO
OTHER 0% PROCESSES ARE SHORT RESIDENCE TIME AND THE ABILITY TO SWITCH FROM
HOMOPOLYMERS TO COPOLYMERS INCORPORATING POLAR COMONOMERS IN THE
SAME REACTOR 4HE HIGH
PRESSURE PROCESS PRODUCES LONG
CHAIN BRANCHED
PRODUCTS FROM ETHYLENE WITHOUT EXPENSIVE COMONOMERS THAT ARE REQUIRED
BY OTHER PROCESSES TO REDUCE PRODUCT DENSITY !LSO THE HIGH
PRESSURE
PROCESS ALLOWS FAST AND EFl CIENT TRANSITION FOR A BROAD RANGE OF POLYMERS
Products: 0OLYMER DENSITY IN THE RANGE UP TO FOR HOMO
POLYMERS THE MELT INDEX MAY BE VARIED FROM TO GREATER THAN
6INYLACETATE CONTENT UP TO WT
#OMPRESSOR
#OOLER
)NIT
2EACTOR
(03
#OMPRESSORS
3EPARATORS
,03
%XTRUDER
3ILO
Economics:
2AW MATERIALS AND UTILITIES PER METRIC TON OF PELLETIZED POLYMER
%THYLENE TONTON
%LECTRICITY K7H
3TEAM TONTON
.ITROGEN .MT
Commercial
plants: !Fl LIATES OF %XXON-OBIL #HEMICAL 4ECHNOLOGY ,ICENS
ING ,,# OPERATE HIGH
PRESSURE REACTORS ON A WORLDWIDE BASIS WITH A
CAPACITY OF APPROXIMATELY --TPY (OMOPOLYMERS AND A VARIETY OF
COPOLYMERS ARE PRODUCED 3INCE %XXON-OBIL #HEMICAL 4ECHNOL
OGY ,ICENSING ,,# HAS SOLD LICENSES WITH A TOTAL INSTALLED CAPACITY EITHER
Polyethylene, CONTINUED
IN OPERATION OR UNDER CONSTRUCTION OF APPROXIMATELY MILLION TPY
Licensor: %XXON-OBIL #HEMICAL 4ECHNOLOGY ,ICENSING ,,#
Polyethylene
Applications: 4O PRODUCE HIGH DENSITY POLYETHYLENE ($0% AND MEDIUM
DENSITY POLYETHYLENE -$0% UNDER LOW
PRESSURE SLURRY PROCESSh#8
PROCESSv
Description: 4HE #8 PROCESS USES TWO POLYMERIZATION REACTORS IN SE
RIES 4HE PRODUCTS HAVE BIMODAL MOLECULAR WEIGHT DISTRIBUTION -7$
WHERE -7$ AND COMPOSITION DISTRIBUTION IS FREELY AND EASILY CONTROLLED
BY ADJUSTING THE OPERATING CONDITIONS OF TWO REACTORS WITHOUT CHANGING
THE CATALYST
4HIS PROCESS PRODUCES A WIDE MELT INDEX RANGE BY APPLYING INNO
VATIVE CATALYST CHEMISTRY COMBINED WITH A SOPHISTICATED POLYMERIZATION
PROCESS !N ALL ROUND CATALYST AND SIMPLE POLYMERIZATION OPERATION PRO
VIDE EASY PRODUCT CHANGEOVER THAT REDUCES TRANSITION TIME AND YIELDS
NEGLIGIBLE OFF SPEC PRODUCT FROM THE TRANSITION -ITSUI HAS ALSO DEVEL
OPED NEW CATALYST THAT CONTRIBUTES BETTER MORPHOLOGY OF THE POLYMER
POWDER AND ETHYLENE CONSUMPTION
%THYLENE HYDROGEN CO MONOMER AND A SUPER HIGH ACTIVITY CATA
LYST ARE FED INTO THE REACTORS 0OLYMERIZATION REACTION OCCURS UNDER
A SLURRY STATE 4HE AUTOMATIC POLYMER PROPERTY CONTROL SYSTEM PLAYS A
VERY EFFECTIVE ROLE IN PRODUCT QUALITY CONTROL 3LURRY FROM THE REACTORS IS
PUMPED TO THE SEPARATION SYSTEM 4HE WETCAKE IS DRIED INTO POWDER
IN THE DRYER SYSTEM !S MUCH AS OF THE SOLVENT IS SEPARATED FROM
THE SLURRY AND IS DIRECTLY RECYCLED TO THE REACTORS WITHOUT ANY TREATMENT
4HE DRY POWDER IS PELLETIZED IN THE PELLETIZING SYSTEM ALONG WITH RE
QUIRED STABILIZERS
Products: "ROAD RANGE OF HOMO
POLYMER AND COPOLYMER CAN BE PRO
DUCED INCLUDING 0% PIPE GRADE
-ELT INDEX
-OLECULAR
WEIGHT DISTRIBUTION
#OMONOMER DISTRIBUTION
$ENSITY
TO
&REELY CONTROLLED FROM
NARROW TO VERY WIDE
TO
3EPARATION
AND DRYING
0OLYMERIZATION
%THYLENE
0ELLETIZING
3TABILIZER
3ILO STORAGE
AND PACKING
#ATALYST
0ACKING AND
SHIPPING
Economics: 4YPICAL CONSUMPTION PER METRIC TON OF NATURAL ($0% PELLETS
%THYLENE AND CO
MONOMER KG
%LECTRICITY K7H
3TEAM KG
7ATER COOLING T
Commercial
plants: &ORTY
ONE REACTION LINES OF #8 PROCESS ARE IN OPERA
TION OR CONSTRUCTION WORLDWIDE WITH A TOTAL PRODUCTION CAPACITY OF OVER
MILLION TPY
Licensor: -ITSUI #HEMICALS )NC
Polyethylene
Application: 4HE 3#,!)24%#( TECHNOLOGY 0% PROCESS CAN PRODUCE
LINEAR
LOW
DENSITY MEDIUM
DENSITY AND HIGH
DENSITY POLYETHYLENE 0%
WITH NARROW TO BROAD MOLECULAR WEIGHT DISTRIBUTION USING EITHER :IEGLER
.ATTA :. OR PROPRIETARY SINGLE
SITE CATALYST 33#
2ECOVERY AND
RECYCLE
#OMONOMERS
Description: %THYLENE AND COMONOMER ARE DISSOLVED IN SOLVENT THEN FED
INTO A REACTOR "UTENE
OCTENE
OR BOTH TOGETHER CAN BE USED AS CO
MONOMER 4HE REACTOR SYSTEM OPERATES IN A SOLUTION PHASE AND DUE
TO INHERENT LOW RESIDENCE TIME LESS THAN MINUTES IT OFFERS A TREMEN
DOUS m EXIBILITY FOR GRADE TRANSITIONS AND SIGNIl CANT VERSATILITY FOR MEET
ING PRODUCT NEEDS OF A DIVERSE MARKET
(IGH CONVERSIONS MAXIMIZE PRODUCTION AND ELIMINATE ANY POTENTIAL
FOR RUNAWAY REACTIONS ! HYDROCARBON SOLVENT IS USED TO KEEP THE CON
TENTS OF THE REACTOR IN SOLUTION AND ALSO AIDS IN HEAT REMOVAL 4HE SOLVENT
IS m ASHED AND RECOVERED ALONG WITH THE ENERGY CAPTURED FROM THE HEAT
OF REACTION AND CIRCULATED BACK TO THE REACTOR -OLTEN POLYMER IS SENT TO
A SIMPLE EXTRUDER AND PELLETIZER ASSEMBLY
3EPARATION
0URIFICATION
%THYLENE
2EACTOR
FEED
2EACTOR
SYSTEM
%XTRUSION
4O FINISHING
0ELLITIZER
Products: 3#,!)24%#( PROCESS CAN PRODUCE 0% PRODUCTS WITH DENSITY
RANGE OF n KGM MELT INDEX -) FROM TO IN EXCESS OF
AND NARROW TO BROAD MOLECULAR WEIGHT DISTRIBUTION -7$ 4HIS
ALLOWS PRODUCERS TO PARTICIPATE IN THE MAJORITY OF THE POLYETHYLENE MAR
KET SEGMENTS INCLUDING AMONG LOW MEDIUM AND HIGH DENSITY l LMS
ROTATIONAL INJECTION AND BLOW MOLDING APPLICATIONS
0RODUCTS MADE WITH THIS TECHNOLOGY OFFER EXCEPTIONAL QUALITY AS
MEASURED BY LOW GEL SUPERIOR OPTICALS AND LOT TO LOT CONSISTENCY ALONG
WITH HIGH PERFORMANCE CHARACTERISTICS FOR DEMANDING APPLICATIONS
Economics: 4HIS TECHNOLOGY OFFERS ADVANTAGED ECONOMICS FOR PRODUCERS
DESIROUS OF PARTICIPATING IN A BROAD RANGE OF MARKET SEGMENTS ANDOR
NICHE APPLICATIONS DUE TO ITS ABILITY TO TRANSITION QUICKLY AND COVER A
LARGE PRODUCT ENVELOPE ON A SINGLE LINE !N ABILITY TO INCORPORATE COMO
NOMERS SUCH AS OCTENE
ALLOWS PRODUCERS TO PARTICIPATE IN PREMIUM
MARKETS RESULTING IN HIGHER BUSINESS RETURNS
Commercial
plants: 4HE l RST 3#,!)24%#( PLANT WAS BUILT IN #UR
RENTLY MORE THAN PLANTS WORLDWIDE ARE EITHER OPERATING IN DESIGN
OR UNDER CONSTRUCTION WITH THIS TECHNOLOGY REPRESENTING ABOUT MILLION
TPY TOTAL CAPACITY
Licensor: ./6! #HEMICALS )NTERNATIONAL 3!
3#,!)24%#( IS A TRADEMARK OF ./6! #HEMICALS
Polyethylene
Application: 4O PRODUCE LINEAR LOW
DENSITY POLYETHYLENE ,,$0% TO HIGH
DENSITY POLYETHYLENE ($0% USING THE LOW
PRESSURE GAS
PHASE 5.)0/,
0% PROCESS
Description: ! WIDE RANGE OF POLYETHYLENES IS MADE IN A GAS PHASE m U
IDIZED BED REACTOR USING PROPRIETARY SOLID AND SLURRY CATALYSTS 4HE PROD
UCT IS IN A DRY FREE m OWING GRANULAR FORM SUBSTANTIALLY FREE OF l NES AS
IT LEAVES THE REACTOR AND IS CONVERTED TO PELLET FORM FOR SALE -ELT INDEX
AND MOLECULAR WEIGHT DISTRIBUTION ARE CONTROLLED BY SELECTING THE PROPER
CATALYST TYPE AND ADJUSTING OPERATING CONDITIONS 0OLYMER DENSITY IS CON
TROLLED BY ADJUSTING COMONOMER CONTENT OF THE PRODUCT (IGH PRODUC
TIVITY OF CONVENTIONAL AND METALLOCENE CATALYSTS ELIMINATES THE NEED FOR
CATALYST REMOVAL
4HE SIMPLE AND DIRECT NATURE OF THIS PROCESS RESULTS IN LOW
INVESTMENT AND OPERATING COSTS LOW LEVELS OF ENVIRONMENTAL POLLUTION
MINIMAL POTENTIAL l RE AND EXPLOSION HAZARDS AND EASY OPERATION AND
MAINTENANCE
'ASEOUS ETHYLENE COMONOMER AND CATALYST ARE FED TO A REACTOR
CONTAINING A m UIDIZED BED OF GROWING POLYMER PARTICLES AND OPERATING
NEAR KG CM AND APPROXIMATELY # ! CONVENTIONAL SINGLE STAGE
CENTRIFUGAL COMPRESSOR CIRCULATES REACTION GAS WHICH m UIDIZES THE
REACTION BED PROVIDES RAW MATERIAL FOR THE POLYMERIZATION REACTION AND
REMOVES THE HEAT OF REACTION FROM THE BED #IRCULATING GAS IS COOLED IN
A CONVENTIONAL HEAT EXCHANGER
4HE GRANULAR PRODUCT m OWS INTERMITTENTLY INTO PRODUCT DISCHARGE
TANKS WHERE UNREACTED GAS IS SEPARATED FROM THE PRODUCT AND
RETURNED TO THE REACTOR (YDROCARBONS REMAINING WITH THE PRODUCT ARE
REMOVED BY PURGING WITH NITROGEN 4HE GRANULAR PRODUCT IS SUBSEQUENTLY
PELLETIZED IN A LOW ENERGY SYSTEM WITH THE APPROPRIATE ADDITIVES FOR
EACH APPLICATION
Products: 0OLYMER DENSITY IS EASILY CONTROLLED FROM TO GCM
$EPENDING ON CATALYST TYPE MOLECULAR WEIGHT DISTRIBUTION IS EITHER NAR
%THYLENE AND
COMONOMERS
#ATALYST
0OLYETHYLENE TO
RESIN LOADING
ROW OR BROAD -ELT INDEX MAY BE VARIED FROM LESS THAN TO GREATER
THAN 'RADES SUITABLE FOR l LM BLOW
MOLDING PIPE ROTO
MOLDING
AND EXTRUSION APPLICATIONS ARE PRODUCED
Commercial
plants: .INETY
SIX REACTION LINES ARE IN OPERATION UNDER CON
STRUCTION OR IN THE DESIGN PHASE WORLDWIDE WITH SINGLE
LINE CAPACITIES
RANGING FROM TPY TO MORE THAN TPY
Licensor: 5NIVATION 4ECHNOLOGIES
Polypropylene
Application: 3PHERIPOL PROCESS TECHNOLOGY PRODUCES PROPYLENE
BASED
POLYMERS INCLUDING HOMOPOLYMER 00 AND MANY FAMILIES OF RANDOM AND
HETEROPHASIC IMPACT AND SPECIALTY IMPACT COPOLYMERS
#7
Description: )N THE 3PHERIPOL PROCESS HOMOPOLYMER AND RANDOM CO
POLYMER POLYMERIZATION TAKES PLACE IN LIQUID PROPYLENE WITHIN A TUBULAR
LOOP REACTOR (ETEROPHASIC IMPACT COPOLYMERIZATION CAN BE ACHIEVED
BY ADDING A GAS PHASE REACTOR IN SERIES
2EMOVAL OF CATALYST RESIDUE AND AMORPHOUS POLYMER IS NOT REQUIRED
5NREACTED MONOMER IS m ASHED IN A TWO STAGE PRESSURE SYSTEM
AND RECYCLED BACK TO THE REACTORS 4HIS IMPROVES YIELD AND MINIMIZES
ENERGY CONSUMPTION $ISSOLVED MONOMER IS REMOVED FROM THE POLYMER
BY A STEAM SPARGE 4HE PROCESS CAN USE LOWER ASSAY CHEMICAL GRADE
PROPYLENE OR THE TYPICAL POLYMERIZATION GRADE
#ATALYST
3TEAM
0ROPYLENE
3TEAM
%THYLENE
0OLYMER
TO STORAGE
Yields: 0OLYMER YIELDS OF n KG KG OF SUPPORTED CATALYST
ARE OBTAINED 4HE POLYMER HAS A CONTROLLED PARTICLE SIZE DISTRIBUTION AND
AN ISOTACTIC INDEX OF n
Economics: 4HE 3PHERIPOL PROCESS OFFERS A BROAD RANGE OF PRODUCTS WITH
EXCELLENT QUALITY AND LOW
CAPITAL AND OPERATING COSTS
#ONSUMPTION PER METRIC TON OF 00
0ROPYLENE AND COMONOMER T
#ATALYST KG
%LECTRICITY K7H
3TEAM KG
7ATER COOLING MT
n
n
)N CASE OF COPOLYMER PRODUCTION AN ADDITIONAL K7H IS REQUIRED
Products:
4HE PROCESS CAN PRODUCE A BROAD RANGE OF PROPYLENE
BASED
POLYMERS INCLUDING HOMOPOLYMER 00 VARIOUS FAMILIES OF RANDOM COPO
LYMERS AND TERPOLYMERS HETEROPHASIC IMPACT AND SPECIALITY IMPACT CO
POLYMERS UP TO BONDED ETHYLENE AS WELL AS HIGH
STIFFNESS HIGH
CLARITY COPOLYMERS
Commercial
plants:
3PHERIPOL TECHNOLOGY IS USED FOR ABOUT OF THE
TOTAL GLOBAL 00 CAPACITY 4HERE ARE 3PHERIPOL PROCESS PLANTS OPERATING
WORLDWIDE WITH TOTAL CAPACITY OF ABOUT MILLION TPY 3INGLE
LINE DESIGN
CAPACITY IS AVAILABLE IN A RANGE FROM TO TPY
Licensor: "ASELL 0OLYOLEl NS
Polypropylene
Application: 4O PRODUCE POLYPROPYLENE
BASED POLYMERS INCLUDING HO
&INISHING STEAMING
DRYING AND ADDITIVATION
#7
!DDITIVES
2EAGENT
3TEAM
#ATALYST AND
COCATALYST
.ITROGEN
#7
2EAGENT
#7
%XTRUSION
Description: 4HE 3PHERIZONE PROCESS IS "ASELLS NEW PROPRIETARY GAS
LOOP
REACTOR TECHNOLOGY BASED ON A -ULTI
:ONE #IRCULATING 2EACTOR -:#2
CONCEPT )NSIDE THE REACTOR THE GROWING POLYMERIC GRANULE IS CONTINU
OUSLY RECIRCULATING BETWEEN TWO INTERRELATED ZONES WHERE TWO DISTINCT
AND DIFFERENT m UODYNAMIC REGIMES ARE REALIZED
)N THE l RST ZONE A THE POLYMER IS KEPT IN A FAST m UIDIZATION REGIME
WHEN LEAVING THIS ZONE THE GAS IS SEPARATED AND THE POLYMER CROSSES THE
SECOND ZONE B IN A PACKED BED MODE AND IS THEN REINTRODUCED IN THE
l RST ZONE ! COMPLETE AND MASSIVE SOLID RE
CIRCULATION IS OBTAINED BE
TWEEN THE TWO ZONES
4HE m UODYNAMIC PECULIAR REGIME OF THE SECOND ZONE WHERE THE
POLYMER ENTERS AS DENSE PHASE IN PLUG m OW ALTERING THE GAS COMPO
SITION WITH RESPECT TO THE CHAIN TERMINATOR HYDROGEN AND TO THE CO
MONOMER 4HIS IS ACCOMPLISHED BY INJECTING MONOMERS FROM THE EXTER
NAL SYSTEM IN ONE OR MORE POINTS OF THE SECOND ZONE B AND SO TWO
OR MORE DIFFERENT POLYMERS -&2 ANDOR COMONOMER TYPE AND CONTENT
CAN GROW ON THE SAME GRANULE
7HILE THE GRANULES RECYCLE THROUGH THE MULTIPLE ZONES DIFFERENT
POLYMERS ARE GENERATED IN AN ALTERNATE AND CYCLIC WAY VIA CONTINUOUS
POLYMERIZATION 4HIS ALLOWS THE MOST INTIMATE MIXING OF DIFFERENT POLY
MERS GIVING A SUBSTANTIAL HOMOGENEITY OF THE l NAL PRODUCT
5NREACTED MONOMER IS m ASHED AT INTERMEDIATE PRESSURE AND RE
CYCLED BACK TO THE LOOP REACTOR WHILE POLYMER CAN BE FED TO A m UIDIZED
GAS
PHASE REACTOR OPERATED IN SERIES OPTIONAL WHERE ADDITIONAL CO
POLYMER CAN BE ADDED TO THE PRODUCT FROM THE GAS LOOP
&ROM THE INTERMEDIATE SEPARATORSECOND REACTOR THE POLYMER IS DIS
CHARGED TO A RECEIVER THE UNREACTED GAS IS RECOVERED WHILE THE POLY
MER IS SENT TO A PROPRIETARY UNIT FOR MONOMER STEAM STRIPPING AND CATA
LYST DEACTIVATION 4HE REMOVED RESIDUAL HYDROCARBONS ARE RECYCLED
!DDITIONAL
COPOLYMERIZATION
0OLYMERIZATION
MOPOLYMER POLYPROPYLENE RANDOM HETEROPHASIC IMPACT AND SPECIALTY
DUAL COMPOSITION COPOLYMERS USING 3PHERIZONE PROCESS TECHNOLOGY
0ELLETS
%THYLENE
TO THE REACTION 7HILE THE POLYMER IS DRIED BY A CLOSED
LOOP NITROGEN
SYSTEM AND NOW FREE FROM VOLATILE SUBSTANCES THE POLYMER IS SENT TO
ADDITIVES INCORPORATION STEP
Economics: 2AW MATERIAL AND UTILITY REQUIREMENTS PER METRIC TON OF
PRODUCT
0ROPYLENE PLUS COMONOMER FOR COPOLYMERS KG
#ATALYST KG
%LECTRICITY K7H
3TEAM KG
7ATER COOLING M
n
)N CASE OF HIGH IMPACT COPOLYMER PRODUCTION AN ADDITIONAL K7H IS REQUIRED
Polypropylene, CONTINUED
Products: 4HE PROCESS CAN PRODUCE A BROAD RANGE OF PROPYLENE
BASED
POLYMERS INCLUDING MONO
AND BIMODAL MEDIUMWIDEVERY WIDE MO
LECULAR WEIGHT DISTRIBUTION HOMOPOLYMER 00 HIGH STIFFNESS HOMOPOLY
MERS RANDOM COPOLYMERS AND TERPOLYMERS HIGH
CLARITY RANDOM COPO
LYMERS AS WELL AS TWO COMPOSITIONS HOMOPOLYMERRANDOM COPOLYMER
TWIN
RANDOM OR RANDOMHETEROPHASIC COPOLYMER #ONVENTIONAL HETERO
PHASIC IMPACT COPOLYMERS WITH IMPROVED STIFFNESSIMPACT BALANCE CAN
BE PRODUCED WITH THE SECOND ADDITIONAL GAS PHASE REACTOR WITH ETHYL
ENEPROPYLENE RUBBER CONTENT UP TO
Commercial
plants: ! RETROlTTED TPY PLANT IS IN OPERATION AT THE
"ASELL SITE IN "RINDISI SINCE AND LICENSES FOR A TOTAL CAPACITY OF
MILLION TON HAVE BEEN GRANTED DURING 4HE LARGEST UNIT LICENSE IS A
TPY SINGLE
LINE PLANT
Technology
owner: "ASELL 0OLYOLElNS
Polypropylene
Application: 4O PRODUCE POLYPROPYLENE 00 HOMOPOLYMER RANDOM CO
POLYMER AND IMPACT COPOLYMER USING THE "0 )NNOVENE GAS
PHASE PRO
CESS WITH PROPRIETARY TH GENERATION SUPPORTED CATALYST
Description: #ATALYST IN MINERAL OIL SLURRY IS METERED INTO THE REACTOR TO
GETHER WITH CO CATALYST AND MODIl ER 4HE PROPRIETARY SUPPORTED CATALYST
DEVELOPED BY "0 HAS CONTROL MORPHOLOGY SUPER HIGH ACTIVITY AND VERY
HIGH STEROSPECIl TY 4HE RESULTING 00 PRODUCT IS CHARACTERIZED BY NARROW
PARTICLE SIZE DISTRIBUTION GOOD POWDER m OWABILITY MINIMUM CATALYST
RESIDUES NONCORROSIVENESS EXCELLENT COLOR AND LOW ODOR
4HE HORIZONTAL STIRRED BED REACTOR IS UNIQUE IN THE INDUSTRY IN THAT
IT APPROACHES PLUG m OW TYPE OF PERFORMANCE WHICH CONTRIBUTES TO TWO
MAJOR ADVANTAGES &IRST IT MINIMIZES CATALYST BYPASSING WHICH ENABLES THE
PROCESS TO PRODUCE VERY HIGH PERFORMANCE IMPACT COPOLYMER 3ECOND IT
MAKES PRODUCT TRANSITIONS VERY QUICK AND SHARP WHICH MINIMIZES OFF SPEC
TRANSITION MATERIALS 4HE REACTOR IS NOT A m UIDIZED BED AND POWDER MIXING
IS ACCOMPLISHED BY VERY MILD AGITATION PROVIDED BY A PROPRIETARY DESIGNED
HORIZONTAL AGITATOR -ONOMER LEAVING THE REACTOR IS PARTIALLY CONDENSED
AND RECYCLED 4HE CONDENSED LIQUID TOGETHER WITH FRESH MAKEUP
MONOMER IS SPRAYED ONTO THE STIRRED REACTOR POWDER BED TO PROVIDE
EVAPORATIVE COOLING REMOVE THE HEAT OF POLYMERIZATION AND CONTROL THE
BED TEMPERATURE 5NCONDENSED GAS IS RETURNED TO THE REACTOR
&OR IMPACT COPOLYMER PRODUCTION A SECOND REACTOR IN SERIES IS
REQUIRED ! RELIABLE AND EFFECTIVE GAS LOCK SYSTEM TRANSFERS POWDER
FROM THE l RST HOMOPOLYMER REACTOR TO THE SECOND COPOLYMER REACTOR
AND PREVENTS CROSS CONTAMINATION OF REACTANTS BETWEEN REACTORS
4HIS IS CRITICALLY IMPORTANT WHEN PRODUCING THE HIGHEST QUALITY IMPACT
COPOLYMER )N MOST RESPECTS THE OPERATION OF THE SECOND REACTOR SYSTEM
IS SIMILAR TO THAT OF THE l RST EXCEPT THAT ETHYLENE IN ADDITION TO PROPYLENE
IS FED TO THE SECOND REACTOR 0OWDER FROM THE REACTOR IS TRANSFERRED AND
DEPRESSURIZED IN A GASPOWDER SEPARATION SYSTEM AND INTO A PURGE
COLUMN FOR CATALYST DEACTIVATION 4HE DEACTIVATED POWDER IS THEN
PELLETIZED WITH ADDITIVES INTO THE l NAL PRODUCTS
#OCATALYST
-ODIFIER
#7
#ATALYST
0ROPYLENE RECYCLE
TO REACTOR
#ONDENSER
0ROPYLENE
0OWDER
GAS
SEPARATION
2EACTOR
FIRST POLYMERIZATION
2EACTOR
POWDER
TRANSFER
SYSTEM
#ONDENSER
#7
0OWER
DEACTIVATION
-OIST NITROGEN
0ROPYLENE
!DDITIVES
%THYLENE
2EACTOR
SECOND POLYMERIZATION
0ROPYLENE
RECOVERY
FUEL
OR FLARE
0ELLETIZED
PRODUCT
Products: ! WIDE RANGE OF POLYPROPYLENE PRODUCTS HOMOPOLYMER RAN
DOM COPOLYMER AND IMPACT COPOLYMER CAN BE PRODUCED TO SERVE MANY
APPLICATIONS INCLUDING INJECTION MOLDING BLOW MOLDING THERMOFORM
ING l LM EXTRUSION SHEET AND l BER )MPACT COPOLYMER PRODUCED USING
THIS PROCESS EXHIBITS A SUPERIOR BALANCE OF STIFFNESS AND IMPACT RESISTANCE
OVER A BROAD TEMPERATURE RANGE
Commercial
plants: &OURTEEN PLANTS ARE EITHER IN OPERATION OR IN DE
SIGNCONSTRUCTION WORLDWIDE WITH CAPACITIES RANGING FROM TO
MTPY
Licensor: "0
Polypropylene
Application: ! PROCESS TO PRODUCE HOMOPOLYMER POLYPROPYLENE AND
ETHYLENE
PROPYLENE RANDOM AND IMPACT CO
POLYMERS USING #HISSO 'AS
0HASE 4ECHNOLOGY UTILIZING HORIZONTAL PLUG
m OW REACTOR
Description: 4HE PROCESS FEATURES A HORIZONTAL AGITATED REACTOR AND A
HIGH PERFORMANCE CATALYST SPECIl CALLY DEVELOPED BY THE LICENSOR 4HE
CATALYST HAS A CONTROLLED MORPHOLOGY VERY HIGH ACTIVITY AND VERY HIGH
SELECTIVITY 4HE PROCESS PROVIDES LOW ENERGY CONSUMPTION SUPERIOR
ETHYLENE PROPYLENE IMPACT CO POLYMER PROPERTIES MINIMUM TRANSITION
PRODUCTS HIGH POLYMER THROUGHPUT AND A HIGH OPERATING FACTOR %ACH
PROCESS STEP HAS BEEN SIMPLIl ED CONSEQUENTLY THE TECHNOLOGY OFFERS
A LOW INITIAL CAPITAL INVESTMENT AND REDUCED MANUFACTURING COSTS WHILE
PROVIDING PRODUCT UNIFORMITY EXCELLENT QUALITY CONTROL AND WIDE RANGE
OF POLYMER DESIGN ESPECIALLY FOR COMONOMER PRODUCTS
0ARTICLES OF POLYPROPYLENE ARE CONTINUOUSLY FORMED AT LOW PRESSURE
IN THE REACTOR IN THE PRESENCE OF CATALYST %VAPORATED MONOMER
IS PARTIALLY CONDENSED AND RECYCLED 4HE LIQUID MONOMER WITH FRESH
PROPYLENE IS SPRAYED ONTO THE STIRRED POWDER BED TO PROVIDE EVAPORA
TIVE COOLING 4HE POWDER IS PASSED THROUGH A GAS LOCK SYSTEM TO A
SECOND REACTOR 4HIS ACTS IN A SIMILAR MANNER TO THE l RST EXCEPT THAT
ETHYLENE AS WELL AS PROPYLENE IS FED TO THE SYSTEM FOR IMPACT CO POLY
MER PRODUCTION 4HE HORIZONTAL REACTOR MAKES THE POWDER RESIDENCE
TIME DISTRIBUTION APPROACH THAT OF PLUG m OW 4HE STIRRED BED IS WELL
SUITED TO HANDLING SOME HIGH ETHYLENE CO POLYMERS THAT MAY NOT m OW
OR m UIDIZE WELL
4HE POWDER IS RELEASED PERIODICALLY TO A GAS POWDER SEPARATION SYS
TEM )T IS DEPRESSURIZED TO A PURGE COLUMN WHERE MOIST NITRO
GEN DEACTIVATES THE CATALYST AND REMOVES ANY REMAINING MONOMER 4HE
MONOMER IS CONCENTRATED AND RECOVERED 4HE POWDER IS CONVERTED INTO
A VARIETY OF PELLETIZED RESINS TAILORED FOR SPECIl C MARKET APPLICATIONS
Commercial
plants: 4EN POLYPROPYLENE PLANTS ARE IN OPERATION OR UNDER
CONSTRUCTION WITH CAPACITIES RANGING FROM TPY TO TPY
#OCATALYST
0ROPYLENE RECYCLERECOVERY
0ROPYLENE
#ATALYST
0OWDERGAS
SEPARATION
0ROPYLENE
RECOVERY
2EACTOR
'AS
LOCK
%THYLENE
PROPYLENE
0URGE
COLUMN
-OIST NITROGEN
!DDITIVES
2EACTOR
0ELLETIZED
PRODUCT
#HISSO OFFERS PROCESSING DESIGNS FOR SINGLE PRODUCTION WITH CAPACITIES
REACHING TPY
Licensor: *APAN 0OLYPROPYLENE #ORP
4HE RIGHTS TO LICENSE THIS TECHNOLOGY WERE GIVEN FROM #HISSO TO *A
PAN 0OLYPROPYLENE #ORP WHICH IS A 00 JOINT VENTURE BETWEEN #HISSO
AND -ITSUBISHI #HEMICAL #ORP
Polypropylene
Applications: 4O PRODUCE POLYPROPYLENE 00 INCLUDING HOMO
POLYMER
0OLYMERIZATION
RANDOM COPOLYMER AND IMPACT COPOLYMER
$RYING
Description: 4HE PROCESS WITH A COMBINATION OF THE MOST ADVANCED
HIGH YIELD AND HIGH STEREOSPECIl CITY CATALYST IS A NONSOLVENT NONDEASH
ING PROCESS )T ELIMINATES ATACTIC POLYMERS AND CATALYST RESIDUE REMOVAL
4HE PROCESS CAN PRODUCE VARIOUS GRADES OF 00 WITH OUTSTANDING PRODUCT
QUALITY 0OLYMER YIELDS OF TO KGKG OF SUPPORTED CATALYST
ARE OBTAINED AND THE TOTAL ISOTACTIC INDEX OF POLYMER CAN REACH TO
7ITH NEW CATALYSTS BASED ON DI ETHER TECHNOLOGY TH GENERATION
CATALYST 2+ #ATALYST AND 2( #ATALYST WIDER MELT INDEX RANGED POLYMERS
CAN BE PRODUCED COMPARE WITH THOSE PRODUCED WITH TH GENERATION
CATALYST DUE TO THE HIGH HYDROGEN RESPONSE OF 2+2( #ATALYST
4HE REACTOR POLYMER HAS NARROW AND CONTROLLED PARTICLE SIZE
DISTRIBUTION THAT STABILIZES PLANT OPERATION AND ALSO PERMITS EASY
SHIPMENT AS POWDER $UE TO THE PROPRIETARY DESIGN OF THE GAS PHASE
REACTOR NO FOULING IS OBSERVED DURING THE OPERATION AND CONSEQUENTLY
REACTOR CLEANING AFTER PRODUCING IMPACT COPOLYMER IS NOT REQUIRED )N
ADDITION COMBINATION OF THE m EXIBILITY OF THE GAS PHASE REACTOR AND
HIGH PERFORMANCE CATALYSTS ALLOW PROCESSING IMPACT COPOLYMER WITH A
HIGH ETHYLENE CONTENT
)N THE PROCESS HOMOPOLYMER AND RANDOM COPOLYMER POLYMERIZATION
OCCURS IN THE LOOP TYPE REACTOR OR VESSEL TYPE REACTOR &OR IMPACT
COPOLYMER PRODUCTION COPOLYMERIZATION IS PERFORMED IN A GAS PHASE
REACTOR AFTER HOMOPOLYMERIZATION 4HE POLYMER IS DISCHARGED FROM
A GAS PHASE REACTOR AND TRANSFERRED TO THE SEPARATOR 5NREACTED GAS
ACCOMPANYING THE POLYMER IS REMOVED BY THE SEPARATOR AND RECYCLED TO
THE REACTOR SYSTEM 4HE POLYMER POWDER IS THEN TRANSFERRED TO THE DRYER
SYSTEM WHERE REMAINING PROPYLENE IS REMOVED AND RECOVERED 4HE
DRY POWDER IS PELLETIZED BY THE PELLETIZING SYSTEM ALONG WITH REQUIRED
STABILIZERS
0ELLETIZING
%THYLENE
3ILO STORAGE
AND PACKING
3TABILIZER
0ROPYLENE
#ATALYST
0ACKING AND
SHIPPING
Product: 4HE PROCESS CAN PRODUCE A BROAD RANGE OF POLYPROPYLENE POLY
MERS INCLUDING HOMO
POLYMER RANDOM COPOLYMER AND IMPACT COPOLY
MER WHICH BECOME HIGH
QUALITY GRADES THAT CAN COVER VARIOUS APPLICA
TIONS
Economics: 4YPICAL CONSUMPTION PER METRIC TON OF NATURAL PROPYLENE
HOMOPOLYMER PELLETS
0ROPYLENE AND ETHYLENE FOR COPOLYMER KG
%LECTRICITY K7H
3TEAM KG
7ATER COOLING T
Polypropylene, CONTINUED
Commercial
plants: 4WENTY
lVE REACTOR LINES ARE IN OPERATION ENGINEER
ING DESIGN OR CONSTRUCTION WORLDWIDE WITH A TOTAL PRODUCTION CAPACITY
OF OVER --TPY
Licensor: -ITSUI #HEMICALS )NC
Polypropylene
Application: 4O PRODUCE HOMOPOLYMER RANDOM COPOLYMER AND IMPACT
COPOLYMER POLYPROPYLENE USING THE $OW GAS
PHASE 5.)0/, 00 PROCESS
Description: ! WIDE RANGE OF POLYPROPYLENE IS MADE IN A GAS PHASE m U
IDIZED BED REACTOR USING PROPRIETARY CATALYSTS -ELT INDEX ISOTACTIC LEVEL
AND MOLECULAR WEIGHT DISTRIBUTION ARE CONTROLLED BY UTILIZING THE PROPER
CATALYST ADJUSTING OPERATING CONDITIONS AND ADDING MOLECULAR WEIGHT
CONTROL AGENTS 2ANDOM COPOLYMERS ARE PRODUCED BY ADDING ETHYLENE
OR BUTENE TO THE REACTOR %THYLENE ADDITION TO A SECOND REACTOR IN SERIES
IS USED TO PRODUCE THE RUBBER PHASE OF IMPACT COPOLYMERS
4HE 5.)0/, 00 PROCESS SIMPLE YET CAPABLE DESIGN RESULTS IN LOW
INVESTMENT AND OPERATING COSTS LOW ENVIRONMENTAL IMPACT MINIMAL PO
TENTIAL l RE AND EXPLOSION HAZARDS AND EASY OPERATION AND MAINTENANCE
4O PRODUCE HOMOPOLYMERS AND RANDOM COPOLYMERS GASEOUS PROPYLENE
COMONOMER AND CATALYST ARE FED TO A REACTOR CONTAINING A m UIDIZED
BED OF GROWING POLYMER PARTICLES AND OPERATING NEAR KGCM AND AP
PROXIMATELY # ! CONVENTIONAL SINGLE STAGE CENTRIFUGAL COMPRESSOR
CIRCULATES THE REACTION GAS WHICH m UIDIZES THE REACTION BED PROVIDES
RAW MATERIALS FOR THE POLYMERIZATION REACTION AND REMOVES THE HEAT OF
THE REACTION FROM THE BED #IRCULATING GAS IS COOLED IN A CONVENTIONAL
HEAT EXCHANGER 'RANULAR PRODUCT m OWS INTERMITTENTLY INTO PRODUCT
DISCHARGE TANKS UNREACTED GAS IS SEPARATED FROM THE PRODUCT AND
RETURNED TO THE REACTOR
4O MAKE IMPACT COPOLYMERS THE POLYPROPYLENE RESIN FORMED IN
THE l RST REACTOR IS TRANSFERRED INTO THE SECOND REACTOR 'ASEOUS
PROPYLENE AND ETHYLENE WITH NO ADDITIONAL CATALYST ARE FED INTO THE SEC
OND REACTOR TO PRODUCE THE POLYMERIC RUBBER PHASE WITHIN THE EXISTING
POLYPROPYLENE PARTICLES 4HE SECOND REACTOR OPERATES IN THE SAME MAN
NER AS THE INITIAL REACTOR BUT AT APPROXIMATELY HALF THE PRESSURE WITH A
CENTRIFUGAL COMPRESSOR CIRCULATING GAS THROUGH A HEAT EXCHANGER
AND BACK TO THE m UID BED REACTOR 0OLYPROPYLENE PRODUCT IS REMOVED BY
PRODUCT DISCHARGE TANKS AND UNREACTED GAS IS RETURNED TO THE REACTOR
(YDROCARBONS REMAINING IN THE PRODUCT ARE REMOVED BY PURGING WITH
#ATALYST
0ROPYLENE
COMONOMERS
0OLYPROPYLENE TO
RESIN LOADING
NITROGEN 'RANULAR PRODUCTS ARE PELLETIZED IN SYSTEMS AVAILABLE FROM MUL
TIPLE VENDORS $OW HAS ONGOING DEVELOPMENT PROGRAMS WITH THESE
SUPPLIERS TO OPTIMIZE THEIR SYSTEMS FOR 5.)0/, 00 RESINS GUARANTEEING
LOW ENERGY INPUT AND HIGH PRODUCT QUALITY #ONTROLLED RHEOLOGY HIGH
MELT
m OW GRADES ARE PRODUCED IN THE PELLETING SYSTEM THROUGH THE AD
DITION OF SELECTED PEROXIDES
Products: (OMOPOLYMERS CAN BE PRODUCED WITH MELT m OWS FROM LESS
THAN TO DGMIN AND ISOTACTIC CONTENT IN EXCESS OF 2AN
DOM COPOLYMERS CAN BE PRODUCED WITH UP TO WT ETHYLENE OR UP TO
WT BUTENE OVER A WIDE MELT m OW RANGE TO DGMIN !
Polypropylene, CONTINUED
FULL RANGE OF IMPACT COPOLYMERS CAN BE POLYMERIZED WITH EXCELLENT STIFF
NESS FOR EVEN THE MOST DEMANDING APPLICATIONS 0RODUCTS FROM NARROW
TO BROAD MOLECULAR
WEIGHT DISTRIBUTION CAN BE MANUFACTURED IN GRADES
PROVEN ADVANTAGE FOR lLM INJECTION MOLDING BLOW MOLDING EXTRUSION
AND TEXTILE APPLICATIONS
Commercial
plants: .EARLY REACTION LINES ARE IN OPERATION WITH CA
PACITIES RANGING FROM TO TPY AND PLANTS IN DESIGN UP
TO TPY 4OTAL WORLDWIDE PRODUCTION OF POLYPROPYLENE WITH THIS
TECHNOLOGY IS NEARLY MILLION TPY
Licensor: 4HE $OW #HEMICAL #O 5NIVATION 4ECHNOLOGIES IS THE LICENSOR
OF THE 5.)0/, 0% PROCESS
Polystyrene,
expandable
Application: 4O PRODUCE EXPANDABLE POLYSTYRENE %03 VIA THE SUSPENSION
PROCESS USING "0 #HEMICALS!"" ,UMMUS 'LOBAL TECHNOLOGY
)NITIATOR AND
CHEMICAL ADDITIVES
Description: 4HE "0,UMMUS STYRENE POLYMERIZATION TECHNOLOGY FOR THE
MANUFACTURE OF REGULAR AND m AME
RETARDANT GRADES OF %03 IS A ONE
STEP
BATCH SUSPENSION REACTION FOLLOWED BY CONTINUOUS DEWATERING DRYING
AND SIZE CLASSIl CATION
3TYRENE MONOMER WATER INITIATORS SUSPENDING AGENTS NUCLEATING
AGENTS AND OTHER MINOR INGREDIENTS ARE ADDED TO THE REACTOR 4HE
CONTENTS ARE THEN SUBJECTED TO A TIME
TEMPERATURE PROl LE UNDER AGITATION
4HE SUSPENDING AGENT AND AGITATION DISPERSE THE MONOMER TO FORM BEADS
!T THE APPROPRIATE TIME A PREMEASURED QUANTITY OF PENTANE IS INTRODUCED
INTO THE REACTOR 0OLYMERIZATION IS THEN CONTINUED TO ESSENTIALLY
CONVERSION !FTER COOLING THE %03 BEADS AND WATER ARE DISCHARGED TO A
HOLDING TANK
&ROM THIS POINT THE PROCESS BECOMES CONTINUOUS 4HE BEADWATER
SLURRY IS CENTRIFUGED WHERE MOST OF THE hMOTHER LIQUORv IS REMOVED
4HE BEADS ARE CONVEYED TO A PNEUMATIC DRYER WHERE THE REMAINING
MOISTURE IS REMOVED
4HE DRY BEADS ARE THEN SCREENED YIELDING AS MANY AS FOUR PRODUCT
CUTS %XTERNAL LUBRICANTS ARE ADDED IN A PROPRIETARY BLENDING OPERATION
AND THE l NISHED PRODUCT IS CONVEYED TO SHIPPING CONTAINERS
Economics: 4HE "0,UMMUS PROCESS IS ONE OF THE MOST MODERN TECHNOLO
GIES FOR %03 PRODUCTION #OMPUTER CONTROL IS USED TO PRODUCE PRODUCT UNI
FORMITY WHILE MINIMIZING PLANT ENERGY REQUIREMENTS "0 PROVIDES ONGOING
PROCESS RESEARCH FOR PRODUCT IMPROVEMENT AND NEW PRODUCT POTENTIAL
2AW MATERIALS AND UTILITIES BASED ON ONE METRIC TON OF %03
3TYRENE AND PENTANE KG
n
0ROCESS CHEMICALS KG
n
$EMINERALIZED WATER KG
%LECTRICITY K7H
3TEAM MT
7ATER COOLING M
3USPENDING AGENTS
4O ATMOSPHERE
#ENTRIFUGE
3TYRENE
7ATER
$RYER
3CREENING
2EACTOR
3LURRY
TANK
%FFLUENT
TREATMENT
!IR
!IR
!IR !IR
!IR
"LENDER
!DDITIVES
4O
PRODUCT
PACKAGING
)NTERMEDIATE
STORAGE HOPPERS
Commercial
plants: 4HREE COMMERCIAL PRODUCTION UNITS ARE IN OPERATION
ONE IN &RANCE ONE IN 'ERMANY AND ONE IN #HINA FOR A TOTAL CAPACITY OF
METRIC TONS
Licensor: !"" ,UMMUS 'LOBAL"0 #HEMICALS
Polystyrene,
high
impact
Application: 4O PRODUCE A WIDE RANGE OF GENERAL PURPOSE AND HIGH
IMPACT POLYSTYRENES 03 VIA THE BULK CONTINUOUS PROCESS USING THE "0
#HEMICALS!"" ,UMMUS 'LOBAL TECHNOLOGY
Description: 4HE PRODUCTION OF GENERAL PURPOSE 03 '003 AND HIGH
IMPACT 03 ()03 IS ESSENTIALLY THE SAME WITH THE EXCEPTION OF THE INITIAL
RUBBER
DISSOLUTION STEP FOR ()03
4HE PRODUCTION OF ()03 BEGINS WITH THE GRANULATING AND DISSOLVING
OF RUBBER AND OTHER ADDITIVES IN STYRENE MONOMER AND THEN
TRANSFERRING THE RUBBER SOLUTION TO A STORAGE TANK &OR GENERAL
PURPOSE PRODUCT CONTROLLED AMOUNTS OF INGREDIENTS ARE FED DIRECTLY TO
THE FEED PREHEATER
&ROM THIS POINT ON THE PRODUCTION STEPS FOR '003 AND ()03 ARE THE
SAME 4HE FEED MIXTURE IS PREHEATED AND CONTINUOUSLY FED TO THE
PREPOLYMERIZER WHERE THE RUBBER MORPHOLOGY IS ESTABLISHED
&OLLOWING PREPOLYMERIZATION THE POLYMER MIXTURE IS PUMPED TO
THE POLYMERIZATION REACTOR OF PROPRIETARY DESIGN !T THE EXIT OF THE
REACTOR THE POLYMERIZATION IS ESSENTIALLY COMPLETE 4HE MIXTURE IS THEN
PREHEATED IN PREPARATION FOR DEVOLATIZATION
4HE DEVOLATILIZER IS HELD UNDER A VERY HIGH VACUUM TO REMOVE
UNREACTED MONOMER AND SOLVENT FROM THE POLYMER MELT 4HE MONOMER
IS DISTILLED IN THE STYRENE RECOVERY UNIT AND RECYCLED BACK TO THE
PREPOLYMIZER 4HE POLYMER MELT IS THEN PUMPED THROUGH A DIE HEAD
TO FORM STRANDS A WATERBATH TO COOL THE STRANDS A PELLETIZER
TO FORM PELLETS AND IS SCREENED TO REMOVE LARGE PELLETS AND l NES
4HE RESULTANT PRODUCT IS AIR
CONVEYED TO BULK STORAGE AND PACKAGING
FACILITIES
Economics: 4HE "0,UMMUS PROCESS OFFERS ONE OF THE MOST MODERN
TECHNOLOGIES FOR '003 AND ()03 PRODUCTION ! BROAD PRODUCT LINE IS
AVAILABLE WITH A CONSISTENTLY HIGH PRODUCT QUALITY "0 PROVIDES ONGOING
PROCESS RESEARCH FOR PRODUCT IMPROVEMENT AND NEW PRODUCT POTENTIAL
3TYRENE
0REHEATER
3TYRENE RECYCLE
2UBBER
GRINDER
!DDITIVES
$ISSOLVER
3TORAGE
&EED
STORAGE
0ELLETIZER
0REPOLY
REACTOR
7ATER
BATH
0OLYMERIZATION
REACTOR
0REHEATER
3TYRENE 0URGE
RECOVERY
$EVOL
$IE
HEAD
2AW MATERIALS AND UTILITIES BASED ON ONE METRIC TON OF POLYSTYRENE
'003
()03
3TYRENE AND MINERAL OIL KG
2UBBER KG
!DDITIVES
%LECTRICITY K7H
&UEL KCAL
7ATER COOLING M
3TEAM ,0 KG
Commercial
plants: 0LANTS IN &RANCE 'ERMANY AND 3WEDEN ARE IN OP
ERATION WITH A TOTAL CAPACITY OF APPROXIMATELY MTPY OF '003
AND ()03 !NOTHER MTPY '003 AND ()03 UNIT WILL START UP IN
#HINA IN
Polystyrene,
high
impact, CONTINUED
Licensor: !"" ,UMMUS 'LOBAL"0 #HEMICALS
Polystyrene,
general
purpose
(GPPS)
Application: 4O PRODUCE A WIDE RANGE OF GENERAL PURPOSE POLYSTYRENE
'003 WITH EXCELLENT HIGH CLARITY AND SUITABLE PROPERTIES TO PROCESS 03
FOAM VIA DIRECT INJECTION EXTRUSION BY THE CONTINUOUS BULK POLYMERIZA
TION PROCESS USING 4OYO %NGINEERING #ORP 4%# -ITSUI #HEMICALS )NC
TECHNOLOGY
3TYRENE
3OLVENT
!DDITIVES
2EACTOR
Description: 3TYRENE MONOMER A SMALL AMOUNT OF SOLVENT AND ADDITIVES
ARE FED TO THE SPECIALLY DESIGNED REACTOR WHERE THE POLYMERIZATION IS
CARRIED OUT 4HE POLYMERIZATION TEMPERATURE OF THE REACTOR IS CAREFULLY
CONTROLLED AT A CONSTANT LEVEL TO KEEP THE DESIRED CONVERSION RATE 4HE
HEAT OF POLYMERIZATION IS EASILY REMOVED BY A SPECIALLY DESIGNED HEAT
TRANSFER SYSTEM
!T THE EXIT OF THE REACTOR THE POLYMERIZATION IS ESSENTIALLY COMPLETE
4HE MIXTURE IS THEN PREHEATED AND TRANSFERRED TO THE DEVOLATILIZERS
WHERE VOLATILE COMPONENTS ARE SEPARATED FROM THE POLYMER SOLUTION BY
EVAPORATION UNDER VACUUM 4HE RESIDUALS ARE CONDENSED AND RECYCLED
BACK TO THE PROCESS 4HE MOLTEN POLYMER IS PUMPED THROUGH A DIE
AND CUT INTO PELLETS BY A PELLETIZER
Economics: "ASIS MTPY '003 53 'ULF #OAST
)NVESTMENT MILLION 53
2AW MATERIALS CONSUMPTION PER ONE METRIC TON OF '003 KG
5TILITIES CONSUMPTION PER ONE METRIC TON OF '003 53
Installations:
3IX PLANTS IN *APAN +OREA #HINA )NDIA AND 2USSIA ARE IN
OPERATION WITH A TOTAL CAPACITY OF METRIC TPY
Licensor: 4OYO %NGINEERING #ORP4%# -ITSUI #HEMICALS )NC
0REHEATERS
6ACUUM
2ECOVERED MONOMER
3TORAGE
0ELLETIZER
#ONDENSERS
$IE HEAD
$EVOLATILIZERS
Polystyrene,
high-impact
(HIPS)
Application: 4O PRODUCE A WIDE RANGE OF HIGH
IMPACT POLYSTYRENE
()03 WITH WELL
BALANCED MECHANICAL PROPERTIES AND PROCESSABILITY VIA
THE CONTINUOUS BULK POLYMERIZATION PROCESS USING 4OYO %NGINEERING
#ORP 4%# -ITSUI #HEMICALS )NC TECHNOLOGY 4HE PROCESS HAS A SWING
PRODUCTION FEATURE AND IS ALSO CAPABLE OF PRODUCING GENERAL PURPOSE
POLYSTYRENE '003
3TYRENE
2UBBER
3OLVENT
!DDITIVES
0REPOLYMERIZER
2EACTORS
0REHEATERS
Description: 3TYRENE MONOMER GROUND RUBBER CHIPS AND SMALL AMOUNT
OF ADDITIVES ARE FED TO THE RUBBER DISSOLVER 4HE RUBBER CHIPS COM
PLETELY DISSOLVED IN STYRENE 4HIS RUBBER SOLUTION IS SENT TO A RUBBER
SOLU
TION
FEED TANK 4HE RUBBER SOLUTION FROM THE TANK IS SENT TO THE PRE
POLYMERIZER WHERE IT IS PREPOLYMERIZED AND THE RUBBER MORPHOLOGY
IS ESTABLISHED
4HE PREPOLYMERIZED SOLUTION IS THEN POLYMERIZED IN SPECIALLY DE
SIGNED REACTORS ARRANGED IN SERIES 4HE POLYMERIZATION TEMPERATURE
OF THE REACTORS IS CAREFULLY CONTROLLED AT A CONSTANT LEVEL TO MAINTAIN THE
DESIRED CONVERSION RATE 4HE HEAT OF THE POLYMERIZATION IS EASILY REMOVED
BY A SPECIALLY DESIGNED HEAT
TRANSFER SYSTEM
4HE POLYMERIZATION PRODUCT A HIGHLY VISCOUS SOLUTION IS PREHEATED
AND TRANSFERRED TO THE DEVOLATILIZERS 6OLATILE COMPONENTS ARE SEPARAT
ED FROM THE POLYMER SOLUTION BY EVAPORATION UNDER VACUUM 4HE RESIDU
ALS ARE CONDENSED AND RECYCLED TO THE PROCESS 4HE MOLTEN POLYMER IS
PUMPED THROUGH A DIE AND CUT INTO PELLETS BY A PELLETIZER
Economics: "ASIS METRIC TPY ()03 UNIT 53 'ULF #OAST
)NVESTMENT MILLION 53
2AW MATERIALS CONSUMPTION PER ONE METRIC TON OF ()03 KG
5TILITIES CONSUMPTION PER ONE METRIC TON OF ()03 53
Installations: 3IX PLANTS IN *APAN +OREA #HINA AND )NDIA ARE IN OPERATION
WITH A TOTAL CAPACITY OF METRIC TPY
Licensor: 4OYO %NGINEERING #ORP 4%# -ITSUI #HEMICALS )NC
$ISSOLVER
&EED TANK
6ACUUM
#ONDENSERS
2ECOVERED MONOMER
3TORAGE
0ELLETIZER
$IE HEAD
$EVOLATILIZERS
Propylene
(and
isobutylene)
Application: 4ECHNOLOGY FOR DEHYDROGENATION OF PROPANE OR ISOBUTANE
TO MAKE HIGH
PURITY PROPYLENE OR ISOBUTYLENE 4HE #!4/&). PROCESS
USES SPECIALLY FORMULATED PROPRIETARY CATALYST FROM 3D
#HEMIE
Description: 4HE #!4/&). REACTION SYSTEM CONSISTS OF PARALLEL l XED
BED
REACTORS AND A REGENERATION AIR SYSTEM 4HE REACTORS ARE CYCLED THROUGH
A SEQUENCE CONSISTING OF REACTION REGENERATION AND EVACUATIONPURGE
STEPS -ULTIPLE REACTORS ARE USED SO THAT THE REACTOR FEEDPRODUCT SYSTEM
AND REGENERATION AIR SYSTEM OPERATE IN A CONTINUOUS MANNER
&RESH PROPANE FEED IS COMBINED WITH RECYCLE FEED FROM THE BOTTOM
OF THE PRODUCT SPLITTER VAPORIZED RAISED TO REACTION TEMPERATURE IN
A CHARGE HEATER AND FED TO THE REACTORS 2EACTION TAKES PLACE AT
VACUUM CONDITIONS TO MAXIMIZE FEED CONVERSION AND OLEl N SELECTIVITY
!FTER COOLING THE REACTOR EFm UENT GAS IS COMPRESSED AND SENT
TO THE RECOVERY SECTION WHERE INERT GASES HYDROGEN AND LIGHT
HYDROCARBONS ARE SEPARATED FROM THE COMPRESSED REACTOR EFm UENT
AND # AND HEAVIER ARE REJECTED 4HE ETHANE PROPANE AND PROPYLENE
COMPONENTS ARE THEN SENT TO THE PRODUCT PURIl CATION SECTION DEETHANIZER
AND PRODUCT SPLITTER WHERE PROPYLENE PRODUCT IS SEPARATED FROM
UNREACTED PROPANE 4HE PROPANE IS RECYCLED TO THE REACTORS
!FTER A SUITABLE PERIOD OF ONSTREAM OPERATION FEED TO AN INDIVIDUAL
REACTOR IS DISCONTINUED AND THE REACTOR IS REHEATEDREGENERATED 2EHEAT
REGENERATION AIR HEATED IN THE REGENERATION AIR HEATER IS PASSED THROUGH
THE REACTORS 4HE REGENERATION AIR SERVES TO RESTORE THE TEMPERATURE PROl LE
OF THE BED TO ITS INITIAL ONSTREAM CONDITION IN ADDITION TO BURNING COKE
OFF THE CATALYST 7HEN REHEATREGENERATION IS COMPLETED THE REACTOR IS
RE
EVACUATED FOR THE NEXT ONSTREAM PERIOD
Yields
and
product
quality: 0ROPYLENE PRODUCED BY THE #!4/&). PROCESS
IS TYPICALLY USED FOR THE PRODUCTION OF POLYPROPYLENE WHERE PURITY DE
MANDS ARE THE MOST STRINGENT 4HE CONSUMPTION OF PROPANE
IS METRIC TON MT PER MT OF PROPYLENE PRODUCT
0ROPANE
!IR
/N PURGE
/N STREAM
&UEL GAS
2ECYCLE PROPANE
%XHAUST AIR
/N REHEAT
3TEAM
0ROPYLENE
# AND
HEAVIER
Economics: 7HERE A LARGE AMOUNT OF LOW VALUE ,0' IS AVAILABLE THE
#!4/&). PROCESS IS THE MOST ECONOMICAL WAY TO CONVERT IT TO HIGH VALUE
PRODUCT 4HE LARGE SINGLE
TRAIN CAPACITY POSSIBLE WITH #!4/&). UNITS THE
LARGEST TO DATE IS FOR MTPY PROPYLENE MINIMIZES THE INVESTMENT
COSTMT OF PRODUCT
)NVESTMENT )3", 'ULF #OAST 53MTPY
2AW MATERIAL AND UTILITIES PER MT OF PROPYLENE
0ROPANE MT
0OWER K7H
&UEL -7H
n
n
n
Propylene
(and
isobutylene), CONTINUED
Commercial
plants: #URRENTLY #!4/&). DEHYDROGENATION PLANTS ARE
ONSTREAM PRODUCING OVER MTPY OF ISOBUTYLENE AND
MTPY OF PROPYLENE
Licensor: !"" ,UMMUS 'LOBAL
Propylene
Application: 4O PRODUCE PROPYLENE FROM ETHYLENE AND BUTENES USING
,UMMUS OLEl N CONVERSION TECHNOLOGY /#4 /THER /#4 PROCESS CON
l GURATIONS INVOLVE INTERCONVERSION OF LIGHT OLEl NS AND PRODUCTION OF
# n # MONO
OLEl NS
'UARD BED
%THYLENE FEED
-ETATHESIS REACTOR %THYLENE COLUMN 0ROPYLENE COLUMN
2ECYCLE ETHYLENE
,IGHTS PURGE
0ROPYLENE
Description: %THYLENE FEEDSTREAM PLUS RECYCLE ETHYLENE AND BUTENES
FEEDSTREAM PLUS RECYCLE BUTENES ARE INTRODUCED INTO THE l XED BED
METATHESIS REACTOR 4HE CATALYST PROMOTES REACTION OF ETHYLENE AND
BUTENE TO FORM PROPYLENE AND SIMULTANEOUSLY ISOMERIZES BUTENE TO
BUTENE %Fm UENT FROM THE METATHESIS REACTOR IS FRACTIONATED TO YIELD
HIGH PURITY POLYMERIZATION GRADE PROPYLENE AS WELL AS ETHYLENE AND
BUTENES FOR RECYCLE AND SMALL BYPRODUCT STREAMS $UE TO THE UNIQUE
NATURE OF THE CATALYST SYSTEM THE MIXED # FEED STREAM CAN CONTAIN A
SIGNIl CANT AMOUNT OF ISOBUTYLENE WITHOUT IMPACTING PERFORMANCE OF
THE /#4 PROCESS ! VARIATION OF /#4!UTOMET 4ECHNOLOGYCAN BE
USED TO GENERATE ETHYLENE PROPYLENE AND THE COMONOMERHEXENE
BY METATHESIS OF N BUTENES
# PLUS
PURGE
# FEED
# RECYCLE
Yields: /#4 PROCESS SELECTIVITY TO PROPYLENE IS TYPICALLY GREATER THAN
/VERALL CONVERSION OF N
BUTENES IS n %THYLENE AND BUTENES FEED
STREAMS CAN COME FROM STEAM CRACKERS OR MANY REl NERY SOURCES AND IN
VARYING CONCENTRATIONS !LTERNATIVELY BUTENES CAN COME FROM ETHYLENE
DIMERIZATION WHICH IS ALSO LICENSED BY ,UMMUS
)N THE !UTOMET 4ECHNOLOGY BUTENES YIELD ABOUT ETHYLENE
PROPYLENE AND HEXENE
4HE BALANCE IS # AND HEAVIER MATERIAL
Economics: "ASED ON A MTPY PROPYLENE PLANT 53 'ULF #OAST
MID ASSUMING N BUTENES IN FEEDSTREAM
)NVESTMENT TOTAL DIRECT l ELD COST 53 MILLION
5TILITIES REQUIRED PER POUND OF PRODUCT
&UEL GAS l RED "TU
%LECTRICITY K7H
3TEAM PSIG SATURATED "TU
#OOLING DUTY "TU
.ITROGEN SCF
#ATALYST COST EST PER YR 53
-AINTENANCE PER YR AS OF INVESTMENT
Commercial
plants: ,YONDELL 0ETROCHEMICAL #O #HANNELVIEW 4EXAS
USES BOTH THE /#4 TECHNOLOGY AND ETHYLENE DIMERIZATION TECHNOLOGY
4WO OTHER PLANTS HAVE USED RELATED TECHNOLOGY 4WO PLANTS HAVE RECENTLY
STARTED UP A -- LBYR UNIT FOR "!3& &INA 0ETROCHEMICAL IN 0ORT
!RTHUR 4EXAS AND A -- LBYR UNIT FOR -ITSUI 0ETROCHEMICAL IN /SA
KA *APAN 3IX OTHER PLANTS ARE UNDER DESIGN OR CONSTRUCTION BRINGING
Propylene, CONTINUED
THE WORLDWIDE PROPYLENE CAPACITY VIA /#4 TO OVER MILLION MTPY 4HE
!UTOMET 4ECHNOLOGY IS IN OPERATION ON A SEMI
COMMERCIAL SCALE AT THE
4IANJIN 0ETROCHEMICAL #O IN 4IANJIN #HINA
Licensor: !"" ,UMMUS 'LOBAL
Propylene
Application: 4O PRODUCE POLYMER
GRADE PROPYLENE PLUS EITHER AN
ISOBUTYLENE
RICH STREAM OR -4"% BY UPGRADING LOW
VALUE PYROLYSIS #
CUTS OR BUTENE
RICH STREAMS VIA SELECTIVE HYDROGEN AND -ETA
PROCESS
ES 4HIS PROCESS IS PARTICULARLY PROl TABLE WHEN BUTADIENE MARKETS ARE
WEAK AND PROPYLENE DEMAND IS STRONG
Description: #RUDE # STREAMS ARE CONVERTED INTO PROPYLENE AND AN
-ETHANOL
FOR -4"% ONLY
(YDROGEN
2AW #S FROM
STEAM CRACKER
"UTADIENE
HYDROISOMERIZATION
3EPARATION
)SOBUTENE
RICH CUT
OR -4"%
ISOBUTYLENE RICH STREAM IN THREE )&0 PROCESS STEPS BUTADIENE AND #
ACETYLENES SELECTIVE HYDROGENATION AND BUTENES HYDROISOMERIZATION
ISOBUTYLENE REMOVAL VIA DISTILLATION OR -4"% PRODUCTION AND METATH
ESIS -ETA
4HE HYDROISOMERIZATION STEP FEATURES COMPLETE # ACETYLENES AND
BUTADIENE CONVERSION TO BUTENES MAXIMUM BUTENES PRODUCTION
m EXIBILITY TO PROCESS DIFFERENT FEEDS POLYMER FREE PRODUCT AND NO RESIDUAL
HYDROGEN 4HE SECOND STEP SEPARATES ISOBUTYLENE EITHER BY CONVENTIONAL
DISTILLATION OR BY REACTING THE ISOBUTYLENE WITH METHANOL TO PRODUCE
-4"%
4HE ##2 -ETA PROCESS FEATURES ARE A HARD HIGHLY ACTIVE AND
ROBUST CATALYST LOW CATALYST INVENTORY LOW OPERATING TEMPERATURE AND
PRESSURE OUTSTANDING YIELDS LIQUID PHASE OPERATION AND CONTINUOUS
OPERATION AND CATALYST REGENERATION
OF MOVING BED CONTINUOUS CATALYST REGENERATION TECHNOLOGY IS INDUSTRI
ALLY PROVEN IN !XENS ##2 /CTANIZING AND !ROMIZING REFORMERS
Yields: 0ROCESS SELECTIVITY TO PROPYLENE IS TYPICALLY GREATER THAN
Reference: #HODORGE * ! * #OSYNS $ #OMMEREUC 1 $EBUISSCHERT
/VERALL CONVERSION OF BUTENES CAN REACH
Economics: )3", INVESTMENT FOR A 'ULF #OAST LOCATION OF A -ETA
PROCESS PRODUCING TPY PROPYLENE IS 53 MILLION 4YPICAL
OPERATING COST IS PER METRIC TON OF PROPYLENE
Commercial
plants: /VER # HYDROGENATION UNITS HAVE BEEN BUILT
USING !XENS TECHNOLOGY 4HE ##2 -ETA
TECHNOLOGY HAS BEEN DEVEL
OPED JOINTLY WITH THE #HINESE 0ETROLEUM #ORP AND DEMONSTRATED ON
REAL FEEDSTOCK AT +AOHSIUNG 4AIWAN INDUSTRIAL COMPLEX 4HE SAME TYPE
"UTENES
RICH
CUT
%THYLENE
-ETA
0ROPYLENE
5NREACTED #S
AND #
AND 0 4RAVERS h-AXIMIZING PROPYLENE AND THE -ETA PROCESS v /IL 'AS
Licensor: !XENS !XENS .!
Propylene
Application: 4O PRODUCE PROPYLENE AND ETHYLENE FROM LOW
VALUE LIGHT
HYDROCARBON STREAMS FROM ETHYLENE PLANTS AND REl NERIES WITH FEEDS IN
THE CARBON NUMBER RANGE OF # TO # SUCH AS STEAM CRACKER # #
OLEl NS CAT
CRACKER NAPHTHAS OR COKER GASOLINES
&EED
Description: 4HE 350%2&,%8 PROCESS IS A PROPRIETARY TECHNOLOGY PAT
ENTED BY !2#/ #HEMICAL 4ECHNOLOGY )NC NOW ,YONDELL #HEMICAL
#O AND IS EXCLUSIVELY OFFERED WORLDWIDE FOR LICENSE BY +ELLOGG "ROWN
2OOT )T USES A m UIDIZED CATALYTIC REACTOR SYSTEM WITH A PROPRIETARY
CATALYST TO CONVERT LOW
VALUE FEEDSTOCKS TO PREDOMINATELY PROPYLENE
AND ETHYLENE PRODUCTS 4HE CATALYST IS VERY ROBUST THUS NO FEED PRE
TREATMENT IS REQUIRED FOR TYPICAL CONTAMINANTS SUCH AS SULFUR WATER
OXYGENATES OR NITROGEN !TTRACTIVE FEEDSTOCKS INCLUDE # AND # OLEl N
RICH STREAMS FROM ETHYLENE PLANTS &## NAPHTHAS OR #S THERMALLY
CRACKED NAPHTHAS FROM VISBREAKERS OR COKERS "48 OR -4"% RAFl NATES
# OLEl N
RICH STREAMS REMOVED FROM MOTOR GASOLINES AND &ISCHER
4ROPSCH LIGHT LIQUIDS
4HE m UIDIZED REACTOR SYSTEM IS SIMILAR TO A REl NERY &## UNIT AND
CONSISTS OF A m UIDIZED REACTORREGENERATOR VESSEL AIR COMPRESSION
CATALYST HANDLING m UE
GAS HANDLING AND FEED AND EFm UENT HEAT RECOVERY
5SING THIS REACTOR SYSTEM WITH CONTINUOUS CATALYST REGENERATION ALLOWS
HIGHER OPERATING TEMPERATURES THAN WITH COMPETING l XED
BED REACTORS
SO THAT A SUBSTANTIAL PORTION OF THE PARAFl NS AS WELL AS OLEl NS ARE
CONVERTED 4HIS ALLOWS FOR m EXIBILITY IN THE AMOUNTS OF PARAFl NS IN THE
FEEDS TO 350%2&,%8 AND THE ABILITY TO RECYCLE UNCONVERTED FEED TO
EXTINCTION
4HE COOLED REACTOR EFm UENT CAN BE PROCESSED FOR THE ULTIMATE
PRODUCTION OF POLYMER
GRADE OLEl NS 3EVERAL DESIGN OPTIONS ARE AVAIL
ABLE INCLUDING FULLY DEDICATED RECOVERY FACILITIES RECOVERY IN A NEARBY
EXISTING ETHYLENE PLANT RECOVERY SECTION TO MINIMIZE CAPITAL INVESTMENT
OR PROCESSING IN A PARTIAL RECOVERY UNIT TO RECOVER RECYCLE STREAMS AND
CONCENTRATE OLEl N
RICH STREAMS FOR FURTHER PROCESSING IN NEARBY PLANTS
## RECYCLE
3UPERFLEX
CONVERTER
&UEL OIL
&LUE GAS SYSTEM
#ATALYST
2
E
C
O
V
E
R
Y
,IGHT GAS
%THYLENE
0ROPYLENE
#
/IL WASH
2EGN AIR
Yields: 4HE TECHNOLOGY PRODUCES UP TO WT PROPYLENE PLUS ETHYLENE
WITH A PROPYLENE YIELD ABOUT TWICE THAT OF ETHYLENE FROM TYPICAL # AND
# RAFl NATE STREAMS 3OME TYPICAL YIELDS ARE
&EEDSTOCK
5LTIMATE YIELD WT
&UEL GAS
%THYLENE
0ROPYLENE
0ROPANE
# GASOLINE
&## ,#.
5LTIMATE YIELD WITH #S AND #S RECYCLED
0YROLYSIS 0YROLYSIS
#OKER ,.
#S
#S
Propylene, CONTINUED
Commercial
plants: 4HE lRST 350%2&,%8 LICENSEE WITH A PROPYLENE PRO
DUCTION OF MTPY IS 3ASOL 4ECHNOLOGY %NGINEERING IS UNDERWAY
AND COMPLETION OF THE UNIT IN 3OUTH !FRICA IS SCHEDULED FOR
Licensor: +ELLOGG "ROWN 2OOT )NC
Propylene
methanol
to
propylene
(MTP)
Application: 4O PRODUCE PROPYLENE FROM NATURAL GAS VIA METHANOL 4HIS
ROUTE DELIVERS DEDICATED PROPYLENE FROM NONPETROLEUM SOURCES IE IN
DEPENDENTLY FROM STEAM CRACKERS AND &##S
&UEL GAS
-ETHANOL
$-%
PRE
REACTOR
0RODUCT
CONDITIONING
Description: -ETHANOL FEED FROM A -EGA-ETHANOL PLANT IS SENT TO AN
ADIABATIC $-% PRE
REACTOR WHERE METHANOL IS CONVERTED TO $-% AND
WATER 4HE HIGH
ACTIVITY HIGH
SELECTIVITY CATALYST NEARLY ACHIEVES THERMO
DYNAMIC EQUILIBRIUM 4HE METHANOLWATER$-% STREAM IS ROUTED TO THE
l RST -40 REACTOR STAGE WHERE THE STEAM IS ADDED -ETHANOL$-% ARE
CONVERTED BY MORE THAN WITH PROPYLENE AS THE PREDOMINANT HY
DROCARBON PRODUCT !DDITIONAL REACTION PROCEEDS IN THE SECOND AND THIRD
-40 REACTOR STAGES 0ROCESS CONDITIONS IN THE THREE -40 REACTOR STAGES
ARE CHOSEN TO GUARANTEE SIMILAR REACTION CONDITIONS AND MAXIMUM TOTAL
PROPYLENE YIELD 4HE PRODUCT MIXTURE IS THEN COOLED AND PRODUCT GAS
ORGANIC LIQUID AND WATER ARE SEPARATED
4HE PRODUCT GAS IS COMPRESSED AND TRACES OF WATER #/ AND $-%
ARE REMOVED BY STANDARD TECHNIQUES 4HE CLEANED GAS IS THEN FURTHER
PROCESSED YIELDING CHEMICAL
OR POLYMER
GRADE PROPYLENE AS SPECIl ED
3EVERAL OLEl N
CONTAINING STREAMS ARE RECYCLED TO THE -40 REACTOR AS
ADDITIONAL PROPYLENE SOURCES 4O AVOID ACCUMULATION OF INERT MATERIALS
WITHIN THE LOOP A SMALL PURGE REMOVES LIGHT
ENDS FURTHER PURGE STREAMS
OF # AND # # (IGH
GRADE GASOLINE IS PRODUCED AS A BYPRODUCT
7ATER IS RECYCLED TO STEAM GENERATION EXCESS WATER FROM THE
METHANOL CONVERSION IS PURGED 4HIS PROCESS WATER CAN BE USED FOR
IRRIGATION AFTER APPROPRIATE AND INEXPENSIVE TREATMENT
Economics: #URRENT STUDIES AND PROJECTS ARE BASED ON A COMBINED
-EGA-ETHANOL -40 PLANT WITH A CAPACITY OF MTPD OF METHANOL
MILLION MTPY YIELDING APPROXIMATELY MTPY OF PROPYLENE
AND MTPY OF GASOLINE
"ASED ON A NATURAL GAS COST OF --"TU NET PRODUCTION COST
FOR PROPYLENE WILL BE MT )NCLUDING OWNERS COST CAPITALIZED
0ROPYLENE
,0'
-40
-40
-40
'ASOLINE
7ATER RECYCLE
/LEFIN RECYCLE
7ATER
2EACTOR SECTION
0URIFICATION SECTION
INTEREST AND DEPRECIATION ASSUMING A MODERATE CREDIT OF MT FOR
THE BYPRODUCT GASOLINE
Technology
status: &ROM *ANUARY UNTIL -ARCH A DEMONSTRA
TION UNIT WAS OPERATING AT THE 3TATOIL METHANOL PLANT AT 4JELDBERGODDEN
.ORWAY 4HIS UNIT HAS CONl RMED THE LAB RESULTS 4HE CATALYST IS COMMER
CIALLY AVAILABLE ,URGI OFFERS THE PROCESS ON COMMERCIAL TERMS
References: +OEMPEL ( 7 ,IEBNER AND - 7AGNER h-40 !N
ECONOMICAL ROUTE TO DEDICATED PROPYLENE v 3ECOND )#)3 ,/2 7ORLD
/LEl N #ONFERENCE !MSTERDAM &EB n
+OEMPEL ( 7 ,IEBNER AND - 2OTHAEMEL 0ROGRESS REPORT ON
Propylene
methanol
to
propylene
(MTP), CONTINUED
-40 WITH FOCUS ON $-% !)#H% 3PRING .ATIONAL MEETING .EW /RLEANS
!PRIL n
Licensor: ,URGI !'
Propylene
Applications:
4O PRIMARILY PRODUCE PROPYLENE FROM # TO # OLEl NS SUP
PLIED BY STEAM CRACKERS REl NERIES ANDOR METHANOL TO OLEl NS -4/
PLANTS VIA OLEl N CRACKING
Description: 4HE !4/&).!5/0 /LEl N #RACKING 0ROCESS WAS JOINTLY DE
/LEFINIC # n # FEED
/LEFIN CRACKING
REACTOR SECTION
,IGHT
OLEFIN
PRODUCT TO
RECOVERY
# BYPRODUCT
VELOPED BY 4OTAL 0ETROCHEMICALS FORMERLY !4/&).! AND 5/0 TO CONVERT
LOW
VALUE # TO # OLEl NS TO PROPYLENE AND ETHYLENE 4HE PROCESS FEA
TURES l XED
BED REACTORS OPERATING AT TEMPERATURES BETWEEN # AND
# AND PRESSURES BETWEEN AND BARS GAUGE
4HIS PROCESS USES A PROPRIETARY ZEOLITIC CATALYST AND PROVIDES HIGH YIELDS
OF PROPYLENE 5SAGE OF THIS CATALYST MINIMIZES REACTOR SIZE AND OPERATING
COSTS BY ALLOWING OPERATION AT HIGH
SPACE VELOCITIES AND HIGH CONVERSIONS
AND SELECTIVITIES WITHOUT REQUIRING AN INERT DILUENT STREAM ! SWING
REACTOR
SYSTEM IS USED FOR CATALYST REGENERATION 3EPARATION FACILITIES DEPEND ON
HOW THE UNIT IS INTEGRATED INTO THE PROCESSING SYSTEM
4HE PROCESS IS DESIGNED TO UTILIZE OLEl NIC FEEDSTOCKS FROM STEAM
CRACKERS REl NERY &## AND COKER UNITS AND -4/ UNITS WITH TYPICAL # TO
# OLEl N AND PARAFl N COMPOSITIONS 4HE CATALYST EXHIBITS LITTLE SENSITIVITY
TO COMMON IMPURITIES SUCH AS DIENES OXYGENATES SULFUR COMPOUNDS
AND NITROGEN COMPOUNDS
Commercial
plants: 4OTAL 0ETROCHEMICALS OPERATE A DEMONSTRATION UNIT
Economics: #APITAL AND OPERATING COSTS DEPEND ON HOW THE PROCESS IS
THAT WAS INSTALLED IN AN AFl LIATED REl NERY IN "ELGIUM IN %NGINEER
ING IS IN PROGRESS FOR THE l RST COMMERCIAL UNIT
INTEGRATED WITH STEAM CRACKING REl NERY OR OTHER FACILITIES
Yields: 0RODUCT YIELDS ARE DEPENDENT ON FEEDSTOCK COMPOSITION 4HE PRO
CESS PROVIDES PROPYLENEETHYLENE PRODUCTION AT RATIOS OF NEARLY #ASE
STUDIES OF OLEl N CRACKING INTEGRATION WITH NAPHTHA CRACKERS HAVE SHOWN
HIGHER PROPYLENE PRODUCTION COMPARED TO CONVENTIONAL NAPHTHA
CRACKER PROCESSING
Reference: 6ERMEIREN 7 * !NDERSEN 2 *AMES $ 7EI h-EETING THE
CHANGING NEEDS OF THE LIGHT OLEl NS MARKET v (YDROCARBON %NGINEERING
/CTOBER
$EPROPANIZER
$EBUTANIZER
# BYPRODUCTS
Licensor: 5/0 ,,#
Propylene
Application: 4O PRODUCE POLYMER
GRADE PROPYLENE FROM PROPANE USING
THE /LEm EX PROCESS IN A PROPYLENE PRODUCTION COMPLEX
#
#
2
Description: 4HE COMPLEX CONSISTS OF A REACTOR SECTION CONTINUOUS CATA
LYST REGENERATION ##2 SECTION PRODUCT SEPARATION SECTION AND FRACTION
ATION SECTION &OUR RADIAL
m OW REACTORS ARE USED TO ACHIEVE OPTIMUM
CONVERSION AND SELECTIVITY FOR THE ENDOTHERMIC REACTION #ATALYST ACTIVITY
IS MAINTAINED BY CONTINUOUSLY REGENERATING CATALYST 2EACTOR EFm UENT
IS COMPRESSED DRIED AND SENT TO A CRYOGENIC SEPARATION SYSTEM
! NET HYDROGEN STREAM IS RECOVERED AT APPROXIMATELY MOL HY
DROGEN PURITY 4HE OLEl N PRODUCT IS SENT TO A SELECTIVE HYDROGENATION
PROCESS WHERE DIENES AND ACETYLENES ARE REMOVED 4HE PROPYLENE
STREAM GOES TO A DEETHANIZER WHERE LIGHT
ENDS ARE REMOVED PRIOR TO
THE PROPANE
PROPYLENE SPLITTER 5NCONVERTED FEEDSTOCK IS RECYCLED
BACK TO THE DEPROPANIZER WHERE IT COMBINES WITH FRESH FEED BEFORE
BEING SENT BACK TO THE REACTOR SECTION
4URBO
EXPANDER
2EACTORS AND HEATERS
0ROPANE
FEED
0ROPYLENE
3(0
#n
(
( 2ECYCLE
.ET ( STREAM
#
Yields: 0ROPYLENE YIELD FROM PROPANE IS APPROXIMATELY WT OF FRESH
FEED (YDROGEN YIELD IS ABOUT WT OF FRESH FEED
Economics: 53 'ULF #OAST INSIDE BATTERY LIMITS ARE BASED ON AN /LE
m EX COMPLEX UNIT FOR PRODUCTION OF MTPY OF POLYMER
GRADE
PROPYLENE 4HE UTILITY SUMMARY IS NET UTILITIES ASSUMING ALL LIGHT ENDS ARE
USED AS FUEL
)NSIDE BATTERY LIMITS INVESTMENT MILLION
4OTAL PROJECT INVESTMENT MILLION
4YPICAL NET UTILITY REQUIREMENTS PER TON OF PROPYLENE PRODUCT
%LECTRICITY K7H
7ATER COOLING M
.ET FUEL GAS --KCAL EXPORT CREDIT
#ATALYST AND CHEMICAL COST METRIC TON PRODUCT
Commercial
plants: %LEVEN /LEm EX UNITS ARE IN OPERATION TO PRODUCE
PROPYLENE AND ISOBUTYLENE 3IX OF THESE UNITS PRODUCE PROPYLENE 4HESE
UNITS REPRESENT MILLION MTPY OF PROPYLENE PRODUCTION 4HREE AD
DITIONAL /LEm EX UNITS FOR PROPYLENE PRODUCTION ARE IN DESIGN OR UNDER
CONSTRUCTION
Licensor: 5/0 ,,#
PVC
(suspension)
Application: ! PROCESS TO PRODUCE POLYVINYL CHLORIDE 06# FROM VINYL
CHLORIDE MONOMER 6#- USING SUSPENSION POLYMERIZATION -ANY TYPES
OF 06# GRADES ARE PRODUCED INCLUDING COMMODITY HIGH +
VALUE LOW
+
VALUE MATTED TYPE AND CO
POLYMER 06# 4HE 06# POSSESSES EXCELLENT
PRODUCT QUALITIES SUCH AS EASY PROCESSABILITY AND GOOD HEAT STABILITY
Description: 06# IS PRODUCED BY BATCH POLYMERIZATION OF 6#- DISPERSED
IN WATER 3TANDARD REACTOR SIZES ARE OR M
4HE STIRRED REACTOR IS CHARGED WITH WATER ADDITIVES AND 6#-
$URING POLYMERIZATION REACTION THE TEMPERATURE IS CONTROLLED AT A DE
l NED TEMPERATURE DEPENDING ON THE GRADE BY COOLING WATER OR CHILLED
WATER !T THE END OF THE REACTION THE CONTENTS ARE DISCHARGED INTO A
BLOWDOWN TANK WHERE MOST OF THE UNREACTED 6#- IS m ASHED OFF 4HE
REACTOR IS RINSED AND SPRAYED WITH AN ANTI FOULING AGENT AND IS READY FOR
THE FOLLOWING BATCH
4HE 06# SLURRY CONTAINING 6#- IS CONTINUOUSLY FED TO THE STRIPPING COL
UMN 4HE COLUMN HAS A PROPRIETARY DESIGN AND EFFECTIVELY RECOVERS 6#-
FROM THE 06# SLURRY WITHOUT ANY DETERIORATION OF 06# QUALITY !FTER STRIP
PING THE SLURRY IS DE WATERED AND DRIED EFFECTIVELY BY THE PROPRIETARY
DRYER )T IS THEN PASSED TO STORAGE SILOS FOR TANKER LOADING OR BAGGING
2ECOVERED 6#- IS HELD IN A GAS HOLDER THEN COMPRESSED COOLED
AND CONDENSED TO BE REUSED FOR THE FOLLOWING POLYMERIZATION BATCH
Economics:
2AW MATERIALS AND UTILITIES PER TON OF 06#
6#- T
%LECTRICITY K7H
3TEAM T
!DDITIVES FOR PIPE GRADE 53
Commercial
plants: 4HE PROCESS HAS BEEN SUCCESSFULLY LICENSED TIMES
WORLDWIDE 4OTAL CAPACITY OF THE #HISSO PROCESS IN THE WORLD IS MORE
THAN MILLION TPY )N ADDITION #HISSO 6#- REMOVAL TECHNOLOGY HAS
BEEN LICENSED TO MANY 06# PRODUCERS WORLDWIDE
6#GAS HOLDER
2ECOVERY 6#&RESH 6#!DDITIVES
7ATER
2EACTOR
Licensor: #HISSO #ORP
#ENTRIFUGE
%FFLUENT
"LOWDOWN
TANK
3TRIPPING
COLUMN
3LURRY
TANK
$RYER
06# PRODUCT
PVC
(suspension)
Application: 0RODUCTION OF SUSPENSION POLYVINYL CHLORIDE 06# RESINS
,IQUID
2
6#-
FROM VINYL CHLORIDE MONOMER 6#- USING THE 6INNOLIT PROCESS
Description: 4HE 6INNOLIT 06# PROCESS USES A NEW HIGH PERFORMANCE RE
ACTOR WHICH IS AVAILABLE IN SIZES UP TO M ! CLOSED AND CLEAN
REACTOR TECHNOLOGY IS APPLIED THUS OPENING OF THE REACTORS IS NOT NECES
SARY EXCEPT FOR OCCASIONAL INSPECTIONS %QUALLY IMPORTANT HIGH
PRESSURE
WATER CLEANING IS NOT NECESSARY !LL PROCESS OPERATIONS OF THIS UNIT ARE
CONTROLLED BY A DISTRIBUTED PROCESS CONTROL SYSTEM $#3
4HE BATCH
WISE POLYMERIZATION OCCURS IN THE FOLLOWING OPERATION SE
QUENCE
s 0REPARE THE REACTOR WHICH INCLUDES APPLYING A HIGHLY EFFECTIVE AN
TIFOULING AGENT
s #HARGE REACTION SOLUTIONS INCLUDING DISPERSING AGENTS ADDITIVES
CHEMICALS 6#- AND WATER INTO THE REACTOR
s %XOTHERMIC CONVERSION FROM 6#- TO 06#
s $ISCHARGE OF THE 06# SLURRY INTO THE BLOWDOWN TANK
s &LUSH THE REACTOR INTERNALS
4HE 06# SLURRY AND UNREACTED 6#- FROM THE POLYMERIZATION REACTORS
ARE FED TO THE BLOWDOWN TANK THE INTERMEDIATE BUFFER BETWEEN THE DIS
CONTINUOUS POLYMERIZATION AND THE CONTINUOUS DEGASSING AND DRYING UNIT
)N THE BLOWDOWN TANK UNREACTED 6#- IS m ASHED OUT OF THE 06#
SLURRY &ROM THE BLOWDOWN TANK THE SLURRY IS FED THROUGH HEAT RECU
PERATOR TO THE SIEVE
TRAY TYPE 6INNOLIT DEGASSING COLUMN 6#- IS
STRIPPED OUT WITH STEAM 4HE 6#- CONCENTRATION OF THE SLURRY LEAVING
THE DEGASSING COLUMN IS LESS THAN PPM 4HE UNREACTED 6#- IS LIQUE
l ED IN THE 6#- RECOVERY UNIT AND CHARGED BACK TO POLYMERIZATION !FTER
DEWATERING THE SUSPENSION IN THE CENTRIFUGE THE WET 06# CAKE IS FED
IN THE 6INNOLIT CYCLONE DRYING SYSTEM 4HE SOLID PARTICLES AND AIR ARE
SEPARATED IN THE CYCLONE SEPARATOR
Economics: #HILLED WATER FOR POLYMERIZATION IS NOT REQUIRED (IGH PRO
DUCTIVITY IS ACHIEVED BY USING AN INNER
COOLER REACTOR
6#RECOVERY
&RESH
6##OOLING
WATER
$EMIN
WATER
$ISPER
AGENT
#ATALYST
2 6#2 6#-
3LURRY
3LURRY
3TEAM
.ATURAL GAS
OR STEAM
$RIED
06# TO
STORAGE
&RESH
AIR
3LURRY
$EGASSED
SLURRY TO
CENTRIFUGE
3
06# PROCESS
POLYMERIZATION AND DEGASSING
!IR HEATER
3
06# PROCESS DRYING
2AW MATERIALS AND UTILITIES PER METRIC TON OF 06#
6#- T
3TEAM T
%LECTRICITY K7H
!DDITIVE COSTS FOR PIPE GRADE 53
0RODUCTIVITY T M Y
UP TO
Commercial
plants: 6INNOLIT IS PRODUCING UP TO 06# METRIC TPY
4OTAL CAPACITY OF THE 6INNOLIT PROCESS IN THE WORLD IS ABOUT ONE MILLION
METRIC TPY 6INNOLIT CYCLONE DRYER HAS BEEN LICENSED TO MANY 06# PRO
DUCERS WORLDWIDE
PVC
(suspension), CONTINUED
Licensor: 6INNOLIT
Contractor: 5HDE 'MB(
Upgrading
pyrolysis
gasoline
Application: )NCREASE THE VALUE OF STEAM CRACKER PYROLYSIS GASOLINE PY
GAS USING CONVERSION DISTILLATION AND SELECTIVE HYDROGENATION PROCESS
ES 0YGAS THE # n # FRACTION ISSUING FROM STEAM CRACKERS IS A POTENTIAL
SOURCE OF PRODUCTS SUCH AS DICYCLOPENTADIENE $#0$ ISOPRENE CYCLO
PENTANE BENZENE TOLUENE AND XYLENES
Description: 4O PRODUCE $#0$ AND ISOPRENE PYGAS IS DEPENTANIZED AND
THE # FRACTION IS PROCESSED THERMALLY TO DIMERIZE CYCLOPENTADIENE TO
$#0$ WHICH SEPARATES EASILY FROM THE #S VIA DISTILLATION )SOPRENE
CAN BE RECOVERED BY EXTRACTIVE DISTILLATION AND DISTILLATION 4HE REMAINING
#S AND THE # n # CUT ARE FED TO THE l RST STAGE CATALYTIC HYDROGENA
TION UNIT WHERE OLEl NS AND DIOLEl NS ARE ELIMINATED
4HE #S ARE RECYCLED TO THE STEAM CRACKER OR AN ISOMERIZATION UNIT
3ULFUR AND NITROGEN COMPOUNDS ARE REMOVED IN THE SECOND STAGE
HYDROGENATION UNITS 4HE "48 CUT IS IDEAL FOR PROCESSING IN AN AROMATICS
COMPLEX
#
$#0$
DIMERIZATION
AND RECOVERY
$#0$
#S TO ISOPRENE EXTRACTION
#S FROM ISOPRENE EXTRACTION
0YROLYSIS
GASOLINE
&'
(3
#S TO # n #
&' STEAM
CRACKING
FURNACES
#
ST STAGE
HYDRO
ND STAGE
HYDRO
(
(
# n #
AROMATICS
#
OPTIONAL
Yields: &OR THE NEW GENERATION CATALYSTS RECOVERY AND PRODUCT QUALITY
PARAMETERS ARE AS FOLLOWS
# TO # AROMATICS RECOVERY
"ENZENE RECOVERY
$IENE VALUE
"ROMINE )NDEX MGG
3ULFUR PPM
4HIOPHENE PPM
# CUT "ROMINE )NDEX MGG
# CUT ACID WASH COLOR
Economics: "ASED ON A MILLION METRIC TPY NAPHTHA STEAM CRACKER PRO
DUCING A TPY PYGAS STREAM )3", 'ULF #OAST LOCATION IN
)NVESTMENT 53 METRIC TON OF FEED
5TILITIES CATALYSTS 53 METRIC TON
References: $EBUISSCHERT 1 0 4RAVERS AND 6 #OUPARD h/PTIMIZING
0YROLYSIS 'ASOLINE 5PGRADING v (YDROCARBON %NGINEERING *UNE
Commercial
plants: /VER ST STAGE AND ND STAGE PYGAS HYDROGE
NATION UNITS HAVE BEEN LICENSED
Licensor: !XENS !XENS .!
Styrene
Application: 4O PRODUCE POLYMER
GRADE STYRENE MONOMER 3- BY DEHY
2ECYCLE BENZENE
DROGENATING ETHYLBENZENE %" TO FORM STYRENE USING THE ,UMMUS5/0
h#LASSICv STYRENE PROCESS FOR NEW PLANTS AND THE ,UMMUS5/0 3-!24
PROCESS FOR REVAMPS INVOLVING PLANT CAPACITY EXPANSION
)NHIBITOR
Description: )N THE #LASSIC 3- PROCESS %" IS CATALYTICALLY DEHYDROGE
NATED TO STYRENE IN THE PRESENCE OF STEAM 4HE VAPOR PHASE REACTION
IS CARRIED OUT AT HIGH TEMPERATURE UNDER VACUUM 4HE %" FRESH AND
RECYCLE IS COMBINED WITH SUPERHEATED STEAM AND THE MIXTURE IS DE
HYDROGENATED IN A MULTISTAGE REACTOR SYSTEM ! HEATER REHEATS THE
PROCESS GAS BETWEEN STAGES 2EACTOR EFm UENTS ARE COOLED TO RECOVER
WASTE HEAT AND CONDENSE THE HYDROCARBONS AND STEAM 5NCONDENSED
OFFGAS CONTAINING MOSTLY HYDROGEN IS COMPRESSED AND IS USED AS
FUEL #ONDENSED HYDROCARBONS FROM AN OILWATER SEPARATOR ARE SENT
TO THE DISTILLATION SECTION 0ROCESS CONDENSATE IS STRIPPED TO REMOVE
DISSOLVED AROMATICS
! FRACTIONATION TRAIN SEPARATES HIGH
PURITY STYRENE PRODUCT UN
CONVERTED %" WHICH IS RECYCLED AND THE RELATIVELY MINOR BYPRODUCT TAR
WHICH IS USED AS FUEL 4OLUENE IS PRODUCED AS A MINOR BYPRODUCT
AND BENZENE IS NORMALLY RECYCLED TO THE UPSTREAM %" PROCESS
4YPICAL 3- PRODUCT PURITY RANGES FROM TO 4HE PRO
CESS PROVIDES HIGH
PRODUCT YIELD DUE TO A UNIQUE COMBINATION OF CATALYST
AND OPERATING CONDITIONS USED IN THE REACTORS AND THE USE OF A HIGHLY
EFFECTIVE POLYMERIZATION INHIBITOR IN THE FRACTIONATION COLUMNS
4HE 3-!24 3- PROCESS IS THE SAME AS #LASSIC 3- EXCEPT THAT OXI
DATIVE REHEAT TECHNOLOGY IS USED BETWEEN THE DEHYDROGENATION STAGES
OF THE MULTISTAGE REACTOR SYSTEM 3PECIALLY DESIGNED REACTORS ARE
USED TO ACHIEVE THE OXIDATION AND DEHYDROGENATION REACTIONS )N OXI
DATIVE REHEAT OXYGEN IS INTRODUCED TO OXIDIZE PART OF THE HYDROGEN
PRODUCED OVER A PROPRIETARY CATALYST TO REHEAT THE PROCESS GAS AND TO
REMOVE THE EQUILIBRIUM CONSTRAINT FOR THE DEHYDROGENATION REACTION
4HE PROCESS ACHIEVES UP TO ABOUT %" CONVERSION PER PASS ELIMI
3TYRENE
MONOMER
4OLUENE
4AR
&UEL GAS
%THYLBENZENE
3TEAM
3TEAM
#OMPRESSOR
(YDROCARBONS
!IR/
3UPERHEATER
3-!24 ONLY
#ONDENSATE
NATES THE COSTLY INTERSTAGE REHEATER AND REDUCES SUPERHEATED STEAM
REQUIREMENTS &OR EXISTING 3- PRODUCERS REVAMPING TO 3-!24 3-
MAY BE THE MOST COST EFFECTIVE ROUTE TO INCREASED CAPACITY
Economics: #LASSIC MTPY )3", 53 'ULF #OAST
)NVESTMENT 53 MILLION
%THYLBENZENE TONTON 3-
5TILITIES 53MTON 3-
Commercial
plants: #URRENTLY OPERATING PLANTS INCORPORATE THE
,UMMUS 5/0 #LASSIC 3TYRENE TECHNOLOGY 3EVEN OPERATING FACILITIES
Styrene, CONTINUED
ARE USING THE 3-!24 PROCESS TECHNOLOGY -ANY FUTURE UNITS USING THE
3-!24 PROCESS ARE EXPECTED TO BE RETROlTS OF CONVENTIONAL UNITS SINCE
THE TECHNOLOGY IS IDEALLY SUITED FOR REVAMPS
Licensor: !"" ,UMMUS 'LOBAL AND 5/0 ,,#
Styrene
Application: 0ROCESS TO MANUFACTURE STYRENE MONOMER 3- BY DEHYDRO
GENATING ETHYLBENZENE %" TO STYRENE &EEDSTOCK %" IS PRODUCED BY AL
KYLATING BENZENE WITH ETHYLENE USING THE -OBIL"ADGER %"-AX PROCESS
3TYRENE PRODUCT
"ENZENETOLUENE BYPRODUCT
Description: %" IS DEHYDROGENATED TO STYRENE OVER POTASSIUM PROMOTED
IRON
OXIDE CATALYST IN THE PRESENCE OF STEAM 4HE ENDOTHERMIC REACTION IS
DONE UNDER VACUUM CONDITIONS AND HIGH TEMPERATURE !T WEIGHT RATIO
OF STEAM TO %" FEED AND A MODERATE %" CONVERSION REACTION SELECTIVITY TO
STYRENE IS OVER "YPRODUCTS BENZENE AND TOLUENE ARE RECOVERED VIA
DISTILLATION WITH THE BENZENE FRACTION BEING RECYCLED TO THE %" UNIT
6APORIZED FRESH AND RECYCLE %" ARE MIXED WITH SUPERHEATED STEAM AND
FED TO A MULTI
STAGE ADIABATIC REACTOR SYSTEM "ETWEEN DEHYDROGENATION
STAGES HEAT IS ADDED TO DRIVE THE %" CONVERSION TO ECONOMIC LEVELS
TYPICALLY BETWEEN AND (EAT CAN BE ADDED EITHER INDIRECTLY USING
CONVENTIONAL MEANS SUCH AS A STEAM HEAT EXCHANGER OR DIRECTLY USING A
PROPRIETARY $IRECT (EATING 4ECHNOLOGY DEVELOPED BY 3HELL /IL
2EACTOR EFm UENT IS COOLED IN A SERIES OF EXCHANGERS TO RECOVER WASTE
HEAT AND TO CONDENSE THE HYDROCARBONS AND STEAM 5NCONDENSED
OFFGASPRIMARILY HYDROGENIS COMPRESSED AND THEN DIRECTED TO AN
ABSORBER SYSTEM FOR RECOVERY OF TRACE AROMATICS &OLLOWING AROMATICS
RECOVERY THE HYDROGEN
RICH OFFGAS IS CONSUMED AS FUEL BY PROCESS
HEATERS #ONDENSED HYDROCARBONS AND CRUDE STYRENE ARE SENT TO THE
DISTILLATION SECTION WHILE PROCESS CONDENSATE IS STRIPPED TO REMOVE
DISSOLVED AROMATICS AND GASES 4HE CLEAN PROCESS CONDENSATE IS RETURNED
AS BOILER FEEDWATER TO OFFSITE STEAM BOILERS
4HE DISTILLATION TRAIN l RST SEPARATES THE BENZENETOLUENE BYPRODUCT FROM
MAIN CRUDE STYRENE STREAM 5NCONVERTED %" IS SEPARATED FROM STYRENE
AND RECYCLED TO THE REACTION SECTION 6ARIOUS HEAT RECOVERY SCHEMES ARE USED
TO CONSERVE ENERGY FROM THE %"3- COLUMN SYSTEM )N THE l NAL PURIl CATION
STEP TRACE # COMPONENTS AND HEAVIES ARE SEPARATED FROM THE l NISHED
3- 4O MINIMIZE POLYMERIZATION IN DISTILLATION EQUIPMENT A DINITROPHENOLIC
TYPE INHIBITOR IS CO
FED WITH THE CRUDE FEED FROM THE REACTION SECTION 4YPICAL
3- PURITY RANGES BETWEEN AND
2ECYCLE %"
#RUDE
STYRENE
/FFGAS
TO FUEL
(EAVIES TO FUEL
&RESH %"
3TEAM
$ECANTER
!IR OR
COOLING
WATER
3TEAM
#LEAN
CONDENSATE
Economics:
%THYLBENZENE CONSUMPTION PER TON OF 3-
.ET ENERGY INPUT KCAL PER TON OF 3-
7ATER COOLING M PER TON OF 3-
OTE 2AW MATERIAL AND UTILITY REQUIREMENTS PRESENTED ARE REPRESENTATIVE EACH PLANT IS
.
OPTIMIZED BASED ON SPECIl C RAW MATERIAL AND UTILITY COSTS
Commercial
plants: 4HE TECHNOLOGY HAS BEEN SELECTED FOR USE IN OVER
UNITS HAVING DESIGN CAPACITIES SINGLE TRAIN RANGING FROM TO
-MTPY 4HE AGGREGATE CAPACITY OF THESE UNITS EXCEEDS --MTPY
Licensor: "ADGER ,ICENSING ,,#
Styrene
Application: 4O DIRECTLY RECOVER STYRENE FROM RAW PYROLYSIS GASOLINE DE
RIVED FROM STEAM CRACKING OF NAPHTHA GAS OILS AND .',S USING THE '4
3TYRENE PROCESS
3TYRENE
CONCENTRATE
Description: 2AW PYROLYSIS GASOLINE IS PREFRACTIONATED INTO A HEARTCUT #
STREAM 4HE RESULTING STYRENE CONCENTRATE IS FED TO AN EXTRACTIVE
DISTILLATION
COLUMN AND MIXED WITH A SELECTIVE SOLVENT WHICH EXTRACTS STYRENE TO THE
TOWER BOTTOMS 4HE RICH SOLVENT MIXTURE IS ROUTED TO A SOLVENT
RECOVERY
COLUMN WHICH RECYCLES LEAN SOLVENT TO THE EXTRACTIVE
DISTILLATION COLUMN
AND RECOVERS THE STYRENE OVERHEAD ! l NAL PURIl CATION STEP PRODUCES A
STYRENE PRODUCT CONTAINING LESS THAN PPM PHENYL ACETYLENE
4HE EXTRACTIVE
DISTILLATION COLUMN OVERHEAD CAN BE FURTHER PROCESSED
TO RECOVER A HIGH
QUALITY MIXED XYLENE STREAM ! TYPICAL WORLD
SCALE
CRACKER COULD PRODUCE APPROXIMATELY TPY STYRENE AND
TPY MIXED XYLENES FROM PYROLYSIS GASOLINE
4HE STYRENE IS A HIGH
PURITY PRODUCT SUITABLE FOR POLYMERIZATION AT
A VERY ATTRACTIVE COST COMPARED WITH CONVENTIONAL STYRENE PRODUCTION
ROUTES )F DESIRED THE MIXED XYLENES CAN ALSO BE EXTRACTED FROM THE
PYGAS UPGRADING THEIR VALUE AS CHEMICAL FEEDSTOCK 4HE PROCESS IS
ECONOMICALLY ATTRACTIVE FOR TYPICAL PYGAS AND SUPPLEMENTAL FEEDS WHICH
CONTAIN TPY OR MORE STYRENE
4RADITIONAL PYGAS PROCESSING SCHEMES DESTROY STYRENE IN THE l RST
STAGE
HYDROGENATION UNIT (YDROTREATED PYGAS IS THEN FRACTIONATED TO EXTRACT
BENZENE AND TOLUENE 7ITH THE '4
3TYRENE PROCESS THIS FRACTIONATION
IS MADE UPSTREAM OF THE HYDROTREATERS WHICH AVOIDS SOME HYDROGEN
CONSUMPTION AND CATALYST FOULING BY STYRENE POLYMERS )N MANY CASES
MOST OF THE EXISTING FRACTIONATION EQUIPMENT CAN BE RE
USED IN THE
STYRENE
RECOVERY MODE OF OPERATION
Economics: 3TYRENE RECOVERY CONSIDERING STYRENE UPGRADE ONLY BASIS
TPY STYRENE CAPACITY
4YPICAL 53 '# CAPITAL COST --
3TYRENE VALUE IN PYGAS T
4O HYDROGENATION
AND "48 RECOVERY
#n#
#
%XTRACTIVE
DISTILLATION
COLUMN
#n#
0YROLYSIS
GASOLINE
0URIFIER
3TYRENE
PRODUCT
3OLVENT
RECOVERY
COLUMN
2ICH SOLVENT
#
,EAN SOLVENT
0REFRACTIONATOR
3TYRENE RECOVERY
3TYRENE PRODUCT SALES VALUE T
0ROCESSING COST T
'ROSS MARGIN --YR
0RETAX 2/)
0URIFICATION
Commercial
plants: /NE LICENSE HAS BEEN PLACED
Reference: h'ENERATE MORE REVENUES FROM PYGAS PROCESSING v (YDRO
CARBON 0ROCESSING *UNE
Licensor: '4# 4ECHNOLOGY
Styrene
acrylonitrile
(SAN)
copolymer
Application: 4O PRODUCE A WIDE RANGE OF STYRENE ACRYLONITRILE 3!. CO
POLYMER WITH EXCELLENT CHEMICAL RESISTANCE HEAT RESISTANCE AND SUITABLE
PROPERTY FOR COMPOUNDING WITH !"3 VIA THE CONTINUOUS BULK POLYMER
IZATION PROCESS USING 4OYO %NGINEERING #ORP 4%# -ITSUI #HEMICALS
)NC TECHNOLOGY
3TYRENE
!CRYLONITRILE
3OLVENT
!DDITIVES
Description: 3TYRENE MONOMER ACRYLONITRILE A SMALL AMOUNT OF SOLVENT
AND ADDITIVES ARE FED TO THE SPECIALLY DESIGNED REACTOR WHERE THE
POLYMERIZATION OF THE FED MIXTURE IS CARRIED OUT 4HE POLYMERIZATION
TEMPERATURE OF THE REACTOR IS CAREFULLY CONTROLLED AT A CONSTANT LEVEL TO
MAINTAIN THE DESIRED CONVERSION RATE 4HE HEAT OF THE POLYMERIZATION IS
EASILY REMOVED BY A SPECIALLY DESIGNED HEAT TRANSFER SYSTEM !T THE EXIT
OF THE REACTOR THE POLYMERIZATION IS ESSENTIALLY COMPLETE
4HE MIXTURE IS PREHEATED AND TRANSFERRED TO THE DEVOLATILIZER
6OLATILE COMPONENTS ARE SEPARATED FROM THE POLYMER SOLUTION BY EVAPO
RATION UNDER VACUUM 4HE RESIDUALS ARE CONDENSED AND RECYCLED TO
THE PROCESS 4HE MOLTEN POLYMER IS PUMPED THROUGH A DIE AND CUT
INTO PELLETS BY A PELLETIZER
Economics: "ASIS METRIC TPY 3!. 53 'ULF #OAST
)NVESTMENT MILLION 53
2AW MATERIALS CONSUMPTION PER ONE METRIC TON OF 3!. KG
5TILITIES CONSUMPTION PER ONE METRIC TON OF 3!. 53
Installations: 3EVENTEEN PLANTS IN *APAN +OREA 4AIWAN #HINA AND 4HAI
LAND ARE IN OPERATION WITH A TOTAL CAPACITY OF METRIC TPY
Licensor:
4OYO %NGINEERING #ORP 4%# -ITSUI #HEMICALS )NC
0REHEATER
2EACTOR
6ACUUM
2ECOVERED MONOMER
3TORAGE
0ELLETIZER
#ONDENSER
$IE HEAD
$EVOLATILIZER
Terephthalic
acid
(E
PTA)
Application: % 04! %ASTMAN POLYMER
GRADE TEREPHTHALIC ACID IS AN EX
CELLENT RAW MATERIAL FOR ENGINEERING PLASTICS AND PACKAGING MATERIALS
BOTTLES OTHER FOOD CONTAINERS INCLUDING HOT l LL AS WELL AS l LMS 4HE
PROCESS IS PROVEN TO BE SUITABLE FOR THE PRODUCTION OF ALL KINDS OF POLYES
TER l BERS AND CONTAINERS WITHOUT LIMITATION AT INTERNATIONAL l RST
GRADE
QUALITY
Description: 4HE GENERAL m OW DIAGRAM TO PRODUCE % 04! USING %AST
MAN #HEMICALS PROPRIETARY PROCESS COMPRISES THREE DIFFERENT MAIN SEC
TIONS CRUDE TEREPHTHALIC ACID #4! POLYMER
GRADE TEREPHTHALIC ACID %
04! AND CATALYST RECOVERY
Crude
terephthalic
acid
(1,2,3): #4! IS PRODUCED BY THE CATALYTIC
OXIDATION OF P
XYLENE WITH AIR IN THE LIQUID PHASE USING ACETIC ACID AS
A SOLVENT 4HE FEED MIX P
XYLENE SOLVENT AND CATALYST TOGETHER
WITH COMPRESSED AIR IS CONTINUOUSLY FED TO THE REACTOR WHICH IS A
BUBBLE
COLUMN OXIDIZER )T OPERATES AT MODERATE TEMPERATURE AND
OFFERS AN EXTREMELY HIGH YIELD 4HE OXIDIZER PRODUCT IS KNOWN AS CRUDE
TEREPHTHALIC ACID #4! DUE TO THE HIGH LEVEL OF IMPURITIES CONTAINED
-ANY IMPURITIES ARE FAIRLY SOLUBLE IN THE SOLVENT )N THE #4! SEPARATION
STEP IMPURITIES CAN BE EFFECTIVELY REMOVED FROM THE PRODUCT BY
EXCHANGING THE REACTION LIQUOR WITH LEAN SOLVENT FROM THE SOLVENT
RECOVERY SYSTEM 4HE REACTOR OVERHEAD VAPOR MAINLY REACTION WATER
ACETIC ACID AND NITROGEN IS SENT TO THE SOLVENT
RECOVERY SYSTEM WHERE
WATER IS SEPARATED FROM THE SOLVENT BY DISTILLATION !FTER RECOVERING ITS
ENERGY THE OFFGAS IS SENT TO A REGENERATIVE THERMAL OXIDATION UNIT FOR
FURTHER CLEANING
Polymer-grade
terephthalic
acid
(5,6): 4HE CRUDE ACID IS PURIl ED
TO OBTAIN % 04! IN A POST
OXIDATION STEP AT ELEVATED TEMPERATURE
CONDITIONS 4HE POST OXIDIZERS SERVE AS REACTORS TO INCREASE CONVERSION
OF THE PARTIALLY OXIDIZED COMPOUNDS TO TEREPHTHALIC ACID 4HE LEVEL OF
CARBOXY BENZALDEHYDE
#"! P
TOLUIC ACID P
4! THE MAIN IMPURITIES
IN TEREPHTHALIC ACID IS SIGNIl CANTLY LOWERED )N A l NAL STEP % 04!
P 8YLENE
!CETIC
ACID
/XIDATION
6ENT GAS TO OFF GAS CLEANING
3OLVENT
RECOVERY
#4!
SEPARATION
7ASTEWATER TO TREATMENT
0OST
OXIDATION
#ATALYST
!IR
% 04!
SEPARATION
AND DRYING
!IR
3OLVENT CATALYST RECYCLE
&ILTRATE
TREATMENT
AND CATALYST
RECOVERY
% 04!
TO 0%4
PROCESS
#4! RESIDUE
TO INCINERATION
IS SEPARATED FROM THE SOLVENT AND DRIED FOR FURTHER PROCESSING IN THE
POLYESTER
PRODUCTION FACILITIES
Catalyst
recovery
(4): !FTER EXCHANGING THE LIQUOR IN THE #4!
SEPARATION THE SUSPENDED SOLIDS ARE SEPARATED AND REMOVED AS #4!
RESIDUE WHICH CAN BE BURNED IN A m UIDIZED
BED INCINERATOR OR IF
DESIRABLE USED AS LAND l LL 4HE SOLUBLE IMPURITIES ARE REMOVED FROM THE
l LTRATE WITHIN THE l LTRATE TREATMENT SECTION AND THE DISSOLVED CATALYST IS
RECYCLED
Economics: 4HE ADVANCED %ASTMAN % 04! TECHNOLOGY USES FEWER PRO
CESSING STEPS )N COMBINATION WITH THE OUTSTANDING MILD
OXIDATION TECH
Terephthalic
acid
(E
PTA), CONTINUED
NOLOGY THIS TECHNOLOGY LEADS TO CONSIDERABLE CAPITAL COST SAVINGS AND
LOWER PRODUCTION COST THAN IN OTHER TECHNOLOGIES
Commercial
plants: #OMMERCIAL PLANTS ARE OPERATING IN THE 53 %UROPE
AND !SIA 0ACIlC
4HE LATEST PLANT WITH A CAPACITY OF TPY FOR :HEJIANG (UALIAN
3UNSHINE 0ETRO
#HEMICAL #O ,TD IN 3HAOXING #HINA IS UNDER CONSTRUC
TION AND WILL BE STARTED UP IN !PRIL INCREASING THE WORLDWIDE CA
PACITY TO MILLION TPY
Licensor: ,URGI !'
Upgrading
steam
cracker
C3
cuts
Application: 4O PURIFY PROPYLENE
PROPANE CUTS FROM PYROLYSIS PROCESSES VIA
SELECTIVE CATALYTIC HYDROGENATION OF METHYLACETYLENE AND PROPADIENE IM
PURITIES -!0$ 3TEAM CRACKER # EFm UENTS TYPICALLY CONTAIN OVER
PROPYLENE WITH PROPANE AND -!0$ MAKING UP THE BALANCE !LTHOUGH
DISTILLATION CAN BE USED TO REMOVE -!0$ IT IS OFTEN NOT PRACTICAL OR
ECONOMICAL FOR ACHIEVING A PROPYLENE PRODUCT MEETING THE PARTS
PER
MILLION
LEVELS REQUIRED BY CHEMICAL AND POLYMER
GRADE PROPYLENE SPECIl CATIONS
&URTHERMORE DISTILLATION RESULTS IN PROPYLENE LOSSES 3ELECTIVE HYDROGENATION
IS THE ROUTE MOST COMMONLY EMPLOYED AS IT NOT ONLY ACHIEVES THE TIGHT
-!0$ SPECIl CATIONS BUT IT PRODUCES MORE PROPYLENE
Description: 4HE # CUT IS JOINED BY RECYCLED #S AND MAKE UP HYDROGEN
PRIOR TO ENTERING THE MAIN REACTOR 4HERE THE -!0$ IS CATALYTICALLY
HYDROGENATED FORMING PROPYLENE AND TRACES OF PROPANE ! SINGLE REACTOR
SUFl CES FOR POLYMER
GRADE PROPYLENE -!0$ CONTENT PPM WHEN A
# SPLITTER IS USED ! l NISHING REACTOR CAN BE USED TO REDUCE -!0$
CONTENT TO l VE OR EVEN ONE PPM ! SECOND REACTOR IS ADVANTAGEOUS WHEN
MAKING CHEMICAL
GRADE PROPYLENE 7ITH A TYPICAL SPECIl CATION OF
PROPYLENE PROPANE AND PPM -!0$ A COSTLY # SPLITTER SYSTEM IS
AVOIDED
Yields: 4HE HIGHLY SELECTIVE ACTIVE AND STABLE CATALYST ,$ PROVIDES
THE TYPICAL YIELDS SHOWN BELOW COMPARED TO ITS PREDECESSOR ,$
WHICH IS USED IN MOST OF THE UNITS WORLDWIDE
%THANE
0ROPANE
0ROPYLENE
0ROPADIENE
-ETHYLACETYLENE
#YCLOPROPANE
#
0ROPYLENE YIELD
&EED
0RODUCT
WITH ,$
WT
PPM
PPM
$ 0ERFORMANCE
(YDROGEN
-AIN
REACTOR
#RUDE #S
&INISHING
REACTOR
(YDROGENATED #S
Economics: "ASED ON A MILLION TPY CAPACITY STEAM CRACKER )3", 'ULF
#OAST LOCATION IN
)NVESTMENT 53METRIC TON OF PROPYLENE
5TILITIES CATALYSTS 53METRIC TON OF PROPYLENE
Commercial
plants: /VER # HYDROGENATION UNITS HAVE BEEN LICENSED
Licensor: !XENS !XENS .!
Upgrading
steam
cracker
C4
cuts
Application: )NCREASE THE VALUE OF STEAM CRACKER # CUTS VIA LOW
TEMPER
ATURE SELECTIVE HYDROGENATION AND HYDROISOMERIZATION CATALYSIS 3EVERAL
OPTIONS EXIST REMOVAL OF ETHYL AND VINYL ACETYLENES TO FACILITATE BUTADI
ENE EXTRACTION PROCESSING DOWNSTREAM CONVERSION OF BUTADIENE TO
MAXIMIZE
BUTENE OR
BUTENE PRODUCTION PRODUCTION OF HIGH
PURITY
ISOBUTYLENE FROM CRUDE # CUTS TOTAL # CUT HYDROGENATION AND TOTAL
HYDROGENATION OF COMBINED # # AND ## CUTS FOR RECYCLE TO CRACKING
FURNACES OR ,0' PRODUCTION
(IGH PURITY #S OLEFINS
(YDROGEN
-AIN
REACTOR
&INISHING
REACTOR
"UTADIENE
RICH
# CUT
Description: %ACH APPLICATION USES A SPECIl C PROCESS CATALYST AND OP
ERATING CONDITIONS 4HE BASIC PROCESS FOR MAXIMIZING BUTENE CONSISTS
OF SENDING A COMBINED BUTADIENE RICH # CUT RECYCLED #S MAKE UP
HYDROGEN TO THE MAIN REACTOR WHERE ACETYLENES AND BUTADIENE
IN THE CASE OF HYDROISOMERIZATION TO A SPECIl ED PRODUCT DISTRIBUTION
ARE HYDROGENATED ! l NISHING REACTOR IS USED IF REQUIRED 2EACTIONS
TAKE PLACE IN THE LIQUID PHASE AT RELATIVELY LOW TEMPERATURES TO PROVIDE
SIGNIl CANT ADVANTAGES IN THE AREA OF HEAT REMOVAL APPROACH TO EQUI
LIBRIUM CATALYST LIFE AND REACTION HOMOGENEITY )NFORMATION HERE IS FOR
THE # SELECTIVE HYDROGENATION PROCESS EMPLOYED TO MAXIMIZE BUTENE
$ISTILLATION IS USED TO SEPARATE THE PRODUCTS 4HE PROCESS IS DIFFERENT IN
THE CASE OF HIGH PURITY ISOBUTYLENE PRODUCTION WHERE A REACTOR AND DIS
TILLATION COLUMN OPERATE ON THE # STREAM SIMULTANEOUSLY
Yields: )N THE EXAMPLE BELOW A HIGHLY SELECTIVE ACTIVE AND STABLE CAT
ALYST ,$ PROVIDES THE TYPICAL YIELDS SHOWN BELOW OF THE
BUTADIENE CONVERTS TO BUTENE
#S
)SOBUTANE
N "UTANE
"UTENE
)SOBUTENE
4RANS BUTENE
&EED
0RODUCT
WITH ,$
WT
#7
#IS
BUTENE
"UTADIENE
"UTADIENE
6INYLACETYLENE
%THYLACETYLENE
PPM
Economics: "ASED ON A
TPY CRUDE # FEED )3", 'ULF #OAST
LOCATION IN
)NVESTMENT 53
5TILITIES CATALYSTS 7ATER COOLING MH
%LECTRICAL POWER K7HH
MILLION
Upgrading
steam
cracker
C4
cuts, CONTINUED
Commercial
plants: ! TOTAL OF OVER # HYDROGENATION UNITS HAVE BEEN
LICENSED FOR THIS PROCESS APPLICATION
Licensor: !XENS !XENS .!
Urea
Application: 4O PRODUCE UREA FROM AMMONIA .( AND CARBON DI
OXIDE #/ USING THE 3TAMICARBON #/ STRIPPING 5REA PLUS
4ECHNOLOGY
Description: !MMONIA AND #/ REACT AT SYNTHESIS PRESSURE OF
BAR TO UREA AND CARBAMATE &IG 4HE CONVERSION OF AMMONIA AS
WELL AS #/ IN THE SYNTHESIS SECTION IS RESULTING IN AN EXTREME
LOW RECYCLE m OW OF CARBAMATE "ECAUSE OF THE HIGH
AMMONIA EF
l CIENCY NO PURE AMMONIA IS RECYCLED IN THIS PROCESS 4HE SYNTHESIS
TEMPERATURE OF # IS LOW AND CONSEQUENTLY CORROSION IN THE
PLANT IS NEGLIGIBLE
"ECAUSE OF THE ELEVATION DIFFERENCE WITHIN THE SYNTHESIS SECTION IN
TERNAL SYNTHESIS RECYCLE IS BASED ON GRAVITY m OW Result: %LECTRICAL ENERGY
REQUIREMENT IS VERY LOW 3YNTHESIS
GAS CONDENSATION IN THE POOL REAC
TOR GENERATES STEAM WHICH IS USED IN DOWNSTREAM SECTIONS WITHIN THE
PLANT 0ROCESS STEAM CONSUMPTION IS LOW
0ROCESSING INERTS ARE VENTED TO THE ATMOSPHERE AFTER WASHING THUS
AMMONIA EMISSIONS FROM THE PLANT ARE VIRTUALLY ZERO
"ECAUSE OF THE HIGH CONVERSIONS IN THE SYNTHESIS THE RECYCLE SECTION
OF THE PLANT IS VERY SMALL !N EVAPORATION STAGE WITH VACUUM CONDENSA
TION SYSTEM PRODUCES UREA MELT WITH THE REQUIRED CONCENTRATION EITHER
FOR THE 3TAMICARBON m UIDIZED
BED GRANULATION OR FOR PRILLING 0ROCESS WA
TER PRODUCED IN THE PLANT IS TREATED IN A DESORBTIONHYDROLYZER SECTION
4HIS SECTION PRODUCES AN EFm UENT WHICH IS SUITABLE FOR USE AS BOILER
FEEDWATER
3TAMICARBON LICENSES SEVERAL PROPRIETARY TECHNOLOGIES
s 5REA 0LUS 4ECHNOLOGY FOR CAPACITIES UP TO METRIC TPD
s 3TAMICARBON m UIDIZED BED UREA GRANULATION &IG
s 5!. TECHNOLOGY
s 3EVERAL REVAMP TECHNOLOGIES
s 0ROPRIETARY MATERIAL 3AFUREX
3TM
3TM
.(
#/
3TM
3TM
!IR
&LUIDIZED BED GRANULATION
-0
STEAM
Urea, CONTINUED
Economics: $EPENDING ON HEAT EXCHANGE OPTIONS INCLUDED WITHIN THE
DESIGN THE RAW MATERIAL AND UTILITY CONSUMPTIONS PER METRIC TON OF
UREA MELT ARE
!MMONIA KG
#ARBON DIOXIDE KG
3TEAM BAR # KG
%LECTRIC POWER K7H
7ATER COOLING M
)NCLUDES STEAM FOR #/ COMPRESSOR DRIVE AND STEAM FOR DESORBTIONHYDROLYZES SECTION
Commercial
plants: -ORE THAN PLANTS BASED ON 3TAMICARBONS #/
STRIPPING TECHNOLOGY ARE IN OPERATION 4HE LARGEST SINGLE
LINE UNIT WITH
5REA PLUS TECHNOLOGY PRODUCES MORE THAN METRIC TPD
(IGHLIGHTS IN INCLUDE
s 4HREE UREA PLANTS WITH 3TAMICARBONS NEW 'RANULATION TECHNOLOGY
ARE UNDER CONSTRUCTION
s /NE 5REA PLUS 4ECHNOLOGY PLANT WITH A COMPLETE SYNTHESIS IN
3AFUREX IS UNDER CONSTRUCTION
s -ORE THAN SIX MAJOR CAPACITY INCREASE REVAMPS ARE UNDER CON
STRUCTION
Licensor: 3TAMICARBON "6
Urea
Application: 4O PRODUCE UREA FROM AMMONIA AND CARBON DIOXIDE #/
USING THE #/ STRIPPING PROCESS
2EACTOR
#ARBAMATE
-0
,0
3TRIPPER CONDENSER DECOMPOSER DECOMPOSER
%VAPORATOR
Description: !MMONIA AND CARBON DIOXIDE REACT AT BAR TO SYNTHESIZE
UREA AND CARBAMATE 4HE REACTOR CONVERSION RATE IS VERY HIGH UNDER THE
. # RATIO OF WITH A TEMPERATURE OF n# 5NCONVERTED MATE
RIALS IN SYNTHESIS SOLUTION ARE EFl CIENTLY SEPARATED BY #/ STRIPPING 4HE
MILDER OPERATING CONDITION AND USING TWO
PHASE STAINLESS STEEL PREVENT
CORROSION PROBLEMS 'AS FROM THE STRIPPER IS CONDENSED IN VERTICAL SUB
MERGED CARBAMATE CONDENSER 5SING AN (0 %JECTOR FOR INTERNAL SYNTHESIS
RECYCLE MAJOR SYNTHESIS EQUIPMENT IS LOCATED ON THE GROUND LEVEL
4HE UREA SOLUTION FROM SYNTHESIS SECTION IS SENT TO -0 DECOMPOSER
AT BAR AND ,0 DECOMPOSER AT BAR FOR FURTHER PURIl CATION .O PURE
AMMONIA RECYCLE IS REQUIRED DUE TO THE HIGH SEPARATION EFl CIENCY IN THE
STRIPPER
4HE VACUUM EVAPORATOR UNIT PRODUCES UREA MELT AT THE REQUIRED
CONCENTRATION EITHER FOR PRILLING OR GRANULATION
4HE VENT SCRUBBER AND PROCESS CONDENSATE TREATMENT UNIT TREAT ALL
EMISSION STREAMS THUS THE PLANT IS POLLUTION FREE 0ROCESS CONDENSATE IS
HYDROLYZED AND REUSED AS BOILER FEEDWATER
4OYO %NGINEERING #ORP 4%# HAS A SPOUT
m UID BED GRANULATION
TECHNOLOGY TO PRODUCE GRANULAR UREATYPICALLY n MM SIZE $UE TO
PROPRIETARY GRANULATOR ELECTRIC POWER CONSUMPTION IS THE LOWEST AMONG
GRANULATION PROCESSES
Economics: 2AW MATERIALS AND UTILITIES CONSUMPTIONS PER METRIC TON OF
PRILLED UREA ARE
!MMONIA KG
#ARBON DIOXIDE KG
3TEAM BAR #
%LECTRIC POWER K7H
7ATER COOLING M
)NCLUDES STEAM FOR #/ COMPRESSOR TURBINE AND STEAM FOR PROCESS CONDENSATE TREATMENT
-3
-3
,3
,3
4O PRILLING
TOWER
5REA
MELT
#/
3# 3TM
-0
ABSORBER
4O ,0$
5REA
SLURRY
.(
.(
PUMP
#/
#/
COMPRESSOR
0ROCESS
COND
STRIPPER (YDROLYZER
3TM
3TM
#ARBAMATE PUMP
Commercial
plants: -ORE THAN PLANTS INCLUDING UREA GRANULATION
PLANTS HAVE BEEN DESIGNED AND CONSTRUCTED BASED ON 4%# TECHNOLOGY
Licensor: 4OYO %NGINEERING #ORP 4%#
Urea-formaldehyde
Application: 5REA
FORMALDEHYDE RESINS ARE USED AS ADHESIVES IN THE
WOOD
WORKING INDUSTRY AND ARE TYPICALLY USED IN THE PRODUCTION OF PLY
WOOD AND PARTICLE BOARD 4HEY ARE AVAILABLE AS CONCENTRATED SOLUTIONS OR
IN POWDER FORM AS A RESULT OF THE SPRAY
DRYING PROCESS
!DDITIVES
-
Description: 4HE REACTION MECHANISMS OF THE MAJOR COMPONENTS ARE
&ORMALDEHYDE AND UREA ARE BY POLYADDITION
(. n #/ n .( #(/ (. n #/ n .( n #(/(
$H n K* MOL
7/
3,0
7#4
3#,
5REA
0)
4HE HYDROXYMETHYL COMPOUNDS UNDERGO FURTHER SLOW REACTION BY
POLYCONDENSATION
(. n #/ n .( (. n #/ n .( n #(/(
(. n #/ n .( n #( n .( n #/ n .( (/
0)
7#4
7#4
&ORMALDEHYDE
WHICH IS ALSO RESPONSIBLE FOR THE VISCOSITY INCREASE DURING THE STORAGE
4HE FORMATION OF METHYLENE BRIDGES CAN BE ACCELERATED BY RAISING
STORAGE TEMPERATURES 4HE TECHNOLOGY IS BASED ON BATCHWISE PRODUCTION
OF THE AQUEOUS SOLUTION SHORT INTERMEDIATE STORAGE AND CONTINUOUSLY
OPERATING SPRAY DRYING IN A CONNECTED STAGE
!FTER COOLING THE RESIN IN THE REACTOR THE RESIN IS PUMPED TO THE
BUFFER TANK OF THE CONNECTED SPRAY DRYER PLANT 5SUALLY THE COMPLETE
BATCH PROCESSING TAKES n H 4HE UREA
FORMALDEHYDE RESIN SOLUTION CAN
BE DRIED IN A SPRAY DRYER BASED ON CO
CURRENT m OW PRINCIPLE
4HIS PROCESS COST
EFFECTIVELY PRODUCES HIGH
QUALITY GLUES AT LARGE
QUANTITIES 4HE PRODUCT IS A LOW
FORMALDEHYDE RESIN ADHESIVE SUITABLE FOR
VENEERING PLYWOOD AND PARTICLE BOARD PRODUCTION BY THE HOT PRESSING
PROCESS 4HE QUALITY OF THE BONDING COMPLIES WITH THE REQUIREMENTS OF
$). 0ART RESPECTIVELY TO $). n 6 &OR PARTICLE BOARD A
PERFORATE VALUE ACCORDING TO $). %. OF LESS MG (#(/ G DRY
BOARD WILL BE MAINTAINED
7#4
0)
Licensor: 5HDE )NVENTA &ISCHER
0)
4)
5& RESIN
VCM
by
thermal
cracking
of
EDC
Application:
6INNOLITS MEDIUM
PRESSURE %$#
CRACKER PROVIDES AN ENERGY
EFl CIENT CRACKING TECHNOLOGY OPERATING AT MODERATE CRACKING PRESSURE
WITH THE BENEl T OF LOW BYPRODUCT FORMATION AND LONG OPERATION CYCLES
BETWEEN CLEANING INTERVALS
1UENCH OVERHEAD CONDENSATION
&URNACE FEED %$#
3TEAM
3TEAM
4O (#L COLUMN
Description: )N THE CRACKING FURNACE FEED %$# ETHYLENE DICHLORIDE FROM
THE %$# PURIl CATION SECTION OR FROM THE %$# STORAGE FACILITY IS CRACKED TO
VINYL CHLORIDE AND HYDROGEN CHLORIDE (#L AT APPROXIMATELY # AND
AT -0A G 0RIOR TO CRACKING THE FEED %$# IS PREHEATED IN THE QUENCH
OVERHEAD EXCHANGER AND IN THE RADIATION COILS OF THE %$# CRACKER 4HE
HOT REACTION GASES DOWNSTREAM OF THE %$# CRACKING FURNACE ARE COOLED
IN THE %$# EVAPORATOR BY VAPORIZING THE FEED %$# !DDITIONAL COOLING
OF THE REACTION GAS OCCURS IN THE QUENCH TOWER &RACTIONS OF THE QUENCH
OVERHEAD STREAM ARE CONDENSED IN THE STEAM GENERATOR IN THE FEED %$#
PREHEATER OF THE QUENCH COLUMN PRIOR TO ENTERING THE (#L COLUMN 4HE
QUENCH BOTTOM PRODUCT IS l LTERED AND FED THROUGH A HIGH EFl CIENCY
m ASH SYSTEM TO REMOVE COKE
&UEL
4O (#L COLUMN
%$# CRACKER
%$# EVAPORATOR
1UENCH
4O %$# DISTILLATION
Process
features
and
economics: 0ROCESSING BENEl TS OF THE 6)../,)4
%$# CRACKING PROCESS CONSIST OF %$# CRACKING FURNACE AND EXTERNAL %$#
EVAPORATION AND INCLUDE
Energy
savings: -ORE THAN SAVINGS OF ELECTRICAL ENERGY
COMPARED TO LOW
PRESSURE CRACKING FURNACE TECHNOLOGY ARE AVAILABLE
BECAUSE OF BAR G CONDENSATION PRESSURE IN THE (#L COLUMN FURTHER
REDUCED FUEL CONSUMPTION BY USING THE HEAT OF THE CRACKING GAS TO HEAT
AND EVAPORATE %$# NETS SAVINGS OF KG BAR G STEAMTON 6#-
&URTHERMORE STEAM IS GENERATED VIA m UE GAS FROM THE FURNACE %$# IS
PREHEATED ON QUENCH TOP PRIOR TO ENTERING THE FURNACE
Operation: 4HE CONTINUOUS OPERATION TIME IS APPROXIMATELY TWO
YEARS WITHOUT DECOKING 4HE HIGH CONVERSION RATE IS DUE TO THE
VAPOR %$#
FEED .O IRON ENTERS THE RADIANT SECTION
!S THE COKE CARRY
OVER WITH THE PRODUCT STREAM IS AVOIDED THE
6INNOLIT DESUPERHEATED QUENCH SYSTEM ALLOWS A LONG OPERATION TIME OF
THE VINYL CHLORIDE MONOMER 6#- DISTILLATION UNIT
Low
maintenance
cost: 4HE NATURAL %$# CIRCULATION IN %$# VAPORIZER
MINIMIZES MAINTENANCE COSTS NO PUMPS NO SEALING PROBLEMS AND NO
PLUGGING
Commercial
plants: 4HE PROCESS IS USED IN PLANTS WITH AN ANNUAL
PRODUCTION OF AROUND MILLION METRIC TONS MTONS OF 6#- ! SINGLE
STREAM PLANT WITH AN ANNUAL CAPACITY OF MTONS OF 6#- WAS
COMMISSIONED IN A RECORD TIME OF TWO MONTHS IN 3EPTEMBER /NE
6#- PLANT WITH AN ANNUAL CAPACITY OF MTONS OF 6#- IS UNDER
CONSTRUCTION
VCM
by
thermal
cracking
of
EDC, CONTINUED
Licensor: 6INNOLIT
Contractor: 5HDE 'MB(
VCM
removal
Application: !DDING A STRIPPING COLUMN TO EXISTING POLYVINYL CHLORIDE
06# PLANTS TO REMOVE VINYL CHLORIDE MONOMER 6#- FROM 06# SLURRY
4HE RECOVERED 6#- CAN BE REUSED IN THE 06# PROCESS WITHOUT ANY DE
TERIORATION OF 06# POLYMER QUALITY
Description: 06# SLURRY DISCHARGED FROM REACTORS CONTAINS SIGNIl CANT
AMOUNTS OF 6#- PPM EVEN AFTER INITIAL m ASHING 4HIS PROCESS
EFFECTIVELY REMOVES THE REMAINING 6#- SO THAT THE MONOMER IS RECOV
ERED AND REUSED 2ECYCLING OF RAW MATERIALS DRASTICALLY REDUCES 6#-
EMISSIONS FROM THE FOLLOWING DRYER 4HERE IS NO SIGNIl CANT CHANGE IN
06# QUALITY AFTER STRIPPING 2ESIDUAL 6#- LEVEL IN THE 06# PRODUCT CAN
BE LOWERED BELOW PPM AND IN SOME CASES BELOW PPM
4HE 06# SLURRY CONTAINING 6#- IS CONTINUOUSLY FED TO THE STRIPPING
COLUMN 4HE SLURRY PASSES COUNTER CURRENTLY TO STEAM WHICH IS FED
INTO THE BASE OF THE COLUMN 4HE PROPRIETARY INTERNALS OF THE COLUMN ARE
SPECIALLY DESIGNED TO ENSURE INTIMATE CONTACT BETWEEN THE STEAM AND
THE 06# SLURRY AND TO ENSURE THAT NO 06# PARTICLES REMAIN INSIDE THE COL
UMN !LL PROCESS OPERATIONS INCLUDING GRADE CHANGE ARE AUTOMATICALLY
DONE IN A COMPLETELY CLOSED SYSTEM
7HILE STEAM STRIPPING IS WIDELY USED THIS PROPRIETARY TECHNOLOGY
WHICH INVOLVES SOPHISTICATED DESIGN AND KNOW HOW OF THE COLUMN OF
FERS ATTRACTIVE BENEl TS TO EXISTING 06# PLANT SITES
4HE PROCESS DESIGN IS COMPACT WITH A SMALL AREA REQUIREMENT AND
LOW INVESTMENT COST 4HE SIZE OF THE COLUMN IS T H TO T H
Economics:
3TEAM
KGT OF 06#
Commercial
plants: #HISSO HAS LICENSED THE TECHNOLOGY TO MANY 06#
PRODUCERS WORLDWIDE -ORE THAN COLUMNS OF THE #HISSO PROCESS ARE
UNDER OPERATION OR CONSTRUCTION AND TOTAL CAPACITY EXCEEDS MILLION
TPY OF 06#
06# SLURRY
FROM
REACTORS
6#GAS HOLDER
6#GAS
4O 6#RECOVERY
6ACUUM
PUMP
3TEAM
"LOWDOWN
TANK
3LURRY
FEED
PUMP
",
Licensor: #HISSO #ORP
3TRIPPING
COLUMN
3LURRY
DISCHARGE
PUMP
3LURRY
TANK
4O DRYER
",
Wet
air
oxidation
(WAO),
spent
caustic
Application: 4O OXIDIZE SODIUM SULl DE .A3 COMPONENT IN THE CAUSTIC
SCRUBBER EFm UENT OF OLEl N PLANTS WITH AIR USING WET AIR OXIDATION 7!/
PROCESS DEVELOPED BY .IPPON 0ETROCHEMICALS #O ,TD .0## THE LI
CENSE BEING AVAILABLE FROM 4OYO %NGINEERING #ORP 4%#
/FFGAS
7ASH TOWER
Description: #ONVENTIONAL WET OXIDATION PROCESSES ADOPT A PLUG m OW
TYPE OF REACTOR SYSTEM WHICH USUALLY HAS PROBLEMS SUCH AS
s 0LUG m OW REACTORS REQUIRE HIGHER REACTION TEMPERATURE FOR THE OXI
DATION REACTION AND NEED A FEED PREHEATER #LOGGING PROBLEMS IN THE
OUTLETS OF THE REACTOR AND PREHEATER OFTEN OCCUR
s (IGH PROCESSING TEMPERATURES CAUSE CORROSION PROBLEMS (IGH
GRADE CONSTRUCTION MATERIALS SUCH AS NICKEL OR NICKEL ALLOY ARE NEEDED
FOR THE REACTOR
.0## PROCESS CONVERSELY USES A COMPLETE MIXING TYPE OF REACTOR
AND HAS SEVERAL ADVANTAGES SUCH AS
s -ILD AND UNIFORM REACTOR CONDITIONS CAN BE MAINTAINED BY COM
PLETE MIXING WITH VERY l NE BUBBLES GENERATED BY A SPECIAL NOZZLE AP
PLICATION
s .O PREHEATER IS REQUIRED
s ! LOWER GRADE CONSTRUCTION MATERIAL SUCH AS STAINLESS STEEL IS USED
FOR THE REACTOR
s ,ESS CLOGGING PROBLEMS AND EASIER OPERATION ARE DUE TO THE SIMPLE
m OW SCHEME
Economics: 4YPICAL PERFORMANCE DATA
"ASE
3PENT CAUSTIC m OWRATE TPH
.A3 )NLET WT
/UTLET WT PPM
5TILITIES
%LECTRIC POWER K7HH
3TEAM (0 KGH
7ATER COOLING MH
7ASHWATER MH
LESS THAN
3TEAM CONDENSATE
3PENT CAUSTIC
7ASTEWATER
TREATMENT UNIT
(0 STEAM
!IR
COMPRESSOR
!IR
Commercial
plants: -ANY OLEl NS PLANTS WORLDWIDE USE THIS 7!/ PROCESS
&OURTEEN PROCESSING UNITS HAVE BEEN DESIGNED BY 4%# SINCE
Licensor: .IPPON 0ETROCHEMICALS #O ,TD
Xylene
isomerization
Application: 4O SELECTIVELY ISOMERIZE A PARAXYLENE DEPLETED
# AROMAT
ICS MIXTURE TO GREATER THAN EQUILIBRIUM PARAXYLENE CONCENTRATION USING
%XXON-OBIL #HEMICALS 8Y-AX AND !DVANCED -(!) PROCESSES 3IMULTA
NEOUSLY ETHYLBENZENE %" AND NONAROMATICS IN THE FEED ARE CONVERTED
TO BENZENE AND LIGHT PARAFl NS RESPECTIVELY #ONVERSION OF %" IS TYPICALLY
n
Description: 4HE PARA DEPLETED LIQUID # AROMATICS RAFl NATE STREAM FROM
THE PARAXYLENE SEPARATION UNIT ALONG WITH HYDROGEN
RICH RECYCLE GAS
ARE PUMPED THROUGH FEEDEFm UENT EXCHANGERS AND THE CHARGE HEATER
AND INTO THE REACTOR 6APOR THEN m OWS DOWN THROUGH THE l XED
DUAL
BED CATALYST SYSTEM $EALKYLATION OF %" AND CRACKING OF NON
ARO
MATICS PREFERENTIALLY OCCURS IN THE TOP BED 4HE BOTTOM BED PROMOTES
ISOMERIZATION OF XYLENES WHILE MINIMIZING LOSS OF XYLENES FROM SIDE REAC
TIONS 4HE REACTOR EFm UENT IS COOLED BY HEAT EXCHANGE AND THE RESULTING
LIQUID AND VAPOR PHASES ARE SEPARATED IN THE PRODUCT SEPARATOR 4HE
LIQUID IS THEN SENT TO A FRACTIONATOR FOR RECOVERY OF BENZENE AND TOLU
ENE FROM THE ISOMERATE
4WO ENHANCED ISOMERIZATION CATALYST TECHNOLOGIES HAVE BEEN
DEVELOPED BY %XXON-OBIL #HEMICAL 4HE l RST TECHNOLOGY REFERRED TO
AS !DVANCED -OBIL (IGH !CTIVITY )SOMERIZATION !-(!) PROVIDES
HIGHER SELECTIVITY AND LOWER OPERATING COSTS COMPARED TO ISOMERIZATION
PROCESSES USED IN THE PAST 4HE !-(!) TECHNOLOGY OFFERS INCREASED
OPERATING m EXIBILITY IN TERMS OF A GREATER RANGE OF %" CONVERSION AND A
LOWER TEMPERATURE REQUIREMENT 4HE SECOND TECHNOLOGY REFERRED TO AS
8Y-AX FURTHER INCREASES YIELD PERFORMANCE AND DEBOTTLENECK POTENTIAL
4HIS TECHNOLOGY CAN OPERATE AT EVEN HIGHER %" CONVERSION WITH HIGHER
SELECTIVITY AND SIGNIl CANTLY LOWER XYLENE LOSS
Operating
conditions: 8Y-AX AND !-(!) UNITS OPERATE WITH A HIGH
SPACE VELOCITY AND A LOW HYDROGEN
TO
HYDROCARBON RATIO WHICH RESULTS
IN INCREASED DEBOTTLENECK POTENTIAL AND DECREASED UTILITIES COSTS "Y CON
VERTING A HIGH PORTION OF %" IN THE FEED THESE TECHNOLOGIES CAN PROVIDE
/FFGAS
#7
'AS
2EACTOR
(EATER
&RACTIONATOR
#7
,IQUID FEED #
AROMATICS PARA
ORTHO DEPLETED
,T AROMATICS
2ECYCLE
COMP
3TEAM
)SOMERATE #
AROMATICS PARA
ORTHO RICH
(YDROGEN MAKEUP
SIGNIl CANT SAVINGS IN ASSOCIATED PARAXYLENE RECOVERY FACILITIES "OTH TECH
NOLOGIES OFFER LONG OPERATING CYCLES
Commercial
plants: 4HE !-(!) PROCESS WAS l RST COMMERCIALIZED IN
&IVE !-(!) UNITS ARE CURRENTLY IN OPERATION 4HE l RST COMMER
CIAL UNIT USING 8Y-AX TECHNOLOGY WAS BROUGHT ONSTREAM IN 3INCE
THEN TWO ADDITIONAL APPLICATIONS OF THE 8Y-AX TECHNOLOGY HAVE BEEN
LICENSED )NCLUDING OTHER %XXON-OBIL XYLENE ISOMERIZATION TECHNOLOGIES
THERE ARE A TOTAL OF UNITS IN OPERATION
Licensor: %XXON-OBIL #HEMICAL 4ECHNOLOGY ,ICENSING ,,# RETROl T AP
PLICATIONS !XENS !XENS .! GRASSROOTS APPLICATIONS
Xylene
isomerization
Application: 4O SELECTIVELY ISOMERIZE A PARAXYLENE DEPLETED
# AROMAT
ICS MIXTURE TO GREATER THAN EQUILIBRIUM PARAXYLENE CONCENTRATION USING
%XXON-OBIL #HEMICALS 8Y-AX AND !DVANCED -(!) PROCESSES 3IMUL
TANEOUSLY ETHYLBENZENE %" AND NONAROMATICS IN THE FEED ARE CON
VERTED TO BENZENE AND LIGHT PARAFl NS RESPECTIVELY #ONVERSION OF %" IS
TYPICALLY n
Description: 4HE PARA DEPLETED LIQUID # AROMATICS RAFl NATE STREAM FROM
THE PARAXYLENE SEPARATION UNIT ALONG WITH HYDROGEN
RICH RECYCLE GAS ARE
PUMPED THROUGH FEEDEFm UENT EXCHANGERS AND THE CHARGE HEATER AND
INTO THE REACTOR 6APOR THEN m OWS DOWN THROUGH THE l XED DUAL
BED
CATALYST SYSTEM $EALKYLATION OF %" AND CRACKING OF NON
AROMATICS PREFER
ENTIALLY OCCURS IN THE TOP BED 4HE BOTTOM BED PROMOTES ISOMERIZATION OF
XYLENES WHILE MINIMIZING LOSS OF XYLENES FROM SIDE REACTIONS 4HE REACTOR
EFm UENT IS COOLED BY HEAT EXCHANGE AND THE RESULTING LIQUID AND VAPOR PHAS
ES ARE SEPARATED IN THE PRODUCT SEPARATOR 4HE LIQUID IS THEN SENT TO A
FRACTIONATOR FOR RECOVERY OF BENZENE AND TOLUENE FROM THE ISOMERATE
4WO ENHANCED ISOMERIZATION CATALYST TECHNOLOGIES HAVE BEEN
DEVELOPED BY %XXON-OBIL #HEMICAL 4HE l RST TECHNOLOGY REFERRED TO
AS !DVANCED -OBIL (IGH !CTIVITY )SOMERIZATION !-(!) PROVIDES
HIGHER SELECTIVITY AND LOWER OPERATING COSTS COMPARED TO ISOMERIZATION
PROCESSES USED IN THE PAST 4HE !-(!) TECHNOLOGY OFFERS INCREASED
OPERATING m EXIBILITY IN TERMS OF A GREATER RANGE OF %" CONVERSION AND A
LOWER TEMPERATURE REQUIREMENT 4HE SECOND TECHNOLOGY REFERRED TO AS
8Y-AX FURTHER INCREASES YIELD PERFORMANCE AND DEBOTTLENECK POTENTIAL
4HIS TECHNOLOGY CAN OPERATE AT EVEN HIGHER %" CONVERSION WITH HIGHER
SELECTIVITY AND SIGNIl CANTLY LOWER XYLENE LOSS
Operating
conditions: 8Y-AX AND !-(!) UNITS OPERATE WITH A HIGH
SPACE VELOCITY AND A LOW HYDROGEN
TO
HYDROCARBON RATIO WHICH RESULTS
IN INCREASED DEBOTTLENECK POTENTIAL AND DECREASED UTILITIES COSTS "Y
CONVERTING A HIGH PORTION OF %" IN THE FEED THESE TECHNOLOGIES CAN
PROVIDE SIGNIl CANT SAVINGS IN ASSOCIATED PARAXYLENE RECOVERY FACILITIES
/FFGAS
#7
'AS
2EACTOR
(EATER
#7
,IQUID FEED #
AROMATICS PARA
ORTHO DEPLETED
,T AROMATICS
&RACTIONATOR
2ECYCLE
COMP
3TEAM
)SOMERATE #
AROMATICS PARA
ORTHO RICH
(YDROGEN MAKEUP
"OTH TECHNOLOGIES OFFER LONG OPERATING CYCLES
Commercial
plants: 4HE !-(!) PROCESS WAS l RST COMMERCIALIZED IN
3EVEN !-(!) UNITS ARE CURRENTLY IN OPERATION 4HE l RST COMMERCIAL UNIT
USING 8Y-AX TECHNOLOGY WAS BROUGHT ONSTREAM IN 3INCE THEN l VE
ADDITIONAL TOTAL OF SIX APPLICATIONS OF THE 8Y-AX TECHNOLOGY HAVE BEEN
LICENSED )NCLUDING OTHER %XXON-OBIL XYLENE ISOMERIZATION TECHNOLOGIES
THERE ARE A TOTAL OF UNITS IN OPERATION
Licensor: %XXON-OBIL #HEMICAL RETROl T APPLICATIONS !XENS !XENS .!
GRASSROOTS APPLICATIONS
Xylene
isomerization
Application: 4HE )SOMAR PROCESS ISOMERIZES # AROMATICS TO MIXED XY
LENES TO MAXIMIZE THE RECOVERY OF PARAXYLENE IN A 5/0 AROMATICS COM
PLEX $EPENDING ON THE TYPE OF CATALYST USED ETHYLBENZENE %" IS ALSO
CONVERTED INTO XYLENES OR BENZENE
Description: 4HE )SOMAR PROCESS RE
ESTABLISHES AN EQUILIBRIUM DISTRIBUTION
OF XYLENE ISOMERS ESSENTIALLY CREATING ADDITIONAL PARAXYLENE FROM THE RE
MAINING ORTHO
AND META
XYLENES 4HE FEED TYPICALLY CONTAINS LESS THAN
WT OF PARAXYLENE AND IS l RST COMBINED WITH HYDROGEN
RICH RECYCLE GAS
AND MAKEUP GAS 4HE COMBINED FEED IS THEN PREHEATED BY AN EXCHANGER
WITH REACTOR EFm UENT HEATED IN A l RED HEATER AND RAISED TO THE
REACTOR OPERATING TEMPERATURE 4HE HOT FEED VAPOR IS THEN SENT TO THE
REACTOR WHERE IT IS PASSED RADIALLY THROUGH A l XED
BED CATALYST
4HE REACTOR EFm UENT IS COOLED BY EXCHANGER WITH THE COMBINED FEED
AND THEN SENT TO THE PRODUCT SEPARATOR (YDROGEN
RICH GAS IS TAKEN
OFF THE TOP OF THE PRODUCT SEPARATOR AND RECYCLED BACK TO THE REAC
TOR ,IQUID FROM THE BOTTOM OF THE PRODUCTS SEPARATOR IS CHARGED TO THE
DEHEPTANIZER COLUMN 4HE #n OVERHEAD FROM THE DEHEPTANIZER IS
COOLED AND SEPARATED INTO GAS AND LIQUID PRODUCTS 4HE GAS IS EXPORTED
TO THE FUEL GAS SYSTEM AND THE LIQUID IS SENT TO A DEBUTANIZER COLUMN
OR A STRIPPER 4HE # FRACTION FROM THE BOTTOM OF THE DEHEPTANIZER IS
RECYCLED BACK TO A XYLENE COLUMN
4HERE ARE TWO BROAD CATEGORIES OF XYLENE ISOMERIZATION CATALYSTS
%" ISOMERIZATION CATALYSTS WHICH CONVERT ETHYLBENZENE INTO ADDITIONAL
XYLENES AND %" DEALKYLATION CATALYSTS WHICH CONVERT ETHYLBENZENE TO
VALUABLE BENZENE COPRODUCT 4HE SELECTION OF THE ISOMERIZATION CATALYST
DEPENDS ON THE CONl GURATION OF THE 5/0 AROMATICS COMPLEX THE
COMPOSITION OF THE FEEDSTOCKS AND THE DESIRED PRODUCT SLATE
Economics: ! SUMMARY OF THE INVESTMENT COST AND THE UTILITY CONSUMP
TION FOR A TYPICAL )SOMAR UNIT PROCESSING CAPACITY OF MILLION MTPY IS
SHOWN BELOW 4HE ESTIMATED INSIDE BATTERY LIMITS )3", ERECTED COST FOR
THE UNIT ASSUMES CONSTRUCTION ON A 53 'ULF #OAST SITE IN
4O FUEL GAS
0URGE GAS
# AROMATICS
FEED
/VERHEAD
LIQUID TO
DEBUTANIZER
-AKEUP
HYDROGEN
2ECYCLE GAS
)NVESTMENT 53 MILLION
5TILITIES PER MT OF FEED
%LECTRICITY K7H
3TEAM MT
7ATER COOLING M
&UEL 'CAL
0RODUCT TO 8YLENE
FRACTIONATION
Commercial
plants: 5/0 HAS LICENSED MORE ISOMERIZATION UNITS THAN ANY
OTHER LICENSOR IN THE WORLD 4HE l RST )SOMAR UNIT WENT ONSTREAM IN
3INCE THAT TIME 5/0 HAS LICENSED A TOTAL OF )SOMAR UNITS
Licensor: 5/0 ,,#
0REMIER 3PONSOR
,ICENSE !GREEMENT
'ULF 0UBLISHING #OMPANY PROVIDES THIS PROGRAM AND LICENSES ITS USE
THROUGHOUT THE WORLD 9OU ASSUME RESPONSIBILITY FOR THE SELECTION OF THE
PROGRAM TO ACHIEVE YOUR INTENDED RESULTS AND FOR THE INSTALLATION USE AND
RESULTS OBTAINED FROM THE PROGRAM
,)#%.3%
9OU MAY
5SE THE PROGRAM ON A SINGLE MACHINE
#OPY THE PROGRAM INTO ANY MACHINE READABLE OR PRINTED FORM FOR
BACKUP OR MODIlCATION PURPOSES IN SUPPORT OF YOUR USE OF THE PROGRAM ON
THE SINGLE MACHINE
4RANSFER THE PROGRAM AND LICENSE TO ANOTHER PARTY IF THE OTHER PARTY
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CONDITION OF THIS AGREEMENT 9OU AGREE UPON SUCH TERMINATION TO DESTROY
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