REFINING GAS PROCESSING PETROCHEMICALS ptq Q2 2024
NAPHTHA SPLITTER REVAMP BIOGENIC CO-PROCESSING
AI APPLICATIONS
BLUE HYDROGEN
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Q2 (Apr, May, Jun) 2024 www.digitalrefining.com ptq PETROLEUM TECHNOLOGY QUARTERLY
3 Keeping refineries profitable Rene Gonzalez 5 ptq&a 15 Optimising furnace run length in a steam cracker using AI Surabhi Thorat and Vivek Srinivasan Dorf Ketal Chemical (I) Pvt Ltd Sudarshan Vijayaraghavan Dorf Ketal Chemicals PTE Ltd 21 Dryout design considerations for cryogenic gas plants: Part 2 Scott A Miller, David A Jelf, J A Anguiano and Joe T Lynch Honeywell UOP 27 FCC co-processing of biogenic and recyclable feedstocks: Part 2 Jon Strohm, Darrell Rainer, Oscar Oyola-Rivera and Clifford Avery Ketjen 33 Revamping a conventional naphtha splitter to a dividing wall column Giuseppe Mosca, Joshi Chandrakant, Andrei Cimpeanu and Brad Fleming Sulzer Chemtech 41 A refinery’s strategic journey towards sustainability Aleix Carrillo, Duncan Manuel and Michelle Wicmandy KBC (A Yokogawa Company) 47 SAF production via co-processing in the kerosene hydrotreater Maria J L Perez, Gitte Thomsen Nygaard and Sylvain Verdier Topsoe 53 Flexible downscaling of MAPD removal from C3/C4 olefin streams Edgar Jordan, Charlotte Fritsch and Joachim Haertlé hte GmbH 59 Sulphur reduction, sulphur removal, and spent caustic reuse Richard Stambaugh Merichem Technologies 65 Optimising compressor dry gas seal line design in FEED stage Rajib Talukder Saudi Aramco 71 Integrating refining/petrochemicals for increased chemicals production Narendra Verma HMEL (HPCL-Mittal Energy Ltd.) 77 Blue hydrogen – a low-carbon energy carrier: Part 1 Himmat Singh Research Scientist 83 Effect of redundancy/voting in SIL calculation Partha S Mondal Fluor Daniel India Pvt. Ltd 90 Co-processing renewable feeds in hydrodesulphurisation units
Cristian S Spica OLI Systems, Inc 94 Technology in Action
Cover Commercial relevance of technology ranging from refinery FCC assets to chemical plastic waste recycling reflects investments exceeding $185 billion to expand operations for meeting increased demand.
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Vol 29 No 3 Q2 (Apr, May, Jun) 2024 ptq PETROLEUM TECHNOLOGY QUARTERLY
Keeping refineries profitable
T hroughout every quarterly issue of PTQ , we have seen the need to find new ways to improve and apply existing technology for changing market forces and regulatory requirements. So, with adaptation of carbon taxation, refiners must produce higher yields of fuels per unit of CO 2 from conversion units such as the fluid catalytic cracking (FCC) unit. One interesting route is to operate FCCs more sus - tainably by supporting the co-processing of alternative feeds. But how many FCC units are co-processing alternative feedstocks? The consensus is that co-processing is feasible if less than 5% of the feedstock is from alternative sources. Above 5%, processing unknowns weigh in on the need for additional expertise, such as the use of more active and poison-resistant cata- lysts and absorbents for efficient conversion of renewable feedstocks to fuels and chemicals, bringing new capabilities to existing facilities seen in Europe and North America. Elsewhere, project start-ups reflect strategies to increase fuel production and feed - stock volumes for monetisation to petrochemicals, as seen in the Middle East and other countries. For example, Saudi Arabia is building nine liquid-based ethylene steam crackers to produce a wide range of products, such as a high-margin polymers. Through joint ventures, steam cracker projects will process byproducts from crude processing, including naphtha and off-gas, to produce ethylene, such as with a multi-billion-dollar project between Saudi Aramco and South Korea to pro- duce propylene, butadiene, and other basic chemicals by 2026. Petrochemicals are set to account for nearly half of growth in oil demand to 2050, according to the International Energy Agency. Petrochemicals are also poised to consume an addi- tional 56 billion cubic metres of natural gas by 2030, the agency recently noted. The global petrochemical market is projected to be worth roughly $800 billion by 2030, according to Precedence Research. At this juncture, there is a lot of pressure to close refineries in Europe if old assets cannot be modified, such as with the ability to co-process alternative fuels. What is happening with refinery growth in Africa now could significantly impact European refineries, such as with a refinery in Nigeria that includes a new 600,000 bpd single column crude unit. According to Honeywell UOP’s Keith Couch, speaking at the January NARTC in Houston, “when that unit starts up (i.e., at the Dangote refinery), the price pressure on European refineries will approach $4 per barrel”. The Dangote refinery has ramped up its stock of imported crude oil, including shipments of US light sweet crude oil, according to trader and ship tracking data. So, the facility is well on its way to running at full capacity. Will European refiners be able to stave off imports? Perhaps with government subsidies and ESG-focused projects. Elsewhere, the rapid start-up of major capital projects in China and India is taking 36 months, while projects in the Middle East need perhaps 96 months to complete due to supply chain and labour restrictions. This makes refineries such as Reliance in India more competitive, even as they are leveraged by a lack of crude oil reserves. In almost every instance, the road to success for refiners involves a shift to petrochemicals, such as with olefins and aromatics. For ‘older’ refinery facilities, such as in the US, that petrochemical opportunity could begin with benzene, as its octane-enhancing importance in the gasoline mar- ket is diminishing due to regulatory restrictions. Propylene is another bankable pet- rochemical that can be considered with the right process and catalyst upgrades, as discussed in this issue of PTQ . Further into the year, this narrative will discuss track- ing a facility’s carbon footprint from new profitable and energy-efficient projects.
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PTQ Q2 2024
Vacuum tower cutpoint delivers profits
Cutpoint Concerns
poorly designed heaters may experience coking with COT below 700°F (370°C).
Crude unit vacuum tower performance is often critical to a refiner’s bottom line. e vacuum tower bottoms stream is valued far below the gas oil cuts, so most refineries look to minimize it. Many vacuum columns are also designed or revamped to produce a diesel cut, recovering diesel slipped from the atmospheric column that would otherwise be downgraded to VGO product. Good vacuum column performance can maximize the profitability of downstream units by removing distillate hydrotreater feed (diesel) from FCCU or hydrocracker feed (VGO) and removing VGO from coker feed (resid). One important measure of vacuum column performance is VGO/resid cutpoint. e cutpoint is the temperature on the crude TBP curve that corresponds to the vacuum tower resid yield. Vacuum column cutpoint depends on three variables: 1. Flash zone temperature 2. Flash zone pressure 3. Stripping section performance (if present) Flash zone temperature is driven by vacuum heater coil outlet temperature (COT). Increasing COT increases cutpoint. Vacuum heater outlet temperature is typically maximized against firing or coking limits. When processing relatively stable crudes, vacuum heaters with better designs and optimized coil steam can avoid coking even at very high COT (800°F+, 425°C), but
Flash zone pressure is set by vacuum system performance and column pressure drop. Lower flash zone pressure increases cutpoint until the tower shell C-factor limit is reached, at which point the packed beds begin to flood. Vacuum producing systems are mysterious to many in the industry, so a large number of refiners unnecessarily accept poor vacuum system performance. With technical understanding and a good field survey, the root causes of high tower operating pressure can be identified and remedied. In columns with stripping trays, stripping steam rate and tray performance are important. Stripping steam rate is limited by vacuum column diameter (C-factor) and vacuum system capacity. Any steam injected into the bottom of the tower will act as load to the vacuum system, so vacuum system size, tower operating pressure, and stripping steam rate must be optimized together. Depending on the design, a stripping section with 6 stripping trays can provide between zero and two theoretical stages of fractionation, which can drive a big improvement in VGO yield. Although the variables for maximizing vacuum tower cutpoint are simple, manipulating them to maximize cutpoint without sacrificing unit reliability is not. Contact Process Consulting Services, Inc. to learn how to maximize the performance of your vacuum unit.
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pt q&a
More answers to these questions can be found at www.digitalrefining.com/qanda
Q What technologies do you see dominating the long- term development of alternative fuels like ammonia, methanol, and hydrogen? A Ujjal Mukherjee, Chief Technology Officer, Lummus Technology I see a variety of opportunities coming forth across a broader spectrum of timelines. In the medium term, blue hydrogen combined with carbon capture and storage will continue as the dominant technology. With the advance- ment of electrolysers incentivised by programmes such as the Inflation Reduction Act in the US, the cost of green hydrogen production will continue to drop. However, scal- ing to match blue hydrogen capacities will require a level of investment that only an enforceable penalty on CO 2 pro- duction could justify. I see niche areas with plentiful solar, wind or hydroelec- tric power as first adopters of large-scale green hydrogen projects, such as Neom in Saudi Arabia. In countries with an abundance of nuclear energy, such as Abu Dhabi, I soon see the production of pink hydrogen as a reality, especially post-COP28. Pink hydrogen will be used first in the cement and steel industries and later in the refining and petrochemicals sec - tor. In the long term, turquoise hydrogen produced by the direct conversion of methane to hydrogen and solid carbon could become attractive at scale, especially if combined with an electrical heat source from renewable power. Ammonia and methanol will continue to see growth as hydrogen carriers. The current cost of renewable hydrogen production remains much higher than producing hydrogen via steam methane reforming. In the long term, large-scale use of renewable hydrogen will become economically via- ble driven by governmental policy incentives, maturation of electrolysers, and carbon dioxide (CO₂) taxation. Back cracking of ammonia using a catalytic process to produce hydrogen and nitrogen will become an attractive option. Produced hydrogen can be used in fuel cells for power packs. At scale, these power packs can replace marine fuel. Firing of 100% hydrogen is technically feasible and tested, and it avoids the challenges associated with the use of ammonia as fuel. Using ammonia for direct firing will require careful consideration of burner types and the design of the selective catalytic reduction equipment. There are also lingering concerns about fugitive ammonia emis- sions leading to increased particulate matter (PM 2.5 and PM 10.0) when combined with other pollutants found in acid rain. The use of methanol as a marine fuel will rise, especially with the growth of green methanol. Green methanol pro- duced from sustainable biomass will see large-scale adop- tion in Asia, especially in India. Europe will see increased adoption of methanol from hydrogen produced with renew- able power and captured CO 2 (e-methanol).
Q What technology and strategies can resolve the huge gaps between ethylene and propylene production in cer- tain markets? A Jeffery Nichols, Solutions Delivery Senior Advisor, HSB Solomon Associates The boom over the past 15 years in demand for olefinic derivatives, most notably polyolefin plastics, has ushered in a supply deficit in multiple markets, leaving producers scrambling to capitalise on incremental margins. While the introduction of new production lines has been realised, with multiple fleet operators executing major capital projects since 2010, existing facilities are examining their options for squeezing every possible pound from their units. The keys to maximising olefin production from any facility – whether a new, world-scale complex or a vintage cracker, and regardless of feed or technology – fall into four foun- dational areas: • Shrinking or eliminating losses • Increasing yield • Increasing capacity • Sustaining high availability and minimising slowdowns and downtime. As intuitive as these strategies for maximising produc - tion may seem, applying them in the real world may not be straightforward. In addition, they are likely to involve ini- tial costs that hinge on the strategy or strategies adopted. Furthermore, no action exists in a vacuum. In some cases, improvement in one area will be complemented by positive results in another, but sometimes there are trade-offs. Robust mechanical maintenance programmes, including sound predictive and preventive maintenance components, are critical to increasing unit availability. Higher availabil- ity, almost without fail, translates into reductions in losses within a particular plant. Operational risk analysis that takes into account a facility’s tolerance for approaching critical plant limits or constraints is another essential element. Key points to consider include excess utility capacity, redun- dancy in contaminant removal, and safe operating limits for major equipment such as compressors. Consider this: For a 1,500-kiloton-per-year facility with a 98.5% service factor, a four-day reliability event translates into a produc- tion impact of more than 15 kilotons of product. Solomon Robust mechanical maintenance programmes, including sound predictive and preventive maintenance components, are critical to increasing unit availability
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can assist plant operators in evaluating the critical balance between maintenance cost and reliability to improve long- term performance. Some loss mitigation programmes are not focused spe- cifically on increasing plant reliability. These include capi - tal-intensive projects aimed at recovering flare gas, taking advantage of improved separation technologies (for exam- ple, tower internals), and purifying recycle/fuel gas (and thereby minimising olefin loss). Frequent objectives such as improving plant yields or expanding capacity can involve everything from unit opera- tional debottlenecking to incremental marginal yield shifts. Economic feasibility is a major factor in executing any pro- gramme in these areas. Recent technological advances in furnace coil design and metallurgy are having a significant positive impact on once-through yields, with the bonus of considerably extended run lengths. For furnace-limited plants, a 50% average run length increase could translate into an increase of 1-2% in annual furnace availability. Another option is adding furnace capacity, but this can be considerably more cost-intensive, at least initially. Though attractive in principle, incorporating flexibil - ity into a plant’s operation to take advantage of changes in demand or price disparities for ethylene, propylene, or another co-product may or may not be a practical pur- suit. One must consider not only market demand but also supply-side factors. For plants equipped to handle multiple feed types, shifting to heavier feedstocks to increase pro - pylene production is an intuitive response. Other options for increasing propylene production include the incorporation of metathesis units (at the expense of ethylene production) and propane dehydrogenation (PDH). The current focus on sustainability has also brought attention to methanol-to- olefins (MTO) technology, especially when integrated with blue hydrogen production from steam methane reforming and with processes for carbon capture, utilisation, and stor - age (CCUS). The overriding takeaway is that there are numerous options available for any particular producer to consider when attempting to address deficiencies in olefins demand vs supply. However, regardless of the technology consid - ered or the strategies employed, an intense focus on avail - ability must be maintained to keep the unit running and running well. Solomon Advisors can assist plant operators in achieving best-in-class performance. A Ujjal Mukherjee, Chief Technology Officer, Lummus Technology When there is an abundance of cheap gas such as ethane, producing ethylene from ethane is the most cost-effective production pathway. However, the product slate is severely tilted towards ethylene. Excess ethylene can be combined with 2-butene to produce propylene using metathesis, a low-cost energy-neutral process. Lummus’ olefins conver - sion technology is the most widely used route to convert ethylene to propylene to balance product slates in the most economic manner. When both ethane and propane are in abundance, we see a growing need for propane or propane/ butane dehydrogenation technology to produce a very high
yield of propylene. This approach has been adopted in the US, the Middle East, and even in China with imported pro - pane from the US. The other way to reduce ethylene and propylene produc - tion gaps is using mixed feed crackers designed to handle a wide range of feedstocks from ethane, liquefied petro - leum gas (LPG), naphtha, gasoils, and conditioned crudes and condensates. Mixed feed steam crackers have specially designed furnaces that can handle a wide range of liquids while maintaining long heater run lengths. Mixed feed crackers are particularly useful in the crude-to-chemicals strategy being adopted in many regions of the world. A Hernando Salgado, Technical Service Manager, BASF Refining Catalysts One strategy to adapt to changing market conditions, such as seasonal changes in ethylene and propylene demand, is having flexible process technologies that can adapt their product slate to the changing demand of both products. One of these process technologies is the always resilient work-horse of the refining industry (and becoming increas - ingly important to the petrochemical industry) – the fluid catalytic cracking (FCC) process. The FCC process is char - acterised by its inherent flexibility to manipulate severity, and therefore, it can have the flexibility to shift between types of light olefins produced. This is particularly true for FCC units specially designed to maximise light olefins – these can operate at very high severity (with reactor outlet temperatures higher than 540°C/1,000°F) and are equipped with special hardware, such as an additional riser to crack naphtha recycles or other light streams, and/or special riser terminations to maximise these secondary cracking reactions. Also, some units are designed to crack naphtha streams exclusively instead of conventional vacuum gasoil (VGO) or resid stock. These specialised FCC designs combined with the appro - priate FCC catalyst and additive systems are very effective in maximising a variety of light olefins products. The presence of this kind of process unit in a refining or petrochemical complex can provide huge flexibility to play between propylene and ethylene production by changing operating conditions, particularly severity. In addition, the selection of a proper catalyst, such as BASF MPS, MPS-R, Fourte, Fourtune or Fourtitude, in combination with an olefins additive to crack naphtha range material, such as ZIP, will contribute to enhanced flexibility in the FCC unit, allowing adjustment to shifting demand for propylene and ethylene. A Francy Barrios, Technology Engineer, Axens, Francy. Barrios@axens.net Ethylene and propylene are fundamental in the petrochemi- cal industry and have a wide range of applications across numerous industries, such as packaging, automotive, con - struction, and textiles. The market for these chemicals is growing due to the global demand for plastics and expand- ing end-use industries. For this, it is important to solve the huge gaps between ethylene and propylene production in certain markets.
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PTQ Q2 2024
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A Philippe Mege, Digital Services Factory Manager, Axens, Philippe.MEGE@axens.net Proposing a client upgrade a refinery plant from a conven - tional market to new products is generally based on con- sumer preferences, market trend analyses, and regulatory changes. AI can use machine learning algorithms to analyse historical data and make predictions about future market trends. It can also help by running different market scenar - ios to assess potential risks and associated impacts while developing a new product. NLP can also be used to extract valuable information from unstructured data sources to get a better understanding of the market and, therefore, stay ahead of the trends. A Ujjal Mukherjee, Chief Technology Officer, Lummus Technology AI, an integral part of a digital strategy, can be used effec - tively in retrofitting downstream units. We have a joint venture with TCG Digital, called Lummus Digital, which AI-driven digital solutions can be adjusted within equipment, product specification, and utility constraints to minimise energy and CO₂ emissions leverages AI-based platforms such as tcgmcube. We couple this with rigorous first principle-based process technology tools to take available data, quickly create digital twins, and develop unique hybrid solutions. These AI-driven digital solutions can be adjusted within equipment, product speci - fication, and utility constraints to minimise energy and CO₂ emissions while maximising production of the most valu- able products. These techniques are applicable to optimis - ing existing operations, designing new plants, or evaluating potential retrofit options. Once the products have been maximised within existing constraints, new solutions are developed with retrofits. This can include the change-out of catalyst systems, the addi- tion of new equipment, and sometimes entire upstream or downstream process technology. All of these impact the overall product slate while remaining within the turndown constraints of the base complex. Examples of such strategies include: •The introduction of biofeedstocks and waste plastic- derived pyrolysis oils to existing refineries or petrochemical complexes. • The elimination of gasoline production while maximising jet and diesel production, high-sulphur fuel oil production, and high-sulphur coke production. • Increasing chemicals production from 10-30% and sometimes 50% production of needle coke and anode coke from an existing coker, which is a dramatic shift in crude slates and more.
An increase in ethylene and propylene production can be reached by applying simple strategies to existing technolo- gies in the industry. For instance, increasing the severity in FCC units and/or using specific catalyst technologies and additives like ZSM-5 zeolite with high selectivity to olefins provides the product flexibility required by market demand. Even investment in additional and new technologies can be evaluated to maximise olefins production, like the integration of FlexEne technology, which is an innovative combination of two well-proven technologies – FCC and oligomerisation – to expand the capabilities of the FCC process to maximise olefins production, especially propylene. This flexibility is achieved by selective oligomerisation of light FCC alkenes (olefins) for recycle cracking in the FCC unit. Another important technology to be considered is High Severity Fluid Catalytic Cracking (HS-FCC), an excel - lent prospect for olefins maximisation. It is an evolution of the well-known FCC process to reach a considerably higher level of light olefins production, in particular propylene. This technology is, therefore, bridging the gap between the refining and petrochemicals industries. Q What role does artificial intelligence (AI) play in revamping downstream facilities that are scaling back on conventional fuels production while upgrading to capture value from new products? A Bradley Ford, Global Process Optimisation Solution Leader – Technology, KBC (A Yokogawa Company) The growing scarcity of skilled labour is impacting the per- formance of facilities worldwide. In fact, a study by Deloitte and The Manufacturing Institute reports that the manufac - turing skills gap in the US alone could result in 2.1 million unfilled jobs by 2030, resulting in a projected cost total - ling $1 trillion. As the industry pushes for optimisation, the infrastructure’s increasing complexity poses a challenge. KBC is observing the emergence of various types of AI technologies that are starting to address these challenges. For example, process simulation technologies are preva- lent at nearly all global assets, operating as process digital twins or online real-time optimisers. However, simulation models that reflect reality still require calibration from engi - neers. KBC now sees AI handling this critical task to: u Monitor the asset and models v Identify when calibration is lost w Automatically recalibrate it. The critical impact is allowing the available finite human resources to focus on higher-value tasks. Looking into the next steps, generative AI’s capabilities are potentially game-changing in capturing organisational knowledge that is dispersed across silos, contextualising that knowledge, and allowing junior staff to use it for idea generation. Careful oversight is needed to prevent genera- tive AI systems from ‘hallucinating’ or producing theoretical outputs that conflict with the data on which the algorithm has been trained. Hence, training programmes are required to educate staff on how to leverage generative AI to cre - ate ideas for improvement, which still requires peer reviews before implementation.
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PTQ Q2 2024
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Turn iron into gold? Alchemy? No. It’s chemistry.
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The AI digital twin assesses plant performance under various configurations and integrates with economic and capital cost models to evaluate the full impact of the revamp considered. Q Under what conditions do you see opportunities for blending petrochemical byproducts with refinery fuel feedstocks to lower conversion costs? A Romain Roux, VP Decarbonisation & Consulting, Axens, Romain.ROUX@axens.net Pygas is easily valorised in a refinery to produce an aro - matic rich cut or a gasoline after different hydrogenation steps. To produce an aromatic rich cut, a first step of hydro - genation will remove the diolefins and styrene. A second step of hydrogenation will remove the sulphur and olefins. To produce a gasoline, the first step of hydro - genation remains. It is then processed in a Prime-G+ unit to produce ultra-low sulphur gasoline. A Ujjal Mukherjee, Chief Technology Officer, Lummus Technology Whenever a refinery is being integrated with a petrochemi - cals complex, the opportunity to upgrade low-value prod- ucts from one unit to another increases. For example, the extremely low-value pyrolysis fuel oil from an ethylene unit is a good feedstock to a residue hydrocracking unit, where it will be converted to transportation fuels and/or petro - chemical feedstock. Hydrogen from propane dehydrogena- tion, catalytic reforming, and ethylene units can significantly reduce the hydrogen production demand in the refinery. When demand for gasoline is high, which is still the case in several parts of the developing world, the pyrolysis gaso- line from the ethylene unit or reformate from an aromat- ics unit can offer good value, especially when the price of certain polymers is depressed. The C 9 + aromatics from an ethylene unit can be recycled back to a hydrocracker to pro - duce incremental jet or heavy naphtha. Q What heat and mass transfer technologies are helping the industry lower Opex? A Caroline Bird, Senior Marketing Specialist, Solenis LLC, cbird@solenis.com Heat exchanger efficiency is critical to the success of any industrial operation, yet many plants rely on outdated or inadequate data to assess the health of their heat exchanger networks. As digitalisation is slowly becoming accepted and explored in the industry, there are opportuni- ties for refining and petrochemical operations to improve data management and lower operating expenses. Digital monitoring of heat exchanger reliability and per - formance is allowing companies to identify problem heat exchangers and create appropriate action plans to optimise heat exchanger efficiency. Solenis’ HexEval performance monitoring program for heat exchangers is an example of this digitalisation. The program allows plant operators to identify and monitor problem heat exchangers that are operating outside of set
limits for fouling and scale. As a result, plant operators can address fouling and scale issues in real time to help avoid a plant shutdown or slowdown. Additionally, Solenis’ HexEval program provides an online repository for all heat exchanger activity, allowing access to historical data when needed. This allows plant personnel to devise action plans to proactively address system issues, thereby maintaining plant productivity and generating operational savings. The utilisation of the HexEval program has enabled numerous Solenis customers to decrease cor - rosion and corrosion-related pitting, cleanings outside of turnarounds, and heat exchanger failures. Knowledge is power, and having the knowledge of their heat exchangers at their fingertips has enabled refining and petrochemical operations to significantly reduce their operating costs. A Jan Reneteau, Managing Director, Axens, Jan. RENETEAU@axens.net Very high-efficiency heat exchangers are key to lowering the Opex of heavy energy consumption processes. While standard S&T technology can offer limited thermal per- formances, spiral tube heat exchanger technology greatly enhances thermal and hydraulic performances. This technology has been used for many years in the cryo - genic liquefaction industry. For more than 30 years, ZPJE has developed a unique state-of-the-art know-how of heat exchange calculation, hydraulic simulation, and mechanical modelling of spiral tubes design to enable this technology to be used in refining and petrochemical applications. The design of spiral tube heat exchangers consists of many tubes arranged in multiple layers of helical coils, around a centre pipe. This tube bundle is enclosed in a cylindrical pressure vessel. The fluid on the tube side and shell side flows in opposite directions, making the equip - ment a true countercurrent heat exchanger, allowing a heat transfer efficiency two to three times higher than conven - tional S&T exchangers. The minimum temperature difference between the two fluids can be as low as 2°C, permitting the unlocking of heat integration opportunities in demanding process services. Those exchangers can be applied in reforming, aromatics applications and also in hydroprocessing applications where their high performance and high tolerance towards fouling can drastically reduce the Opex, allowing, in some cases, the end user to operate the furnace only during start-up phases. The newly created joint venture between ZPJE and Axens named Nectis aims to promote the application of spiral tube heat exchangers in the refining and petrochemical busi - nesses to help the industry lower its carbon intensity. A Ujjal Mukherjee, Chief Technology Officer, Lummus Technology Some technologies that are especially useful include: • New membrane technologies for separation and coil- wound heat exchangers. • Air preheat systems that can significantly reduce energy consumption. • Advanced integrated separation devices used in Lummus’ proprietary TC2C technology.
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Capturing green opportunities
Carbon capture and storage or utilization (CCS/CCU) is a key strategy that businesses can adopt to reduce their CO 2 emissions. By selecting the right technologies, pressing climate change mitigation targets can be met while benefitting from new revenue streams. Sulzer Chemtech offers cost-effective solutions for solvent-based CO 2 absorption, which maximize the amount of CO 2 captured and minimize the energy consumption. To successfully overcome technical and economic challenges of this capture application, we specifically developed the structured packing MellapakCC™. This packing is currently applied in several leading CCS/CCU facilities worldwide, delivering considerable process advantages. By partnering with Sulzer Chemtech – a mass transfer specialist with extensive experience in separation technology for carbon capture – businesses can implement tailored solutions that maximize their return on investment (ROI). With highly effective CCS/CCU facilities, decarbonization
becomes an undertaking that can enhance sustainability and competitiveness at the same time. For more information: sulzer.com/ chemtech
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• The use of stripping media to eliminate expensive furnaces. TC2C is a trademark of Lummus Technology. Q How are technology suppliers dealing with attracting young professionals to the industry? A Louise Maratos, Head of Consulting Delivery, Lourdes Cozzitorto, Vice President, Technology Services, KBC (A Yokogawa Company) Technology suppliers are increasingly recognising the importance of attracting young professionals to the indus- try. Companies are leveraging modern technologies not only to enhance their products and services, but also to streamline their recruitment and onboarding processes. These companies are using applications that offer multi- channel sourcing, making it more convenient for candidates to apply for jobs matching their skills profile and interests. They also encourage engagement via specific young pro - fessional/graduate websites. Emphasising a flexible work environment, work-life bal - ance, and an innovative culture resonates with Gen Z’s aspirations. Moreover, offering opportunities for skill devel- opment and career growth, along with a commitment to sustainability and social responsibility, must be actively integrated into recruitment strategies. Companies are leveraging modern technologies not only to enhance their products and services, but also to streamline their recruitment and onboarding processes Adapting to the preferences and values of this younger workforce is crucial to ensuring the industry remains vibrant and competitive. In Europe, collaborating with schools and colleges encourages young adults to pursue STEM careers. We are establishing partnerships with open opportunities within our organisation for internships across technology and con- sulting, giving young people insight and experience in our industry. Additionally, a junior network is in place to facili- tate discussions on various topics of interest with our global experts, which actively engages with relevant universities. A Mathilde Nerrant, Head of Talent Manager, Axens, Mathilde.NERRANT@axens.net Axens Group provides a complete range of solutions for the conversion of oil and biomass to cleaner fuels, the produc- tion and purification of major petrochemical intermediates, the chemical recycling of plastics, all natural gas treatment and conversion options along with water treatment and carbon capture. The offer includes technologies, equipment, furnaces, modular units, catalysts, adsorbents and related ser- vices. Axens is ideally positioned to cover the entire value
chain, from feasibility study to unit start-up and follow-up throughout the entire unit life cycle. This unique position ensures the highest level of perfor- mance with a reduced environmental footprint. As a key player in energy transition, Axens Group offers many guar- antees to young professionals willing to join the energy industry. These promises stand for both their professional and personal development, which is facilitated by four major HR levers that support our employer brand: Empower yourself At Axens, you can choose how to take your future into your own hands: at your own pace, independently, but not alone. Personalised training, career paths, taking on responsibili- ties, geographical or intra-group mobility, you decide how you venture forward, and we will build a secure future together. Worldwide Working at Axens is also about building and living your success story in France or abroad. Working in energy per- formance for major industrial companies on a large scale, international projects with our subsidiaries around the world is a daily reality. As a young professional, you can quickly meet our customers and suppliers from different countries who speak different languages and exchange with them on a daily basis. Diversity and inclusion Within the Group, we all interact with men and women of more than 50 nationalities, different cultures, generations, professions and backgrounds guided by a common ambi- tion: to take the challenges of energy transition further. The goal is that we like to live to the full at Axens by continu- ously challenging stereotypes and clichés. It is the foun- dation of our commitment to diversity and inclusion. Only talent and personality matter to us. Happy Let us put it straight. Axens has obtained the label ‘Happy at work’ for the ninth consecutive year. Young graduates and professionals are also forging lasting relationships thanks to strong values embodied by all Axens communi- ties throughout the world. It is not by chance that most of our people make the decision to build a long career path with Axens. A Nora Yap, Strategic Marketing Manager, Syngas and Fuels, Clariant Catalysts, Nora.Yap@clariant.com We need to ensure the fundamentals are right. Offering candidates competitive salaries and benefits and ensuring employees are supported in their continued growth with- out compromising their work-life balance are key. Fostering an innovative and inclusive work environment is also about having a purpose they can believe in, where their contribution matters. Additionally, if we further foster openness and trust within the organisation, we can ensure not only talent attraction but also talent retention.
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Optimising furnace run length in a steam cracker using AI
Case study on improving ethylene furnace run length by leveraging the synergy of digitalisation and artificial intelligence to provide the necessary insights
Surabhi Thorat and Vivek Srinivasan Dorf Ketal Chemical (I) Pvt Ltd Sudarshan Vijayaraghavan Dorf Ketal Chemicals PTE Ltd
E thylene serves as a predominantly petrochemically derived monomer essential for producing plastics, fibres, and various organic chemicals. These end -products find applications across industries such as pack - aging, transportation, construction, and other industrial and consumer markets. Notably, more than half of global ethyl - ene derivative consumption is attributed to non-durable or consumable end uses, especially in packaging. The majority of this consumption is associated with poly - ethylene, a plastic resin that constitutes most ethylene usage. Given its status as one of the largest volume petrochemicals globally, the consumption of ethylene is influenced by eco - nomic and energy cycles. Its extensive and diverse derivative portfolio, covering both non-durable and durable end uses, positions ethylene as a benchmark for gauging the overall performance of the petrochemical industry. Furnace efficiency In the complex realm of ethylene production, furnace efficiency plays a pivotal role in determining overall operational success. However, a significant challenge arises from shortened run lengths, increasing downtime and production costs. This issue is rooted in the increasing tube metal temperature (TMT) of the furnace, a critical factor affecting operational longevity. A decrease in run length in an ethylene furnace due to coke formation and a rise in TMT can result in significant financial losses for several reasons. Here are some potential factors contributing to the financial impact: • Production interruption: Reduced run length means the ethylene furnace is not operating at its optimal capacity for the intended duration. This interruption in production can lead to lower yields of ethylene and other desired products, resulting in lost revenue. • Increased decoking: Coke formation and elevated TMT may call for frequent decoking, resulting in higher energy costs and reduced capacity utilisation rates. Frequent decok - ing can also affect the overall reliability of the tubes, compro - mising the life span of radiant tubes. • Energy consumption: A less efficient furnace may require more energy to maintain the desired operating conditions. Higher energy consumption not only leads to increased operational costs but also contributes to environmental con - cerns if the energy source is not sustainable.
• Impact on selectivity: Inefficient furnace operation, com - bined with a high potential for coking, leads to a critical TMT threshold during mid-run cycles, constraining achiev - able severity levels. Consequently, this limitation adversely affects the overall selectivity for ethylene make. • Market dynamics: In the competitive petrochemical indus - try, delays or interruptions in production can affect a compa- ny’s ability to meet customer demands. This can result in lost market share and potential long-term damage to business relationships. • Increased emission and environmental impact: Poorly optimised furnace operations tend to emit higher levels of greenhouse gases, thereby exacerbating the carbon foot - print, as furnaces are commonly fuelled by fossil fuels. The frequent decoking process also introduces further emissions, compounding an already elevated environmental impact. To mitigate these financial losses, it is crucial for plant operators to implement effective monitoring, maintenance, and operational strategies to prevent or address issues such as coke formation and elevated TMTs in a timely man - ner. Regular inspections, proper decoking procedures, and adherence to best practices in furnace operation can contrib - ute to improved efficiency and extended run lengths. Differentiator Understanding and addressing elevated TMTs is key to overcoming these aforementioned challenges. Dorf Ketal’s proprietary artificial intelligence (AI) solution CokeNil offers solutions to extend run lengths through predictive mainte - nance, optimised process control, and improved fault detec- tion. It is a data-driven, deep domain insight-based solution where every process parameter is evaluated thoroughly in the exploratory data analysis phase to ensure the accuracy of the outcome. It is built on advanced deep learning methods such as long short-term memory (LSTM) networks, Random Forest regression, CatBoost regression, XGBoost regression, and time series algorithms to help the model identify the pat- tern and behaviour of each critical process parameter. CokeNil is a unique AI solution for optimising the furnace run length. This plant’s distributed control system (DCS) feeds live operating conditions (such as naphtha feed com - position, coil outlet temperature, steam-to-hydrocarbon ratio [SHC], temperature, and fuel flow) to the CokeNil. These are
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processed by the AI model, and optimal values that need to be set in the real process are recommended. A key point is that the optimal values will never violate the acceptable operational ranges of suggested critical parameters. AI algorithms equipped with real-time data analysis capabilities play a crucial role in predicting and proactively addressing potential furnace issues. By dynamically adjust- ing parameters and ensuring adaptive control, the AI system prevents runway TMT and mitigates stress on critical com- ponents. This dynamic optimisation lays the groundwork for extended operational runs, minimising the interruptions caused by unplanned downtime. AI/digital twins symbiosis AI-driven optimisation plays a key role in ensuring stable fur- nace operation with reduced delta pressure and dilution steam, as well as an optimised feed ratio. This leads to a more con- trolled furnace temperature, contributing to operational stead- iness. The nuanced control provided by AI not only enhances operational efficiency but also contributes significantly to the overall stability of the ethylene production process. The discussion takes an intriguing turn with the introduc- tion of advanced process modelling, including the concept of digital twins. This innovative approach enables virtual test- ing and scenario optimisation, allowing operators to explore various conditions without impacting the physical furnace. The symbiosis of AI and digital twins not only optimises cur- rent operational parameters but also lays the groundwork for future advancements in ethylene production processes. However, challenges persist, and historical data serves as both a hurdle and a guiding light. The initial phase of AI
model building includes critical process parameters identifi - cation, preliminary investigations, pattern discovery, anom- aly spotting, hypothesis testing, and establishing correlations between process parameters and run length by considering TMT as the primary target. AI leverages historical data to train the run length optimi- sation model. Coking in the radiation coil is inevitable at high cracking temperatures. As TMT reaches maximum threshold values, the furnace undergoes decoking, compromising run length. Furnace run length is directly linked to coke forma- tion rate, with operational parameters such as TMT, dilution steam ratio, firing rate, feed composition, feed rate, wall and floor burners in operation, excess oxygen %, coil pressure ratio (CPR), coil outlet pressure and venturi ratio determining the end of furnace runs. In response to these intricacies, the furnace is operated, and parameters are controlled to minimise the rate of increase in TMT throughout the run. This proactive approach mitigates the rise in TMT, ultimately contributing to longer furnace run lengths and improved operational efficiency. TMT prediction model The CokeNil TMT prediction model has demonstrated a com- mendable accuracy rate of 98.2%, underscoring the efficacy of our AI system. This high level of precision substantiates the model’s reliability and underscores its potential impact in practical applications. It is imperative to recognise that model success extends beyond accuracy alone, encompass- ing aspects such as generalisation to unseen data and robust performance across diverse scenarios. Furthermore, a holistic assessment that includes metrics like precision, recall, and F1 score contributes to a more com- prehensive evaluation of the model’s efficacy. The observed effectiveness of the base model in predicting TMT for opti- mal parameter recommendation holds promise for positively influencing associated processes and systems. Continuous monitoring, evaluation, and potential retraining with new data are pivotal for sustaining and improving model performance. Figure 1 shows the results of the TMT prediction model. Whenever a new furnace run starts, the CokeNil model captures critical parameters, which are the base for the model, and generates optimal values for subsequent furnace runs. The generated optimal values are typically in the acceptable operational range, which the plant operator can incorporate into the actual process and see the TMT improvement.
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Figure 3 Scenario 2 where furnace run length is extended by 18 days
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