ethylene production from tennessee fracked natural gas university of tennessee at chattanooga engr...
TRANSCRIPT
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Ethylene Production From Tennessee Fracked Natural Gas
University of Tennessee at ChattanoogaENGR 5910/ENCH 4300
4/26/2012
Brandon Dodd Valentine Mbamalu
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Outline
• Introduction• Design Basis• Cracking Reaction• Process Flow Diagram• Equipment Design• Project Economics• Conclusion
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Introduction
www.timesonline.com
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Design Basis
• Analyze 500,000 metric tons Ethane feedstock per year
• Feedstock will be considered as 100% Ethane
• Negligible reaction byproducts not to be considered for this level of design
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Ethane Cracking Reaction
Byproducts
Methane Propane
Hydrogen Gas
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Generalized Process Flow Diagram
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Steam Cracker• 170 MW heat duty
• Modeled as 2 100MW separate pyrolysis
furnaces
• Each furnace 100 MW capacity
• Operates at 80% capacity.
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Transfer Line Exchanger
• Shell and Tube Model
• 73 MW Heat Removed from Product Stream
• 820 m2 Total Exchange Area
• 2 Units in Series
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Distillation Columns
• 3 Total Columns• 8 stage de-methanizer– 10m high– 3m diameter
• 20 stage de-ethylenizer– 15m high– 3m diameter
• 40 stage de-ethanizer– 27m high– 3m diameter
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Other Equipment Estimated
• Quench Tower
• Compressors
• Refrigeration
• Pumps
• Fans
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Unit Cost SummaryUnit Description # Units Cost (Millions)C-101 Compressor 1 2C-102 Compressor 1 12.7K-101 Drier 1 1.2E-101 Transfer Line Heat Exchanger 1 0.5E-102 Refrigeration Train 1 0.4E-103 Regrigeration Train 1 0.6F-101 Fans 20 0.3H-101 Pyrolysis Furnace/Cracker 1 21.5H-102 Pyrolysis Furnace/Cracker 1 12.6P-101 Pump 10 2.9R-101 Acetylene Converter 1 0.2T-101 De-methanizer - tower 1 3.7T-102 De-ethylenizer - tower 1 5.4T-103 De-ethanizer - tower 1 9.3V-101 Product Holding Tank 1 2.7Z-101 Quench Tower 1 2
Unit Cost Estimation Summary
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Costs – In Millions
• Capital Costs - $121– Includes land cost
• Total Annual Operating Costs - $617– Utility Cost - $142– Raw Material Cost - $475– Labor Cost – estimated $1
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Revenue – In Millions
Total Yearly Revenue - $960
•Ethylene – 560,000 metric tons– $955
•Methane – 3000 metric tons– $0.7
•Propane – 3000 metric tons– $0.7
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Revenue Vs. Cost
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Payback Period
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ENVIRONMENTAL IMPACT
• Air pollution• Primary – Nitrogen dioxide, Particulate Matters, Volatile Organic Component
. Secondary – Ozone
. Incinerators
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Conclusions
• Costing based on key component• Project is profitable• Economic activities will receive boost• Jobs and revenue to state and local gov.