Intensifynaphta crackingfurnacesbyapplyinginnovativecoils

Hans-HenkWoltersCEOECMTechnologies WOERDEN,October 19th 2016

TakeHomeMessage;

• Naphta CrackingcanbeintensifiedbyElectrochemicalMachining

• AllcoilfeaturescanberealizedbyElectrochemicalMachining

“INTENSIFYINGNAPHTACRACKING”OVERVIEW• IntroductionintoECM(ElectrochemicalMachining)

• Processprinciple• DevelopedECMprocesses/applications

• Crackingfurnacetubechallenges• Tubemanufacturingtechnologies• TakeHomeMessages

Flowofelectrons

Flowofelectrons

+ -

Anode Cathode

Dissolutionofmetalfromanode

Men+

Men+Depositionofmetaloncathode

Me

Me

Metalsaltsolution

Electrochemistry

ECM=AM=ECP

ECPECG

ECM

ECP

ECD

EPP

STEM

CEEDM

pECM

PEO

ECRECP

Flowofelectrons

Flowofelectrons

+ -

Anode Cathode

Dissolutionofmetalfromanode

Men+

Men+Depositionofmetaloncathode

Me

Me

Metalsaltsolution

ECMANIMATION

CATHODE

MichaelFaraday(1791-1867)

ThefoundingfatherofthemodernECMtechnique

1996PhilipsDAP1999PhilipsAerospace2003ECMTechnologies

ADVANTAGESECM• Highdimensionalaccuracy• “NO”toolwear• HighMRRatlowcosts• NoHAZ• LowRavaluesfeasible(≈10nm)• Nomechanicalorthermalloadontoolandworkpiece

• Productfreeofburrs• 3Dshapescanbemachinedin1singlestep• DuetotheECMapplicationitispossibletogeneratemoredesignoffreedomforthepart

• Energycompetitive• Closedelectrolytemanagementsystemwithre-useofelectrolyte

• Accurateandhighlyrepeatableprocess

Stainless SteelSteelgrades

Tungsten (carbide)Hardmetal

Cobalt (alloys)

Titanium(alloys)Nickel (alloys)

AlNiCoAluminum (alloys)

Copper (alloys)Molybdenum

3Dprinted materialOther conductive materials/metals

Customers

•Automotive•Aerospace

•Space •Medical

•Steelindustry

•Energymarkete.g.fuelcells,HEandsolar

•Oil&Gasindustry

•Consumerproducts

•Watchindustry

•Hygienemarket

•Membranetechnology

R&D AND SERIES PRODUCTION

The Netherlands

Phase1:Fundamentalresearchonthespecificmaterial

Phase2:Applicationresearch

EXAMPLESDEVELOPEDAPPLICATIONS/PROJECTS

Phase3:Prototyping

Phase4:Production

IntroductionofECMTechnologies

MicrostructureDiameterpilar 60-70μmCentrecentredistance200μmHeightpilar 250μm

Processtime:12min

Mainquestion

ImproveheattransferrateswithoutraisingTubeMetal(wall)Temperatures(TMT)asthisincreasescokedeposition

Cracking furnace tubechallenges

•TubeMetalTemperatures(TMT)• Thermalconductivityofthemetalinitially• Secondaryitwillbeacombinationwiththenonconductivecokedeposition• TMThightoimproveyield• TMTlowtopreventcokedeposition

•Materialandthealloycomposition• WroughtmaterialsaresubjecttostressatelevatedT’s(materialdeformation)• Creepstrength• Nickel,Chromium,Carbon,Niobium,Silicon

• Stablesausteniticstructure• Improvingcreepstrength• Increasecarburizationresistance

Cracking furnace tubechallenges

•Physicsofthewallmaterial• Surfaceroughnessand/orstructuretooptimizethelimitationofcoke

deposition•Configuration

• Straight• Finned• Helical/swirled• Helicalfinned

•Residencetime•Pressuredrop

• Pressuredropwillaffecttheyieldnegatively

Cracking furnace tubechallenges

Standardtube•Cheap•Easytomanufacture•Lowpressuredrop•Limitedheattransferarea

•Cokeformationontheinside•Reducedlifetime•Poormixing•Nonimprovedgasflow•Nonimprovedheattransfer

Cracking furnace tube

Swirlflowtube•Increasedrunlength•Increasedfurnacecapacity•Improvedmixing•Limitedsurfaceincreasetoimproveheattransfer

•Materialdeformationincludesmaterialstress• Limitedselectionofmaterialstobeused

•Sensitiveforcokedeposition• Butlowerduetoreducedwalltemperaturescomparedtostraight

tubes•Limitedincreaseinpressuredrop

Cracking furnace tube

Finnedtubes•Enlargedsurface•Material353MA

• Highresistanceagainstcarburization•Extendedlifetime

•WroughtprocessintroducesmechanicalstressandlimitationinTMT•Onlystraightfinning,nohelicalshapefeasible

Cracking furnace tube

Finnedtubes•HigherTMTbyspuncast processcomparedtowroughtmaterials•Improvedradialgasflow,improvedmixingandheattransfer•Reducedpressuredropcomparedtootherprofiles

•Increasedpressuredropcomparedtostraighttubes

Cracking furnace tube

Helical/twistedtubesbyECM•Improvedheattransferbyenlargedsurface•Notlimitedtolengthofatube

• Now2mdemonstratoravailable,feasiblefor10’sofmeters• Highaspectratiofeasible

•Optimizedsurfacequalityandroughnesstoreducecokeformation•Possibleforallmetalsincludingsuperalloys•Finned,lobbedand/orhelicalpossiblewithoptimizedlimitedpressuredrop•Improvedmixingbyhelicalstructure

AllfeaturescanberealizedbyElectrochemicalMachining

Cracking furnace tube

TakeHomeMessage;

• Naphta CrackingcanbeintensifiedbyElectrochemicalMachining

• AllcoilfeaturescanberealizedbyElectrochemicalMachining

What arewelookingfor;

• Cooperationwithcompaniesthatareinterestedinthistechnology

• PartnersareinvitedforaDemoPIproject

THANKYOUFORYOUR ATTENTION!

Formoreinformationpleasevisitwww.electrochemicalmachining.com