Naphtha Cracking

A presentation by :Niteesh Kumar VatsME, Chemical Engg.IISc Bangalore

Cracking

Need for cracking

Cracking

Less valuable products

More useful & valuable products

most of the gasoline/petrol is produced by cracking!

Naphtha?

Historical Present

Sources of naphtha

*source- origbouk.ru/products.html

• 1941: Standard Jersey developed the world’s first steam cracker at Baton Rouge.

• In 1891 The thermal cracking method was invented.

• modified in 1908

• In 1934 factory of Shukhov cracking process established at Baku, USSR.

History

William Burton

Vladmir Shukov

Naphtha cracking

Petroleum industry

Petrochemical industry

Hydrocracking

Steam cracking

Motivation for steam cracking

The worldwide demand and production of olefins…

Currently, production through steam cracking

1. 94% of the world propylene.2. In Western Europe, 95% of `````ethylene and 70–75% of 111propylene.3. In Asia, 61% of ethylene.

*source-2011-november_Olefinek eloallitasa.pdf

Use of products of steam cracking of naphtha

Chemistry of steam cracking

Propagation

Initiation

Termination

+ C + etc.

etc.

Process of steam cracking of naphtha

Pyrolysis section

Fractionation andCompression Section

Product recovery and Separation Section

Naphtha

Energy analysis in steam cracking sections

Section Energy required

Energy loss

pyrolysis 65% 75%fractionation and compression

15% 25%

recovery section

20% 15%

Pyrolysis section

Pyrolysis furnace

Transfer line exchange(producing steam)

Cracked gas

Naphtha 750-900

300

Separation section

Ethylene (24%)

Propylene(20%)

Butadiene(3%)

BTX(1%)

Petroleum ether(25%)

Products from separation section

“ Steam cracking is the most energy-consuming process in the chemical industry and globally uses approximately 8% of the sector’s total primary energy use.”

Latest Development in steam cracking of naphtha

Advanced furnace materials

Advanced distillation columns

Membranes

“These latest developments in naphtha cracking can lead to approximately 10% savings on the process energy used.”

zeolite

Alternative technologies

Catalytic cracking of naphtha

Hydro-pyrolysis of naphtha

Progress of Cracking Process

Ene

rgy

Naphtha

Olefins and byproducts

Activation Energywithout catalysts

Activation Energywith catalysts

ThermodynamicEnergy requirement

Energy required in a pyrolysis furnaceIn the case of conventional steam cracking

Energy required in a reactor In the case of catalytic cracking technologies

Energy saving!

How Catalytic cracking Technologies Save Energy?

1st way:

2nd way:selectivity of catalyst

3rd way:Removal of coke

Conclusion

Plenty of room for energy savings is possible in steam cracking. And Catalytic cracking technologies can lead to energy saving up to 20%.

90% chemical processes already benefits from catalysis,

so can steam cracking!

References

• Olefins from conventional and heavy feedstock's: Energy use in steam cracking and alternative processes. Energy 31 (2006) 425-251

By Tao Ren, Martin Patel, Kornelis Blok• James. G. Speight (2006). The Chemistry and

Technology of Petroleum (4th ed.). CRC Press.• Dr. Ram Prasad (2010). Petroleum refining Technology (1st edition). Khanna publishers