1 Ethylene Plants
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Transcript of 1 Ethylene Plants
< >1MAN Turbo AG
MAN Turbo Compressors and Steam MAN Turbo Compressors and Steam Turbines for Ethylene PlantsTurbines for Ethylene Plants
May 2010May 2010
< >2MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
References
Application References References for Manufacturing of Large ImpellersReferences for Resulting Dimensions and WeightsReferences for Large Steam Turbines as mechanical drive
< >3MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
Casings in Service
38 Cracked Gas 28 Propylene / Propane
Refrigeration27 Ethylene / Ethane
Refrigeration 8 Recycle Gas 3 Other Service
28 Steam Turbine Drivers
132 Turbomachines in Ethylene Plant Service
Ethylene PlantsApplication References
Latest Reference: Complete Set of Machines for a has been500 kta Ethylene Plant delivered
< >4MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
Schwechat Refinary, Austria, 2005
350 kta Extension of Ethylene Plant
< >5MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
350 kta Extension of Ethylene Plant
Schwechat Refinary, Austria, 2005
< >6MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
Tiszaujvaros Kombinat, Hungary, 2004
250 kta Ethylene Plant - LINDAETH
< >7MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
Tiszaujvaros Kombinat, Hungary, 2004
250 kta Ethylene Plant - TISKO
< >8MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
Tiszaujvaros Kombinat, Hungary, 2004
250 kta Ethylene Plant - TISAETH
< >9MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
Tiszaujvaros Kombinat, Hungary, 2004
250 kta Ethylene Plant - TISPROP
< >10MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
600 kta Cracked Gas Compressor no. 1
TERNKO 4
LP RH100/02D RH100/02D MP RH100/04ST DK080/170
flow 165 504 m3/hp1 1.4 barp2 14.8 barspeed 5 200 rpmcomp. rated 20 170 kWturbine rated 22 187
DOW Benelux LHC-3 Terneuzen, NL, 2000
< >11MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
TERNKO 5
HP RH040/03ST DK035/080
flow 13 044 m3/hp1 11.7 barp2 38.4 barspeed 12 409 rpmcomp. rated 6 987 kWturbine rated 7 686 kW
600 kta Cracked Gas Compressor no. 2
DOW Benelux LHC-3 Terneuzen, NL, 2000
< >12MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
600 kta Ethylene Refrigeration Compressor
TERNAETH
Type RH063/06ST DG040/040
flow 26 820 m3/hp1 1.04 barp2 16.0 barspeed 8500 rpmcomp. rated 6 780 kWturb. rtd 7 458 kW
T1 -102°CSidestream (480%) @ 4 barExtraction (43%) @ 10.3 bar
!!
DOW Benelux LHC-3 Terneuzen, NL, 2000
< >13MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
600 kta Propylene Refrigeration Compressor
TERNPROP
type RH100/06ST DK080/170
flow 88 126 m3/hp1 11.7 barp2 38.4 barspeed 4 058 rpmcomp. rated 16 481 kW
DOW Benelux LHC-3 Terneuzen, NL, 2000
< >14MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
600 kta Steam Turbine Driver
TERNKO 4 /TERNPROP
ST DK080/170
p1 91 barpex 13 barp2 0.1 barRated 22 187 kW
Identical steam turbine for TERNKO 4 and TERNPROPonly 1 spare rotor required
DOW Benelux LHC-3 Terneuzen, NL, 2000
< >15MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
Cracked Gas Compressor
MOSSKO
LP RH100/03DMP RH100/06HP RH050/08
flow 111 850 m3/hp1 1.5 barp2 38.9 barspeed 4 670 / 8 550 rpmcomp. rated 28 000 kW
Gas Turbine driven (Frame 5)with helper steam turbineintermediate gear box
Esso Mossmorran, GB, 1981
< >16MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
Propane Refrigeration Compressor
MOSSPROP
LP RH112/02DMP RH112/02DHP RH112/02
flow 144 223 m3/hp1 1.1 barp2 12.6 barspeed 3543 rpmcomp. rated 28 000 kW
3 casing design
Esso Mossmorran, GB, 1981
< >17MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
Delivered in late 2009
ILAM 500 kta Ethylene Plan
< >18MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
ILAM Cracked Gas Compressor
< >19MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
ILAM Cracked Gas Compressor
Ø 500 kta Cracked Gas CompressorØ MAN TURBO condensing steam turbineØ welded compressor casingsØ HP casing horizontally split with hydro
test pressure of 78,3 bargØ compressor nozzle loads 3 x NEMA
< >21MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
ILAM Propylene Compressor
Ø MAN TURBO condensing steam turbineØWelded Compressor CasingØ compressor nozzle loads 3 x NEMA
< >23MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
ILAM Ethylene Compressor
Ø MAN TURBO condensing steam turbineØ stainless cast steal compressor casingØ compressor nozzle load 3 x NEMA
< >24MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
Cracked Gas Compressor (CGC)Ethylene RefrIgeration Compressor (ERC)Propylene Refrigeration Compressor (PRC)Binary Refrigeration Compressor (BRC), for ABB Lummus instead of ERC
ST ST
Propylene refrigerationcompressor
Ethylene refrigerationcompressor
Amine treatmentCaustic washing
ST 1 1 2 3 4 5
30 - 40 bar
Drying
Cracked gas compressor
Cold box- 50 °C - 105 °C
Compressor Casings
< >25MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
Casing Design ExampleRH090/06 – 39 barg (I)
• Largest fabricated casing built by MAN Turbo to date (~2.6 m)
• 5 nozzle design
< >26MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
Casing Design ExampleRH090/06 – 39 barg (II)
• Initial analysis shows possible leakage • shift bolt pattern closer to shaft bore location
• high local peak-stresses in support strut region • new strut design with less stiffness in the surrounding regions incl. experimental verification
⇒Hydrostatic pressure test successful – First Time Right
leakage path
shift bolt hole
strain gauge measurement at support strut
< >27MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
• All surface stresses below yield• No peak stresses on outside surface• Tightness confirmed
1.3 Mt/a CGC-HP:Surface stresses
⇒ CGC-HP Casings with horizontal split available even for large Ethylen Plantswith high discharge pressures (up to 66 bar water test)
Current ImprovementsStudy of 66 bar Charge Gas Compressor (HP) with Horizontal Split Casing
Casing Scaling:Ethylen 1 Mt/a → RH100 (Impeller ~ 950 mm)
Ethylen 1,3 Mt/a → RH110 (Impeller ~1100 mm)
Modell:
Results:
< >29MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
Ø 3-D and 2-D impeller
Ø cover disc brazed or welded
Ø 40° / 50° / 60° outlet
Ø A 182 (X3CrNi13-4)
Ø 17-4 PH
Impeller Design
< >30MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
NACE MR0175
H2S-Anteil CO2-Anteil Druck (absolut)[Mol-%] [Mol-%] [bar]
EINGABEWERTE: 0,006 0,045 18,6
SSC Regionen nach NACE (Stand heute)
3
3,5
4
4,5
5
5,5
6
6,5
7
0,00001 0,0001 0,001 0,01 0,1 1 10p H2S [bar]
pH
>100°C20°C
Re gion 0
Region 3
Region 2
Region 1
1
10
100
10001 10 100 1000 10000 100000 1000000
Mol-% H2S in gas
Tota
l abs
olut
e pr
essu
re [b
ar]
0,0001 0,001 0,01 0,1 1 10 100
ppm H2S in gas
Sulfide Stress Cracking Region
SSC Regionen nach NACE 2002
Ausdruck DiagrammSCC Regionen nach NACE (Stand heute)
Ausdruck DiagrammSCC Regionen nach NACE (Stand 2002)
MAN Diesel & Turbo selects impeller material according the latest NACE -Standard
< >31MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
Compressor RASRA 1-2Type AR115/10Steam Turbine Driven
Year of Order 2003Suction Flow 690,000 m3/hSuction Pressure 1.000 barDischarge Pressure 8.3 barPower 55600 kW
Large ImpellersReference – RASRA
44 Impellers with a diameter of 1600 mm or larger
< >32MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
RIK 140
Large Impellers Reference RIK 140
< >33MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
Compressor fouling
Basic causes for compressor fouling:
- Feedstock:High valency hydrocarbons and untreated gas components tend to polymerization.
-Temperature:The rate of polymerization increases rapidly at temperatures greater than 85°C (depending on feed stock)
- Pressure:Fouling increases almost proportionally to pressure
- Surface finish: smooth surfaces are less prone to fouling
< >34MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
Polymerized deposits
volute diffuser
< >36MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
Production: At a given speed the discharge head / volume flow characteristic is lower. The efficiency curve tails off accordingly. Increasing the speed can counteract this, howeverthe original volume is now achieved at a less favourable efficiency level and at a higher temperature.The speed of polymerization increases and the fouling process accelerates as a result.
Consequences of polymerized deposits in the compressor for the operator with respect to the efficiency rating and availability
head
drop
of
effic
ienc
yte
mpe
ratu
rin
crea
se
100% point
speed compensation
clean compressor atnormal speed
when fouling ispresent
Clean compressor atnormal speed
when fouling is present
clean compressor atnormal speed
actual suction flow
∆V
constantdischargepressure
85°C
95°C
Consequences of polymerization
< >37MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
Washing system example 3
Water injection in the return channels is used currently.
To optimize
- nozzle type- flow quantity- configurationa CFD engineering is put into execution.
< >38MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
Ø cast steel casing (low temperature)
Ø impeller inline arrangement
Ø internal side stream
Ø DGS in tandem arrangement
Design Refrigeration CompressorTERNPROP - Cross Section
< >39MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
Sideloads
Ø location upstream return channel allows forproper mixing of the two streamsØ cast design allows for very large side streamwith only small increase of bearing span
< >40MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
Example LP-Compressor of Cracked Gas Train BP GrangemouthModified Parts: Shaft (Red)
Impellers (Blue)Diaphragms (Yellow)Labyrinths (Green)
ESSO / EXXON MOSSMORRAN, GBOriginal Delivery 1981CG Compressor Increase by 27 %(1988)Ethylene Compressors Increase by 26 % (1996)Propane Compressor Increase by 39 %(1996)
BP CHEMICALS GRANGEMOUTH, GBOriginal Delivery 1991CG Compressor Increase by 25 %(1997)
SOW / BSL BOEHLEN, GEROriginal Delivery 1972Refurbishment andConversion to Dry Gas Seals (1994)Cracker Capacity Increase by 35 %(1996)
Experience in Ethylene PlantsCapacity Increase
< >41MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
References for Resulting Dimensions and Weights
Works assembly of a large moduls (500 tons) for a GTL plant
< >42MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
References for Resulting Dimensions and Weights
§ Field installation of an 80 MW compressor train for a GTL plant
< >43MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
Steam TurbinesTypically 110 bar, 530 °C or 75 bar, 470 °C
45 bar
18 bar
Turbine ERCTurbine PRC
Turbine CGC
< >44MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
Steam Turbine package
Ethylene Plants –Large Steam Turbines
< >45MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010
ü single source supply, compressors and steam
turbines from same factory
ü design generally acc. to API 617 / 612
ü MAN Turbo has experience with ethylene plants
for various licensees
ü MAN Turbo has as well recent references
ü MAN Turbo has large train capability
in factory and test bed
ü Up-rating and service capability
MAN Turbo Competence in Ethylene Plants - Conclusion