Report No. 29 ETHYLENE. August A private report by the PROCESS ECONOMICS PROGRAM I STANFORD RESEARCH INSTITUTE MENLO PARK, CALIFORNIA

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1 Report No. 29 ETHYLENE by SHIGEYOSHI TAKAOKA August 1967 A private report by the PROCESS ECONOMICS PROGRAM I STANFORD RESEARCH INSTITUTE MENLO I PARK, CALIFORNIA

2 CONTENTS 1 INTRODUCTION SUMMARY INDUSTRY STATUS CHEMISTRY Introduction Thermal Cracking Reaction Mechanism Reaction Rate Constant Equilibrium Approach Heat of Reaction Molar Expansion Reaction Variables Contact Time Temperature Pressure Feedstock Steam Autothermic Cracking REVIEW OF PROCESSES... Introduction Thermal Cracking Processes Direct Heating Process Indirect Heating Process Autothermic Cracking Processes Other Processes Recovery and Purification Processes Quenching Removal of Acid Gases Removal of Water Removal of Acetylenic Materials Demethanization Low Temperature Straight Fractionation Selective Absorption Selective Adsorption Ethylene Purification Propylene Purification iii

3 CONTENTS ETHYLENE BY FIRED TUBULAR HEATER... Process Description... Process Discussion... Capital Costs.... Production Costs... ETHYLENE FROM CRUDE OIL BY AUTOTHERMIC CRACKING... Process Description... Process Discussion... Capital Costs.... Production Costs... ETHYLENE SYNTHESIS FROM CARBON MONOXIDE AND HYDROGEN... Introduction... Process Description... Process Discussion... Cost Estimates... Capital Costs.... Production Costs APPENDIXA DESIGN AND COST BASIS, DEFINITIONS APPENDIX B PHYSICALDATA APPENDIX C RAW MATERIAL AND PRODUCT SPECIFICATIONS APPENDIX D SAFETY, STORAGE, AND TRANSPORTATION REFERENCES SUPPLEMENTARY REFERENCES iv

4 ILLUSTRATIONS Ethylene by Fired Tubular Heater Effect of Plant Capacity on Capital Costs in Ethane and Propane Pyrolysis Effect of Conversion on Heat Required to Decompose Ethane and Propane , Yield of Products from Ethane Pyrolysis at 1500'F..... Yield of Products from Propane Pyrolysis at 1500 F.... Combustion Product Distribution in Autothermic Cracking of Ethane..., Ethylene by Fired Tubular Heater Effect of Plant Capacity on Capital Costs in Naphtha Pyrolysis... Effect of Ethylene Yield in Furnace Effluent on Capital Costs in Naphtha Pyrolysis Effect of Raw Material Cost and By-Product Credit on Ethylene Production Cost in Ethane Pyrolysis Effect of Raw Material Cost and By-Product Credit on Ethylene Production Cost in Propane Pyrolysis Effect of Raw Material Cost and By-Product Credit on Ethylene Production Cost in Naphtha Pyrolysis Effect of Operating Level and Production Capacity on Ethylene Production Cost in Ethane Pyrolysis Effect of Operating Level and Production Capacity on Ethylene Production Cost in Propane Pyrolysis Effect of Operating Level and Production Capacity on Ethylene Production Cost in Naphtha Pyrolysis Effect of Ethylene Yield in Furnace Effluent on Production Costs in Naphtha Pyrolysis V

5 ILLUSTRATIONS 7.2 Ethylene from Crude Oil Cracking Effect of Yield on Capital Costs Ethylene from Crude Oil Cracking Effect of Raw Material Costs and By-Product Credit on Production Cost Ethylene from Crude Oil Cracking Effect of Operating Level and Plant Capacity on Production Cost Ethylene from Crude Oil Cracking Effect of Yield on Production Cost Effect of Raw Material Costs on Ethylene Production Cost Effect of Operating Level and Production Capacity on Ethylene Production Cost Vi

6 TABLES Summary of Ethylene Processes Sensitivity Analysis of the Ethylene Processes Plant Capacities, United States Plant Capacities, Americas (except United States)..... Plant Capacities, Europe Plant Capacities, Asia, Australia, and Africa Plant Capacities, Soviet Bloc Countries Typical Commercial Yields from Fired Tubular Heaters... Ethylene by Direct Heating Ethylene by Indirect Heating (Pebble Bed Reactor) Ethylene by Indirect Heating (Fluidized Bed Reactor) Ethylene by Indirect Heating (Regenerative Furnace) Ethylene by Autothermic Cracking Ethylene by Other Thermal Cracking Processes Ethylene by Thermal Cracking Quenching Processes Summary of Patents Demethanization by Low Temperature Straight Fractionation Summary of Patents Demethanization by Selective Absorption Summary of Patents Ethylene Purification Summary of Patents Vii

7 TABLES Propylene Purification Summary of Patents Total Capital Investment Production Costs Stream Flows Stream Flows Stream Flows Total Capital Investment Total Capital Investment Production Costs Production Costs viii

8 TABLES Stream Flows Total Capital Investment Production Costs Stream Flows, Total Capital Investment Production Costs ix

Report No. 32 HYDROGEN. December A private report by the PROCESS ECONOMICS PROGRAM STANFORD RESEARCH INSTITUTE PARK, CALIFORNIA

Report No. 32 HYDROGEN. December A private report by the PROCESS ECONOMICS PROGRAM STANFORD RESEARCH INSTITUTE PARK, CALIFORNIA Report No. 32 HYDROGEN by RICHARD G. DENNEY December 1967 A private report by the PROCESS ECONOMICS PROGRAM STANFORD RESEARCH INSTITUTE I I MENLO PARK, CALIFORNIA CONTENTS 1 2 3 4 5 6 INTRODUCTION....