Document Type : Original research
Authors
1 School of Chemical and Energy Engineering, Faculty of Engineering, Universiti Teknologi Malaysia, 81310, Johor, Malaysia
2 Manufacturing Division, Pengerang Refining Company Sdn Bhd, PICMO B2, Pengerang Integrated Complex, 81600 Johor, Malaysia
3 Group Technical Solutions, Petroliam Nasional Berhad (PETRONAS), The Intermark Tower, 55000 Kuala Lumpur, Malaysia
Abstract
The study was conducted in the actual world-scale olefin plant with a focus on measuring the impact of identified controlled variables at the steam cracker furnace towards the propylene yield. Surface response analysis was conducted in the Minitab software version 20 using the historical data after the clearance of both the outliers and residuals to ensure the analysis was conducted as normal data. Surface response analysis is a robust mathematical and statistical approach that is having a good potential to be systematically utilized in the actual large-scale olefin plant as an alternative to the expensive olefin simulation software for process monitoring. The analysis was conducted to forecast the maximum propylene yield in the studied plant with careful consideration to select only significant variables, represented by a variance inflation factor (VIF) <10 and p-value <0.05 in the analysis of variance (ANOVA) table. The final model successfully concluded that propylene yield in the studied plant was contributed by the factors of 0.00496, 0.00204, and -3.96 of hearth burner flow, dilution steam flow, and naphtha feed flow respectively. The response optimizer also suggested that the propylene yield from naphtha pyrolysis cracking in the studied plant could be maximized at 11.47% with the control setting at 10,004.36 kg/hr of hearth burner flow, 40,960 kg/hr of dilution steam flow, and 63.50 t/hr of naphtha feed flow.
Keywords
- Mcmurry J (2013) Fundamentals of organic chemistry. 7, Cengage Learning Inc, CA, United States
- Bender M (2014) An overview of industrial processes for the production of olefins – C4 hydrocarbons. Chem Bio Eng Rev 1: 136-147
- Rahimi N, Karimzadeh R (2011) Catalytic cracking of hydrocarbons over modified ZSM-5 zeolites to produce light olefins: A review. Appl Catal-A 398: 1-17
- Sadrameli SM (2015) Thermal/catalytic cracking of hydrocarbons for the production of olefins: A state-of-the-art review I: Thermal cracking review. Fuel 140: 102-115
- Sadrameli SM (2016) Thermal/catalytic cracking of liquid hydrocarbons for the production of olefins: A state-of-the-art review II: Catalytic cracking review. Fuel 173: 285-297
- Zhu G, Xie C, Li Z, Wang X (2017) Catalytic processes for light olefin production. In: Springer handbook of petroleum technology, Eds.: Hsu CS, Robinson PR, Springer International Publishing, Cham, Switzerland, 1063-1079
- Feli Z, Darvishi A, Bakhtyari A, Rahimpour MR, Raeissi S (2017) Investigation of propane addition to the feed stream of a commercial ethane thermal cracker as supplementary feedstock. J Taiwan Inst Chem Eng 81: 1-13
- Akporiaye D, Jensen S, Olsbye U, Rohr F, Rytter E, Rønnekleiv M, Spjelkavik AI (2001) A novel, highly efficient catalyst for propane dehydrogenation. Ind Eng Chem Res 40: 4741- 4748
- Darvishi A, Davand R, Khorasheh F, Fattahi M (2016) Modeling-based optimization of a fixed-bed industrial reactor for oxidative dehydrogenation of propane. Chin J Chem Eng 24: 612-622
- Astruc D (2005) The metathesis reactions: From a historical perspective to recent developments. New J Chem 29: 42-56
- Akah A, Al-Ghrami M (2015) Maximizing propylene production via FCC technology. Appl Petrochem Res 5: 377-392
- Zakria MH, Mohd Nawawi MG, Abdul Rahman MR (2021) Propylene yield from olefin plant utilizing box-cox transformation in regression analysis. E3S Web Conf 287: 03013
- Zakria MH, Mohd Nawawi MG, Abdul Rahman MR (2021) Ethylene yield from a large scale naphtha pyrolysis cracking utilizing response surface methodology. Pertanika J Sci & Technol 29: 791-808
- Zakria MH, Mohd Nawawi MG, Abdul Rahman MR, Saudi MA (2021) Ethylene yield in a large- scale olefin plant utilizing regression analysis. Polyolefins J 8: 105-113
- Sundaram KM, Froment GF (1977) Modeling of thermal cracking kinetics—i: Thermal cracking of ethane, propane and their mixtures. Chem Eng Sci 32: 601-608
- Van De Vijver R, Vandewiele N, Bhoorasingh P, Slakman B, Seyedzadeh Khanshan F, Carstensen HH, Reyniers MF, Marin B, West R, Van Geem K (2015) Automatic mechanism and kinetic model generation for gas- and solution-phase processes: A perspective on best practices, recent advances, and future challenges. Int J Chem Kinet 47: 199- 231
- Vangaever S, Reyniers PA, Symoens SH, Ristic ND, Djokic MR, Marin GB, Van Geem KM (2020) Pyrometer-based control of a steam cracking furnace. Chem Eng Res Des 153: 380- 390
- Epstein LG (1978) The Le Chatelier principle in optimal control problems. J Econ Theory 19: 103-122
- Cai Y, Yang S, Fu S, Zhang D, Zhang Q (2017) Investigation of Portevin–Le Chatelier band strain and elastic shrinkage in Al-based alloys associated with Mg contents. J Mater Sci Technol 33: 580-586
- Shokrollahi Yancheshmeh MS, Seifzadeh Haghighi S, Gholipour MR, Dehghani O, Rahimpour MR, Raeissi S (2013) Modeling of ethane pyrolysis process: A study on effects of steam and carbon dioxide on ethylene and hydrogen productions. Chem Eng J 215-216: 550-560
- Masoumi M, Sadrameli SM, Towfighi J, Niaei A (2006) Simulation, optimization and control of a thermal cracking furnace. Energy 31: 516-527
- Karimi H, Cowperthwaite E, Olayiwola B, Farag H, Mcauley K (2017) Modelling of heat transfer and pyrolysis reactions in an industrial ethylene cracking furnace. Can J Chem Eng 96: 33-48
- Kucora I, Paunjoric P, Tolmac J, Vulovic M, Speight J, Radovanovic L (2017) Coke formation in pyrolysis furnaces in the petrochemical industry. Pet Sci Technol 35: 213-221
- Sun X, Shen L (2017) Research progress of coking mechanism and prevention measures for ethylene cracking furnace tubes. Corros Sci Prot Technol 29: 575-580
- Junfeng Z, Zhiping P, Delong C, Qirui L, Jieguang H, Jinbo Q (2019) A method for measuring tube metal temperature of ethylene cracking furnace tubes based on machine learning and neural network. IEEE Access 7: 158643-158654
- Wang Z, Li Z, Feng Y, Rong G (2016) Integrated short-term scheduling and production planning in an ethylene plant based on lagrangian decomposition. Can J Chem Eng 94: 1723-1739
- Braimah M, Anozie A, Odejobi O (2016) Utilization of response surface methodology (RSM) in the optimization of crude oil refinery process. J Multidiscip Eng Sci Technol 3: 4361- 4369
- Ganesh H, Ezekoye O, Edgar T, Baldea M (2018) Improving energy efficiency of an austenitization furnace by heat integration and real-time optimization. IEEE International Conference on Automation, Quality and Testing, Robotics (AQTR), DOI: 10.1109/AQTR.2018.8402763
- Sun Y, Yang G, Li K, Zhang L, Zhang L (2016) CO2 mineralization using basic oxygen furnace slag: Process optimization by response surface methodology. Environ Earth Sci 75: 1-10
- Sun Y, Zhang J, Zhang L (2016) NH4Cl selective leaching of basic oxygen furnace slag: Optimization study using response surface methodology. Environ Prog Sustain Energy 35: 1387-1394
- Haaland PD (1989) Experimental design in biotechnology. Marcel Dekker, New York, United States
- Wan Omar WNN, Nordin N, Mohamed M, Saidina Amin NA (2009) A two-step biodiesel production from waste cooking oil: Optimization of pre-treatment step. J Appl Sci 9: 3098-3103
- Han Y, Geng Z, Wang Z, Mu P (2016) Performance analysis and optimal temperature selection of ethylene cracking furnaces: A data envelopment analysis cross-model integrated analytic hierarchy process. J Anal Appl Pyrolysis 122: 35-44
- Song G, Tang L (2018) Optimization model for the transfer line exchanger system. Comput Aided Chem Eng 44: 1015-1020
- Yu K, While L, Reynolds M, Wang X, Liang JJ, Zhao L, Wang Z (2018) Multiobjective optimization of ethylene cracking furnace system using self-adaptive multiobjective teaching-learning-based optimization. Energy 148: 469- 481
- Zakria MH, Mohd Nawawi MG, Abdul Rahman MR (2021) Ethylene yield from pyrolysis cracking in olefin plant utilizing regression analysis. E3S Web Conf 287: 03004
)
