23rd Ethylene Producers

Conference 2011

Topical Conference at the 2011 AIChE Spring Meeting and

7th Global Congress on Process Safety

Chicago, Illinois, USA

13-17 March 2011

ISBN: 978-1-61782-892-8

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TABLE OF CONTENTS

Use of IR Camera During Ethylene Unit Startup ............................................................................................................... 1

Darrell Dolmage

Confusion and Anxiety: The Very Latest on the Re-Revised Ozone Standard ................................................................ 2
Steven Ramsey

Green House Gas Reporting In the Ethylene Manufacturing Sector.............................................................................. 13

Valerie Barth, Cheri Kwast

New Flare System VOC Regulations & Reduction Control Options............................................................................... 28

Keith Wade

Impact of New Industrial Boiler and Process Heater Air Regulations on the Chemical Industry................................ 29
Amy Marshall

Centrifugal Process Compressors - The Basics of Performance and Rerate .................................................................. 38

Colman De Jong

Steam Turbine Fundamentals with an Emphasis on Blade Design ................................................................................. 86

Sandra J. Simmons

Train Performance - Evaluation and Monitoring by Torque Meter Applications....................................................... 140

Satoshi Hata, Junichi Horiba, Takuro Koda

Utilization of Equipment Health Management in an Ethylene Plant ............................................................................ 155

Stephen Plaisance

The Energy Challenge: Providing Sustainable Supplies to Meet Growing Demand ................................................... 164
F. Emil Jacobs

Global Olefins Outlook...................................................................................................................................................... 165

Brian Ames

Feed Contamination with Sodium and Its Impact on Ethylene Furnaces..................................................................... 166
Bala Devakottai, Robert M. Pritchett, Pinakin Mistry

The Impact of Ethylene and Propylene Impurities Upon Polyolefins Units ................................................................. 178
Dave Purvis

Mitigation of Fouling from Vinyl Acetate Recycle to Ethylene Plant............................................................................ 215

Scott Smith, Eli Gronowski

Sulfur Myths - What We Know and What We Do Not Know ....................................................................................... 220
Mark Brayden, Vijay Srinivas

Flux Oil Stream Import to Quench System - Risks & Impacts...................................................................................... 221
Andr Bernard, Thomas Pickett, Daniel Frye, Beata Manek

Steam Cracking of Heavy Oil Fractions Revisited.......................................................................................................... 236

Kevin M. Van Geem, Carl M. Schietekat, Steven Pyl, Thomas Dijkmans, Marie-Franoise Reyniers, Guy B. Marin

Design, Installation, and Monitoring of ID Fans for Ethylene Furnaces ...................................................................... 253
Neal D. Boyd

Start up Issues of Ethylene Plants .................................................................................................................................... 269

Thomas Callahan

Optimum Maintenance Interval Considerations for Major Ethylene Plant Compressors and Steam
Turbines ............................................................................................................................................................................. 270
Terryl Matthews, Gampa Bhat, Kevin Yates, Jonathan D. Cardell

Process and Equipment Considerations In the Art of Cold Box Design ....................................................................... 271
John Penton, Bryan Vick

Life Cycle of Aluminum Plate Fin Exchangers ............................................................................................................... 289

Hubert Koepf, Reinhold Hoelzl

Aluminum Plate-Fin Heat Exchanger Thermal Fatigue Study...................................................................................... 298

Rick Swain, Allen C. Miller

Field Repair of Brazed Aluminum Plate-Fin Heat Exchangers..................................................................................... 318

Sam Willard

Investigative Process Uncovers Cause of Surface Tearing In Cold Box Aluminum Alloy Pipe
Components........................................................................................................................................................................ 327
Clay Thiele, Bill Valerioti

Energy Reduction Through Utilities Advanced Control ................................................................................................ 340

David Hokanson

A Novel Approach to Design and Implementation of Multivariable Process Controllers for C3

Fractionation Columns...................................................................................................................................................... 353
James Wu, Tim Song

Experiences Migrating a Process Control System: "Legacy to Bleeding Edge - How Hard Can It Be?".................. 369
Bengt-Ove Andersson, Catharina Winberg, Marcus Hedlund, Olof Gahne, Tomas Tejder, Conny Petersson

Large Scale Ethylene Unit APC Using Shell Multivariable Optimizing Controller (SMOCPro) ................................. 380
Donald Frank, Vinh Nguyen

New Approach for Furnace Severity/Conversion and TMT Inferentials Using SPYRO, AspenPlus and
Aspen Online ...................................................................................................................................................................... 394
Bengt-Ove Andersson, Catharina Winberg, Marcus Hedlund, Olof Gahne, Tomas Tejder, Eddy Fontenot, Conny
Petersson

Use of Process Simulation In Ethylene Plant APC and Dynamic Optimization........................................................... 402
Akitoshi Takinami, Ayumu Fujita, Takeshi Seki, Youichi Takeuchi, Soichi Iwamoto, Tomoo Niikura, Paul Yap, Ravi
Nath

European Ethylene Producers Committee (EEPC) Corrosion Under Insulaton (CUI) Prevention of
CUI: Roadmap to Managing CUI ................................................................................................................................ 432
Klaus Bormuth, Hendrik J. De Bruyn

Industry Standards for Composite Repair of Process Piping ........................................................................................ 442

Julian Bedoya, Chris Alexander

Composite Repairs for the Rehabilitation of Corroded or Damaged Pipework........................................................... 461

Simon Frost, W. J. "Bill" Napier, Nick Moore

Cooling Water Issues - Cause and Solutions to Microbiologically Induced Corrosion................................................ 476
Carl G. Matherne

Furnace Penetration Sealing Systems - Engineered Solutions for Cracking Furnaces................................................ 488
Malcolm A. Peirson

Best Practices for Inlet Cone Refractory of Transfer Line Exchangers........................................................................ 502
Dave Oulton, Carl G. Matherne

Scale-up of Advanced MTO Technology and Integrated OCP Technology ................................................................. 517
John Senetar, Eric Romers

Advanced Catalytic Olefins (ACO) : First Commercial Demonstration Unit Begins Operations .............................. 533
Michael J. Tallman, Curtis Eng, Sun Choi, Deuk Soo Park

Catalytic Cracking of FT Products for Light Olefins Production ................................................................................. 545

Angeline Moodley, Julian Price, Dilip Dharia, Maximo (Max) Salazar, David Banks, Hak Kim

C5 Metathesis for Increased Propylene Production ........................................................................................................ 559

Stephen J. Stanley, Robert J. Gartside

Beyond "Classics": New Technologies to Boost Capacity In a Butadiene Unit............................................................ 570

Bernd Heida, Bernd Metzen, Randolf Hugo, Werner Peschel

Recover Ethylene from Refinery Off-Gas Via the Ole-SIVTM Process.......................................................................... 584
Seong Jun Lee, Jae Ho Lee, Jong-Nam Kim, Jong-Ho Park, Jang Jae Lee

Cracked Gas Compressor Control Tutorial .................................................................................................................... 593

Nauman Islam

Objectives of Anti-Surge Control ..................................................................................................................................... 594

W. Brian Piercy

Severe Erosion in a Charge Gas Compressor.................................................................................................................. 605

Mark A. Dalby, James M. Jordan

Enhance Cracked Gas Compressor Reliability with Novel Antifoulant Technology................................................... 611
P. N. Ramaswamy, Matthew Knight, Mahesh Subramaniyam

Improving Ethylene Charge Gas Compressor Performance ......................................................................................... 624

Giorgio Greco, Dalla Francesca Alessandro, Vincenzo Sangiorgio

Introductory Remarks....................................................................................................................................................... 643

Michael J. Tallman

World Light Olefins Markets Outlook: Impact of Changing Energy and Feedstock Market Dynamics
on Regional Olefins Markets ............................................................................................................................................ 644
Mark Eramo

Improve Plant Flexibility for the Changing Feedstocks and Technologies................................................................... 645
David Leung

Catofin Propane Dehydrogenation Project ..................................................................................................................... 650

Randy Miller

Co-Cracking Vs. Segregated "Hybrid" Cracking In Individual Furnaces - Design and Operational
Considerations ................................................................................................................................................................... 651
Marco Van Goethem, Harry Wang, Bruce Evans

Design Considerations for Propylene Splitters................................................................................................................ 662

Timothy M. Zygula, Karl Kolmetz

Flare Minimization Via Dynamic Simulation.................................................................................................................. 679

Kuyen Li, Qiang Xu

Thoughts about Safety, Staying at Zero........................................................................................................................... 691

Rendell Newton

Ethylene Boil-off Puzzle .................................................................................................................................................... 737

Eliana Vidal, Niara Eckhard

Trip & Throttle Valve Reliability..................................................................................................................................... 751

Joan Del Castillo

Consequences of High-Pressure Tube Ruptures In Low-Pressure Liquid-Filled Shell Heat Exchangers ................. 765
Claire J. Ennis, Kamal K. Botros, Chandresh Patel

Practices to Mitigate NOx Risk In Cryogenic Section of Ethylene Plants ..................................................................... 782
Jennifer L. Bancroft, Michael Moran, Sivakumar Nayarajan

Enhanced Heat Transfer Technology Proves Beneficial In Cooling Water Driven Condensers ................................ 789
Michael R. Sobczyk, Raymond Tucker

Fouling Mitigation Program Recovers Operating Efficiency and Extends Run Length for Ethylene
Plant Oil Quench Tower ................................................................................................................................................... 790
Mike Hong, Jeeranum Jintana, Patrick Lucas, Li Feng

Acetylene Converters Troubleshooting............................................................................................................................ 791

Emerentino B. Quadro, Eliana Vidal, Jaildes Britto, Niara Eckhard, Richard Zoldak

Loss of Flow In a Process Water Pump ........................................................................................................................... 808

Laurence J. Zych

Fouling/Viscosity Control Mitigation Strategy Overcomes Problems In Quench Oil System..................................... 824
Roger Metzler, Zhenning Gu

Improved Ethylene Cracking Furnace Control with Modern Process Mass Spectrometers....................................... 832
Peter J. Traynor

A New Class of Polymer Inhibitors .................................................................................................................................. 833

P. N. Ramaswamy, Matthew Knight, Mahesh Subramaniyam

Loss of Downcomer Seal on a Depropanizer During a Plant Start Up.......................................................................... 842

Andr Bernard
Author Index