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The manufacture of clean fuel gases from hydrocarbon or carbonaceous feedstocks covers a wide field of both processes and feedstocks used in these processes. Light hydrocarbon feedstocks can be converted into fuel gases by catalytic processes (steam reforming) at relatively low costs in terms of capital requirement and energy consumption. Conversion of heavier and residual hydrocarbon fractions into fuel gases can be carried out by first converting these heavy fractions into lighter fractions suitable for the steam reforming process. Alternatively, the heavy fractions can be converted directly into a clean fuel gas by the non-catalytic partial oxidation process. This process, using either oxygen or air as the oxidising medium, converts the fuel into a gas mainly consisting of hydrogen and carbon mono oxide. The feedstocks considered for the partial oxidation process can be heavy residual fuel oil, petroleum coke or coal. The paper by W. L. LOM et aZ. (presented by Dr G. MOSS) summarises economic and technical aspects of alternatives for the conversion of liquid petroleum products of medium to light sulphur content into clean gaseous fuels. As feedstocks LPG, naphtha, middle distillates, fuel oil and crude oil are considered. It is concluded that if SNG is the required product naphtha reforming is economically the most attractive way, while for low caloric value fuel gas production gasification of fuel oil and crude oil could be a good choice. The paper by Dr K. MORIKAWA et al. reviews the progress of process technology for the manufacture of SNG by catalytic low temperature steam reforming of light petroleum fractions. It was concluded that this type of SNG production is suitable for base load only if feed hydrocarbons are available at low prices (SR products), but is more likely to be used for an efficient peak-shaving plant (low capital costs and high reliability). The principle of fuel gas and SNG production from light liquid products was challenged by Mr B. CHAPOTEL (Compagnie Française de Raffinage). Gasification, in his opinion, will give rise to a loss of energy (10–15%) and light liquid products will be urgently needed for other applications in the future. Light liquid petroleum products can also easily be desulphurised, distributed and burned with less extra energy loss. It was stated by Dr MOSS, however, that, because gas burning is 5 % to 10 % more effective than liquid product combusion, the extra energy loss due to gasification is partially counteracted, leaving only an extra loss of 5% to lu%. This loss of energy has to be balanced against the advantages of using gas in each separate application. Clearly for heavy feedstocks such as pitch and coke (and coal) gasification will, in many cases, be attractive as a possibil
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- Energy > Oil & Gas > Upstream (1.00)
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Brief description of process The SNG production process using naphtha consists of two main sub-processes whereby (1) heated naphtha and steam are passed through a catalyst bed and then steam-reformed under a low temperature to gasify the feed and (2) hydrogen in the gas thus produced is converted into methane. The resultant carbon dioxide is eliminated and a gas similar to natural gas in composition, containing methane as its principal component, is produced. In the above gasification process, reforming reactions which are endothermic, and hydrogenolysis and methanation which are exothermic, take place concurrently and the reactions proceed maintaining thermal balance, and when a sufficient quantity of catalyst is provided, the naphtha is gasified and the reactions proceed to a stage where predetermined equilibrium composition is attained according to the specific reaction conditions. The gas obtained in the gasification process can be almost entirely converted into methane and carbon dioxide by having the carbon monoxide, carbon dioxide and hydrogen remaining in the gas reacted upon by selecting the proper reaction conditions of methanation. Although methanation is a major exothermic reaction, the temperature does not exceed the temperature predicted from chemical equilibrium, and the reaction is thus stable. Therefore, throughout both the gasification and methanation processes, the reactions can be carried out in drum type adiabatic reactors. Therefore, the low-temperature steam reforming process is simpler in operation than its high-temperature counterpart. The technology of the low temperature steam reforming evolved from that of methanol gasification1 and the high-temperature steam reforming, was commercialised by the British Gas Council (CRG process)2 and LURGI/BASF (Gasynthan pro ces) in 1965, followed by Japan Gasoline Co. (MRG process) in 196ti4 Prior to the emergence of these processes, fuel gas was produced by means of cyclic processes whereby product gas rich in olefin and carbon monoxide was produced. By adopting low-temperature steam reforming processes, the following advantages have become available. Pressurised operation is possible Town gas production facilities hitherto used have usually been operated at approximately atmospheric pressures and this necessitates blowers or compressors for delivering the product gas. However, low-temperature steam reforming methods have facilitated stable operation up to approximately 700 psig. This is a particular advantage in the case of producing pipeline gas. Product gas is non-toxic Many of the low Btu product gases hitherto in use contain as much as 15–20% carbon monoxide. Therefore, a CO converter or other means is required for reducing the carbon monoxide content. However, with the low-temperature steam reforming process, nontoxic gas with a carbon monoxide content of 1% or less can
- Materials > Chemicals > Commodity Chemicals > Petrochemicals (1.00)
- Energy > Oil & Gas > Downstream (1.00)
Abstract A steam cracking plant designed to produce olefins from vacuum distilled heavy gas oils boiling in the range of 700–1000" FVT was started up in 1967 by Esso Chimie, an affiliate of Exxon Chemical, at Port Jerome, France. The plant was sized to produce 200000 metric tons per year of ethylene. The paper will describe the facility, its performance and special features installed to handle the high coke make. Olefins and by-product yields, investment and operating costs will be compared with steam cracking of naphtha feed. Environmental considerations will also be presented. Résumé Une unité de cracking à la vapeur pour la production d'oléfines à partir de gas-oil lourd provenant de la distillation sous vide à été démarrée en 1967 à Port-Jérôme par Esso Chimie, filiale de Exxon Chemical. Le gas-oil sous vide est une coupe 370–540°C et l'unité a une capacité de production d'éthylène de 200000 tonnes par an. L'article décrira l'unité et ses performances, ainsi que les caractéristiques particulières exigées par la production importante de coke. Les rendements en oléfines, en produits secondaires et les coûts d'investissement et d'opération seront comparés avec ceux du cracking à la vapeur d'un naphta. Les considérations concernant la protection de l'environnement seront aussi présentées. 1. INTRODUCTION Twenty-five years of experience with steam cracking of atmospheric gas oils led to the design and construction of the Port Jerome vacuum gas oil cracking unit. Even so, steam cracking a 370/535°C vacuum gas oil represented a considerable departure from previous experience. This paper will describe the facility, its performance and special features. In addition, a comparison of yields, plant investments and operating costs will be made between vacuum gas oil steam cracking and naphtha steam cracking. The vacuum gas oil steam cracking plant described in this paper was started up by Esso Chimie, an affiliate of Exxon Chemical, at Port Jerome, France, in 1967. It is of historical interest that the first commercial test of gas oil steam cracking was made at the same site in 1939. The early test was made in a conventional thermal cracking coil that was repiped for steam addition. Following the test, design work for the first commercial gas oil steam cracking plant began and the first unit went onstream at Baton Rouge, Louisiana, USA, in September, 1941. The first unit had a feed rate of 140000 tons/year of a 20O/40O0C atmospheric gas oil. A second gas oil cracking unit, almost three times the size of the first, followed within two years, and gas oil has been a major feedstock in our plants ever since. Today, our company and its affiliates combined produce about 2500000 tons/year of ethylene, of which approximately half comes from gas oil c
- Materials > Chemicals > Commodity Chemicals > Petrochemicals (1.00)
- Energy > Oil & Gas > Downstream (1.00)
Abstract The modem olefins plant is being designed to handle a wide range of liquid feedstocks. This paper reviews the technical and economic parameters related to the multi-feedstock olefins plant. Naphtha plant design is reviewed to bring the reader up to date on furnace design, quench systems and purification trains. Emphasis is placed on heavier feedstocks and actual experience with gas oil feeds is discussed. The economic consequences of designing a plant for varying degrees of feedstock flexibility are quantified and the specific technical factors involved are identified. Data from pilot, prototype and commercial heater operations are presented. Résumé Les unités modernes de fabrication d'oléfines sont conçues de façon à traiter une grande variété de charges liquides. Cette communication passe en revue les paramètres techniques et économiques associés aux unités d'oléfines à charges diversifiées. Le projet d'une unité opérant à partir de naphta est étudié de façon à mettre le lecteur au courant des développements récents concernant la conception des fours, des systèmes de trempe et de séparation. On y insiste sur les charges liquides de densité plus élevée et sur l'expérience actuelle acquise en matière de vapocraquage des gasoils. On chiffre les conséquences économiques de l'adaptabilité de l'unité à diverses charges et on identifie les paramètres techniques spécifiques que cette adaptabilité implique. On présente enfin, des données d'opération d'unité pilote, de fours prototypes et d'unité commerciale. 1. INTRODUCTION Much has been written in the past three years about the world's energy crisis and all of us have watched the price of hydrocarbons escalate beyond belief. Crude oil prices have increased by a factor of 4 or 5 and today in the United States it is accepted practice to base economic calculations on an energy cost of 75 cents to $2.20 per million Btu's when not too long ago 25 to 50 cents was used. There is no doubt that the base price for hydrocarbons had, in the past, been unrealistically low in relation to other commodities and that some adiustment was inevitable. There is also little doubt that conditions will move to a new equilibrium, and in fact, are beginning to show some signs of adjustment. The question of what the normalised conditions will be is beyond the scope of this paper. However, these abnormal conditions in hydrocarbon pricing are undoubtedly affecting the feedstock available for chemical production and the design of future chemical plants. Thus, in this paper, we will try to answer the following questions :What feedstocks will be available for petro- What will the olefins plant of 1980 be like? These questions are of significance since the demand for olefins will require the installation of a large number of new olefins plants. The rapid growth in worldwide
- Materials > Chemicals > Commodity Chemicals > Petrochemicals (1.00)
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Abstract Various process routes for the manufacture of H, from hydrocarbon feedstocks will be considered. Developments in technology and their effects on the economics will be discussed. A survey of commercial experience in the areas of the steam reforming process and of the partial oxidation process will be given. An economic comparison will be made between the steam reforming routes using natural gas or naphtha as feedstock and the residual fuel oil partial oxidation route. Résumé Cette communication examine différentes voies pour la fabrication d'hydrogène à partir d'hydrocarbures. Elle présente les progrès technologiques réalisés et leurs conséquences économiques. Elle expose l'expérience commerciale acquise avec les procédés basés sur le reformage à la vapeur et ceux basés sur l'oxydation partielle. Enfin, elle présente une comparaison économique entre la voie du reformage à la vapeur à partir de gaz naturel ou de naphta, et celle de l'oxydation partielle du fuel oil résiduaire. 1. INTRODUCTION steam reforming of natural gas, refinery gases and naphtha which, even today, is used to manufacture the At the end of 1970 world consumption of hydrogen1 majority of hydrogen and H,-rich synthesis gases. was about 220 billion m3. About 50% was used for In view of the shortage of natural gas, a stagnant producing ammonia, 13% for methanol and 30% for coke oven gas production and the surplus of heavy treating refinery products. The balance was taken up petroleum products forecasted for the next few years, by minor fields such as hydrogen peroxide manu- partial oxidation may well be expected to increase in facture, fat hardening, and others. Recently, a new importance. Only about 12% of the world hydrogen major field has opened up due to the rising coke cost, requirement is currently produced from heavy namely ore reduction. petroleum residues. If one views the anticipated increase in H, and Coal is-particularly since the beginning of the oil synthesis gas requirement in the US as typical for the crisis at the end of 1973-very much in discussion as world demand, hydrogen consumption will probably raw material for hydrogen production, however, the double by 1980. The bulk will be used for ammonia accent being quite clearly on the synthesis products production, crude oil refining and synthetic fuels. such as ammonia and methanol and less on pure Hydrogen as nuclear heat carrier is expected to play a hydrogen. role in the 1980s. In the same way as the order of precedence of the hydrogen consumers has changed in the last two decades, so have the feedstocks for H2 production. Coke-oven gas fractionation and electrolysis have become less important since catalytic reforming of hydrocarbons began at the end of the 1930s. Since 1956 partial oxidation of heavy petroleum residues has been applied on an increasing scale in addition to by EMIL SUPP and HEINZ J
- Materials > Chemicals > Commodity Chemicals > Petrochemicals (1.00)
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- Facilities Design, Construction and Operation > Processing Systems and Design (0.68)
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Abstract Advances in compositional analyses obtained online and off-line have improved yield programs, process models and feedstock evaluation. Consequently, better refinery planning models are now available to optimise feedstock selection for a given demand situation. Accurate analytical data are mandatory for the successful optimisation of the overall refining process. Reliable models based on such data are being used both in unit optimisation and refinery planning studies. Economic benefits are derived from improved process control systems based on reliable on-stream analysers and low cost computers. Résumé Les progrès dans les analyses de composition, obtenues tant en direct qu'en différé, ont permis l'amélioration de programmes de rendements, de modèles de procédés et d'évaluation de charges. En conséquence, de meilleurs modèles de planification de raffineries sont maintenant disponibles pour optimiser le choix de la charge selon l'exigence d'une situation donnée. Des données analytiques précises sont indispensables pour réussir l'optimisation de l'ensemble d'un procédé de raffinage. Des modèles fiables, basés sur de telles données, sont utilisés pour l'optimisation des unités, et pour les études de planification de raffineries. Des bénéfices économiques résultent de l'amélioration des méthodes de contrôle de procédés, basées sur des appareils d'analyse en continu et des ordinateurs peu coûteux. 1. INTRODUCTION Technological developments in the petroleum and petrochemical industry have introduced complex process and product quality standards which now require a more scientific approach to the selection of raw materials and to the optimisation and control of processes. Compositional analysis of petroleum has been facilitated in recent years by the rapid developments in modern analytical technology. Detailed component analyses of naphtha range stock can be determined by gas chromatography. Higher boiling fractions ranging from heavy distillates to lubricating oils are analysed for hydrocarbon compound types using mass spectrometry and liquid chromatography. On-line computer techniques now enable large amounts of analytical and process data to be handled. Compositional analysis of petroleum fractions can significantly assist today's refinery or petrochemical by D. D. ZAKAIB, Gulf Oil Canada Ltd., Canada plant operation by replacing the empirical tests still being used. Specific process reactions can be observed to provide the processor with a powerful tool for setting operating conditions for optimum conversion levels, increased catalyst life and the required product distribution. The successful application of compositional analysis to the control of hydrocarbon processes must now be considered a matter of fact. Chromatography and spectrometry are the analytical technique
- Materials > Chemicals > Commodity Chemicals > Petrochemicals (1.00)
- Energy > Oil & Gas > Downstream (1.00)
Abstract The paper summarises alternatives for the conversion of liquid petroleum products of medium to high sulphur content into clean gaseous fuels. It compares the techniques used and the process economics applicable to the manufacture of lean gases and substitute natural gas from a range of liquid fuels, i.e. LPG, naphtha, middle distillates, fuel oil and crude oil. It concludes that whilst naphtha reforming for SNG production will be a first choice on grounds of lowest investment and gas service costs, the gasification of crude oil and fuel oil for lower calorific value fuel gases may also find wide application. In the longer term coal as a raw material, at least in the US, seems likely to replace both light and heavy liquid fuels. Résumé Cette communication passe en revue les différentes possibilités envisageables pour la transformation de produits pétroliers liquides, à teneur en soufre élevée ou moyenne, en combustibles gazeux propres. Elle compare les technologies et l'économie des procédés utilisés pour la fabrication de gaz pauvres, de gaz de ville et de gaz naturel de substitution à partir de plusieurs combustibles liquides, les GPL, le naphta, les distillats moyens, les gas oils, le mazout et le pétrole brut. On conclut qu'en raisons des disponibilités, l'utilisation du pétrole brut augmentera, mais que la méthode la plus économique de gazéification est le reformage du naphta. A long terme, cependant, la houille remplacera comme matière première, au moins aux Etats-Unis, à la fois les fractions légères et les fuels lourds. 1. PURPOSE OF GASIFYING Liquid petroleum fuels by comparison with gaseous fuels have a number of drawbacks including a greater tendency towards incomplete combustion, cracking and carbon formation instead of complete combustion to gaseous products. Therefore, gaseous flames are more adjustable in size and shape than liquid fuel flames, and the minimum oxidant demand to ensure complete combustion is usually lower for gases. In addition, most gases are inherently "cleaner", i.e. contain less non-hydrocarbon material, specifically sulphur compounds, than liquid fuels, and any impurities can be easily and effectively removed by various processes. Furthermore, the chemical composition of gaseous fuels is simpler than that of liquid fuels. Normally no more than four or five chemical species ~ ~ by W. L. LOM, formerly Senior ScientiJic Associate, Esso Research Centre, Abingdon, Oxon., England, and P. J. AGIUS, Director of Research, Esso Petroleum Company Ltd, London, S. W. 1, England will be present and it is thus much easier to react a petroleum gas to produce various petrochemicals than to produce chemical derivatives from liquid hydrocarbons. Finally gaseous fuels are more readily distributed by pipeline, even at low flow rates, to points of consumption. Consequently, the purposes of gas
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