Sponsors Webinars 2020
Live Stream Connection With Adams Test Facility in Herne, Germany
Wednesday 2 December 10:00-11:00
During the ADAMS webinar we will take you in a live stream connection to our workshop where we perform a live factory acceptance test on a MAG –S check valve.
During this event you will receive an explanation and introduction on the application of the valve in the furnace transfer line and where the MAG-S valves is installed.
You can also expect to be brought up to speed with the design requirements for check valves on Transfer Lines including details and best practices.
After this, possible problems in service will be explained. Route causes and how to prevent these. Including samples with pictures and developments to address the following problems:
- Blocking of valve
- Leaking valve (internal)
- Damages due to erosion, etc...
- Problems due to misuse or wrong maintenance
Finally, in-depth information of a case study about maintenance of Check Valves MAG-S during a mayor shut will be shared.
After participation of the ADAMS Webinar you will have an enhanced basic understanding of the working principles of the MAG-S valve and gained insightful information that can be applied to your specific situation.
Cryogenic Ethylene Vaporizers, Supercritical Exchangers, Process Design, Pressure Relief and Instrumentation
Tuesday 15 December 11:00-12:30
Three types of direct steam heated equipment are commonly required in Ethylene Plants: Emergency Ethylene Vaporizers, Cold Flare Vaporizers, and Cold Flare Superheaters. The equipment, processes and fundamental need for these systems will be described. The safety advantages and the design calculations associated with these systems will be explained.
Three types of direct steam heated equipment are commonly required in Ethylene Plants: Emergency Ethylene Vaporizers, Cold Flare Vaporizers, and Cold Flare Superheaters. Occasionally propylene, ethane, or hydrocarbon mixtures are processed in this equipment. The equipment, processes and fundamental need for these systems will be described. The special requirements for determining the safety relief flow in this equipment will be explained. An overview of the calculations required to size a system consisting of a Cold Flare Vaporizer, Knock-out Drum and its thermosyphon loop will be provided. The concept of controlling outlet temperature using a cold fluid bypass will be explored, and the unusual control valve sizing requirements associated with process turndown will be discussed. For supercritical systems, an Emergency Supercritical Ethylene Heater is required in place of an Emergency Ethylene Vaporizer, and the special requirements and hardware for this scenario will be discussed. Suggested control narratives for these processes will be provided.
Comparisons will be made to alternate technologies, specifically indirect systems using a methanol bath and indirect systems using a water/glycol bath. The installed economics of the different technologies will also be discussed.
The following safety issues will be presented: a hardware solution to the problem of thermal turbulent cycling during hot/cold stream mixing, the problems associated with tubesheets with significant thermal gradients across the tubesheet, and a review of the explosion in France that resulted in 18 deaths and changed the industry.
Dennis O. Dever, PE, PhD
Process Engineering and R&D Manager
Reliable and Sustainable Lining Systems in Ethylene Crackers and Pyrolysis Furnaces
Tuesday 3 November 11:00-12:00
Riccardo Cantone, Steve Yardley - Morgan Advanced Materials
Refractory Lining is one of the key components of ethylene crackers and pyrolysis furnaces. Their purpose is to protect the external metal enclosures of high-temperature process equipment and to help ensure the safety of personnel working at the facility.
They have to be a reliable component to avoid unplanned and undesired shut down of the unit, affecting plant operations and production.
There are now lining design concepts that in addition to the above features help to reduce the carbon footprint and can perfectly fit in the sustainability concept of the companies.
This paper will investigate a different way to approach the design and specification of a refractory lining system, drawing on real-life examples and also considering the latest European legislation and regulatory system for dangerous and hazardous substances.
ONIS D3B : A Patented Positive Isolation Solution Designed in One Equipment
Tuesday 17 November 10:30-12:00
The new ONIS D3B innovates by interlocking mechanically the ONIS Line Blind with combined upstream and downstream block valves.
This solution guarantees a 100% secured step by step blinding process.
FULL SAFETY: The 100% mechanical interlock, linking ONIS Line Blind and the two block valves, protects the blinding process, thus preventing any human mistake on step to step and completely eliminating any risk of accidental release to atmosphere during blinding operations.
ENVIRONMENT: This new solution is based on an environment-friendly design, by reducing purged volumes to a minimum. The D3B limits the release of hydrocarbons into the atmosphere.
GAIN OF TIME: Blinding operation is much faster (more than 50%-time reduction), thanks to a super compact design which allows all operations to be located in the same place making it far more efficient.
COST REDUCTION: Downtime reduction allows more production output and consequently more revenues ROI is less than 3 months.
OPERABILITY: Easy installation, operability and maintenance.
Olefin Plant Digitalization: Model-Based Monitoring, Sensing of KPIs and Optimisation for Steam Cracking Furnaces
Thursday 10 December 11:00-12:30
Presenters: Sreekumar Maroor, Lorena Souza
Thermal cracking of hydrocarbons is still the major process used to produce ethylene and propylene, two major starting blocks in the petrochemicals value chain. Due to the large-scale production capacity of this process, small improvements in efficiency can result in significant savings.
The steam cracking furnace is at the heart of the ethylene production process, and its optimal operation is key to maximizing profitability. Accurate information on key process indicators, such as conversion, product yields, tube metal temperatures, and coking rates are essential for the optimal operation and control of steam cracking furnaces. However, measuring these reliably in real time is often either impossible or problematic requiring model based digital applications to estimate them reliably in real time. As the furnace KPIs are affected by coking, it is also essential to have an accurate estimate of state of coking in order to predict them.
In addition, feedstock availability changes with time and it is necessary to identify and operate the furnaces at optimal operating conditions to maximize profitability and to ensure operation within the plant constraints. Such optimization calculations should take into account the current state of coke build up in the furnaces to get correct results.
In this webinar, we present three state-of-the-art Digital Applications for steam cracking furnaces to provide model-based coke buildup monitoring, real-time sensing of KPIs and optimisation of operating conditions. Built on PSE's gPROMS Digital Applications Platform, they use sophisticated numerical manipulations to combine rigorous first principles-based models of steam cracking furnaces with plant operating data. Experience with the deployment of these applications on full-scale industrial plants will be presented.
Coating for Unique Transfer Line Exchanger Durability
Wednesday 25 November 10:00-11:00
All parts of a Transfer Line Exchanger are affected by erosion with the most possible erosion damages up on the gas side. They occur often during decoking or unfavorable operation conditions but can also happen in regular operation. Weld repair of damages are challenging and sometimes carried out incorrectly. This can lead to leaky weld seams due to improperly performed welding.
The right choice of the material for the erosion resistant layer is crucial to ensure a proper wear protection and a long life time. Therefore, the particle properties and the interaction between particles and wear resistant material have to be considered as well as the microscopic wear mechanism to find the appropriate material for the erosion resistant layer. This is done by the fabrication of test pieces, their metallurgical assessment and the experimental determination of the erosion properties of the individual protection coatings under laboratory conditions.
SCHMIDTSCHE SCHACK has developed a special fabrication procedure to apply erosion resistant material onto the Transfer Line Exchanger parts, enhancing durability and improving overall reliability.
In the webinar an overview is given how SCHMIDTSCHE SCHACK identifies the appropriate erosion resistant material and manufacturing procedure to meet operator’s demands Strategies how to prevent failures during weld repair and how SCHMIDTSCHE SCHACK can directly support the operator in case of damages are also addressed.
YIELDUP, Coating Technology for Steamcracker Furnace Coils
Thursday 12 November 10:00-11:30
- Alain Pothuaud, Joop Dees - SUEZ Water Technologies & Solutions (SUEZ WTS)
- Hugues Chasselin - Manoir Industries
- Cyndie Cavagna – Versalis France
Cokes formation on the inner wall of steamcracking furnace coils has a major influence on the process efficiencies and economical operations from the unit. The recent development and test work jointly performed by both Manoir & Suez WT&S has proven the effectiveness of this technology, reducing cokes formation increasing the furnace run-length drastically, in the order of magnitude >2-3 times
Taking into consideration the different types of feedstock being processed in steamcracking units, this coating has been installed in a naphtha / LPG cracking furnace and has shown very promising results since start-up one year and a half ago.
The coating is based upon a microfilm ceramic catalyst capable of converting cokes to carbon oxides on contact. In other words, when cokes forms during cracking it is instantaneously gasified on contact with the wall.
The applied coating has proven to be very robust, including thermal shocks, the exposure to a range of impurities, based on the numbers of decoking which took place during the last 20 months
The webinar will provide additional details of coating manufacturing sequence and the furnace performance
Popcorn related fouling issues in Frac Train, and contro! measures
Thursday 12 November 10:00-11:30
- S. Imbert, J. Dees & J. Rubens SUEZ Water Technologies & Solutions (SUEZ WTS)
- S.J. Korf, DOW Benelux B.V.
Over the recent years an increase in popcorn related fouling has been observed in the fractionation section of ethylene plants, a phenomena typically taking place in butadiene units only. Changing the cracker feedstocks to light (e.g. gas feeds), the presence of butadiene and peroxy-radicals are at the root cause of the problem. This affects the production reliability of the plant, inducing throughput limitations and EH&S risks related to the opening/cleaning of the equipment.
Popcorn type polymers are highly reactive and will act as seeds for further polymer popcorn growth, therefore it is vital to avoid the popcorn polymer formation through an antifoulant treatment program which is effective towards the inhibition of peroxy free radicals and supported by a proper monitoring program to optimize the application in terms of performance.
From an analytical perspective the antifoulant treatment is supported through the measurement of free peroxides and the residual content of active inhibitor components in the bottom section of the related columns which enables an improved reactive approach in controlling the antifoulant dosage at a proper level. Plant tests at Dow Terneuzen clearly show a correlation between residual inhibitor components and free peroxides in the bottom of a depropanizer.
Low NOx Radiant Wall Burner Technology – Optimised for Operation Within a Restricted Operating Envelope
Tuesday 27 October 11:00-12:00
The industry has long since struggled to achieve Low NOx burner performance within old design ethylene crackers, where burner to burner and burner to tube spacing is very tight.
Along with the effort to achieve improved emissions performance, it has always been a balance to ensure an optimal flame pattern. Due to flame to flame interaction, associated flue gas recirculation patterns and the inherent high heat flux tied to the heater design, this has always provided an exhaustive challenge.
Zeeco engaged this requirement with a view to design a burner that could achieve sub 100 mg/nm3 NOx, whilst maintaining an extremely tight flame envelope to thus ensure an optimal overall performance.
The design was rigorously tested at the Zeeco HQ development facility, where 6 off burners were installed and fired to simulate the worst-case spacing arrangement of the tightest configuration.
The burners provided the perfect balance of class leading NOx, tied with strong, consistent flame patterns.