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Innovative energy efficiency examples of different industrial sectors Energy efficiency in the cement, metal and petrochemical industry

ENERGY EFFICIENCY AND INNOVATIVE EMERGING

TECHNOLOGIES FOR OLEFIN PRODUCTION

Tao Ren, Martin Patel and Kornelis Blok

Department of Science, Technology and Society,
Faculty of Chemistry, Utrecht University,
Heidelberglaan 2, 3584 CS, Utrecht, The Netherlands

ENERGY EFFICIENCY AND INNOVATIVE EMERGING

TECHNOLOGIES FOR OLEFIN PRODUCTION
Tao Ren*, Martin Patel and Kornelis Blok, Department of Science, Technology and
Society, Faculty of Chemistry, Utrecht University

ABSTRACT
Among the current IPPC installations, steam cracking for olefin production is the single
most energy consuming process (ca. 30%) in the chemical industry, accounting for ca.
180 million tons of CO2 worldwide. This paper reviews steam cracking and innovative
emerging olefin technologies in terms of energy efficiency. Pyrolysis section alone
consumes ca. 65% of the total energy use and ca. 75% of the total exergy loss. An
overview of state-of-the-art naphtha cracking technologies shows that ca. 20% savings
on the current average energy use are possible. Advanced naphtha steam cracking
technologies in the pyrolysis section (e.g. advanced coil and furnace materials) may
together lead to up to ca. 20% savings on the total energy use by state-of-the-art
technologies. Improvements in the compression and separation sections may together
lead to up to ca. 15% savings on the total energy use by state-of the-art technologies.
Catalytic olefin technologies could possibly save at least ca. 20% on the total energy use
by the state-of-the-art naphtha steam cracking.
Keywords:
energy efficiency, energy analysis, steam cracking, catalytic olefin
technologies, ethylene and propylene

Corresponding author. Email address: [email protected] (T. Ren). Fax: +31.30.253.7601.

Introduction

Among the current IPPC installations, olefin production is the most energy
consuming processes in the chemical industry, accounting for ca. 30% of the sectors
total final energy use [1]. The core process for olefin production is steam cracking1,
which converts hydrocarbon feedstocks (naphtha, ethane, etc.) to olefins (ethylene,
propylene, etc.) and other products, Steam cracking accounts for ca. 2-3 EJ primary
energy use and ca. 180 millions tons of CO2 emission worldwide (see Table 1).
Reduction of this emission can help meet the emission targets set by Kyoto Protocol [2].
Energy cost is counted ca. 70% of production costs in typical ethane or naphtha based
olefin plants [3, 4]. In addition, over 35% of the European crackers are over 25 years
old. Therefore, energy management and re-investment are important considerations [5].
From both environmental and economic perspectives, it is therefore of interest to study
energy losses in the existing processes as well as energy-saving potentials offered by
recent improvements and alternative processes. Also, R&D priority setting and
innovation policy studies may benefit from such characterization.
Many technical papers that describe alternative olefin processes with an emphasis
on technical details on catalysis and engineering can be found in [6]. Interesting technoeconomic studies for various ethylene processes have been done in the 1970s and 80s
[7, 8]. A number of new olefin production technologies for short-term development were
also reviewed by [9]. However, a thorough comparison of alternative olefin technologies
and steam cracking that take into account energy allocation on byproducts and all
feedstock production is still missing. It is interesting to study such olefin technologies,
which might affect energy use in the next 20 to 30 years. Therefore, our research
question is: what are possible technological developments in steam cracking and in
alternative processes for the coming decade and how is their potential energy efficiency
in comparison?
Our approach for energy analysis follows two stages. First, we try to understand the
existing process and how energy is used. Then, we will make an inventory of new
technologies and characterize them in terms of potential energy-efficiency improvement.
This approach is similar to what has been used in [10]. This article is mostly based on
data available in the public literature2. We limit ourselves to technologies that produce
olefins from conventional (ethane, naphtha and propane) and heavy feedstock only.
Also, due to its large share as a feedstock (Table 1), naphtha steam cracking is the main
subject and ethane steam cracking is less discussed. Technologies involving other
feedstocks, i.e. natural gas, biomass, coal, organic waste and CO2 will not be discussed
in this paper3.
This paper first reviews background factors that affect energy use in olefin
production in section 2. Section 3 gives a process description for naphtha steam
cracking. Energy terms used in this article are defined in section 4. Section 5 presents

It includes all production processes in a steam cracker, i.e. from pyrolysis to separation. See process description later.

The major sources are of four categories: government reports (e.g. by EU Joint Research Center and US Department of
Energy), journals (e.g. Oil & Gas, Hydrocarbon Processing, Catalyst Today and Fuel Processing Technology), conference
proceedings (e.g. Ethylene Producers Conference) and publications by producers and licensors (e.g. Stone & Webster,
UOP, Shell, etc.) Interviews and correspondences with producers and licensors made also a limited amount of
contributions.
3

We have completed an analysis of energy use, CO2 emission and production cost for natural gas to olefins (UOP LLC
MTO, ExxonMobil MTO and Lurgi MTP) and oxidative coupling of methane via ethane. Our conclusion shows that these
new processes are far less efficient than the state-of-the-art steam cracking.

the results of the energy analysis. Under section 6, state-of-the-art and advanced
naphtha cracking technologies are described. Section 7 discusses further on catalytic
olefin technologies.
2

Background Factors

We will first discuss three background factors that are relevant for further analysis.
They are: the role of steam cracking in the industrial sectors, market growth and
feedstocks. First, steam cracking and its products, in particular olefins, have a backbone
status for many industrial sectors. The worldwide demand and production of olefins are
higher than any other chemicals [5]. Daily goods ranging from computer parts to
pharmaceuticals are primarily derivatives of steam cracking products. In Western
Europe, 95% of ethylene and 70-75% of propylene are produced through steam cracking
[5]. The rest of propylene comes from refinery fluidized catalytic cracking (FCC) units
(28%) and propane dehydrogenation or metathesis (2%) [5], which will be discussed
later. In general, steam cracking plays a dominant role in olefin production.
Global ethylene production in the late 1990s has grown at a very high rate of 7-8%
per year [11]. This is largely due to the strong demand growth in East Asia, especially
by China, while the current market growth in the US and Europe was rather moderate
[11]. In the last 2-3 years, the annual growth rate of the global olefin market slowed
down to 3-4%. The propylene market is growing faster than the ethylene market by (13%). Recently, large capacities are being built or planned in the Middle East, but most
of them produce ethylene from ethane, which is available at very competitive prices
($0.8-1.3/GJ in Middle East as opposed to $4/GJ in Asia) [11]. This might increase the
global share of ethane relative to naphtha in the coming years (see Table 1).
There are two categories of feedstocks for the current olefin production: one derived
from crude oil (such as naphtha, gas oil, propane, etc.) and another derived from natural
gas (ethane, propane, etc.) (see Table 1). Their availability depends on the composition
of crude oil and natural gas and their production volumes. Generally speaking in terms
of weight, ca. 10% of oil refinery output is naphtha while 1-14% of natural gas is ethane
and 80-90% is methane. Natural gas from the Middle East and Norway usually has
higher ethane content than that from Russia. These regions together have 80-90% of
the worlds natural gas reserves [12].
3

Process Description of Naphtha Steam Cracking

Steam cracking typically refers to all processes inside the battery limits of a steam
cracker. As Figure 1 shows, a steam cracker comprises the following three sections:
pyrolysis (A), primary fractionation/compression (B) and product recovery/separation (C).
Pyrolysis section (A) This is the heart of a steam cracker. Naphtha first enters the
convection section (where a series of heat exchangers are located) of a pyrolysis
furnace and is preheated to 650 oC. Then, it is vaporized with superheated steam and is
passed into long (12-25 meters), narrow (25-125 mm) tubes, which are made of
chromium nickels alloys. Pyrolysis mainly takes place in the radiant section of the
furnace where tubes are externally heated to 750-900 oC (up to 1100 oC) by fuel oil or
gas fired burners [5]. Depending on the severity1, naphtha is cracked into smaller
1

High severity (characterized by residence time of less than 0.5 second and temperature up to 900-1100 C ) conditions
increase ethylene yield (max. 5% increase) and lowers propylene yield. Low severity has the temperatures at lower than

molecules via free-radical mechanism in the absence of catalysts. The beta scission of
the free radicals leads to the formation of light olefins in the gaseous state [14]. After
leaving the furnace, the hot gas mixture is subsequently quenched in the transfer line
exchangers (TLE) to 550-650 oC (or sometimes lower to 400 oC). TLE will then be
followed by a series of heat exchangers and temperatures could drop down to 300 oC
[13]. These heat-transfer activities avoid degradation by secondary reactions and at the
same time generate high-pressure steam for driving compressors, etc. However, heat
exchangers are prone to fouling1 and therefore have to be shut down, both scheduled
and unscheduled.

Primary fractionation/compression (B)

Primary fractionation applies to
naphtha and gas oil feed only. In the primary fractionation section, gasoline and
fuel oil streams (rich in aromatics) are condensed out and fractionated. While
this liquid fraction is extracted, the gaseous fraction is de-superheated in the
quench tower by a circulating oil or water stream. The gaseous fraction is then
passed through four or five stages of gas compression (temperatures at ca. 15100 oC), cooling and final cleanup to remove acid gases, carbon dioxide and
water. Most of the dilution water steam are condensed, recovered and recycled.
Fuel oil and BTX (aromatic gasoline which contains benzene, toluene and
xylene.) are products from this section. A common problem with compression is
fouling in the cracked gas compressors and after-coolers. The built up of
polymers on the rotor and other internals results in energy losses as well as
mechanical problems [16]. Wash oil and water are used to reduce fouling.

Product recovery and fractionation (C)

It is essentially a separation process
through distillation, refrigeration and extraction. Equipment includes chilling
trains (chilling and refrigeration) and fractionation towers (de-methanizer, deethanizer and the rest in Figure 1). De-methanization requires very low
temperatures (e.g. 114 oC). C2 (ethylene and ethane) separation often requires
large distillation columns (splitters) with 120 to 180 trays and high reflux ratios
[17]. Undesired acetylene will be removed through catalytic hydrogenation or
extractive distillation. Similarly, in a C3 splitter, C3 (propane and propylene) are
re-boiled with quench water at ca. 80 oC and separated. Ethylene and propylene
refrigeration systems could be operated at low temperatures (within the range of
10 oC and -150 oC) for cooling and high pressure (200-450 psia) for
compression [5, 18]. Ethane and propane are recycled as feedstock (not fully
shown in Figure 1). Methane and hydrogen are separated at cryogenic
temperatures. As fuel grade byproducts, they are often used as fuel gas in the
pyrolysis process, but they can also be exported. Butadiene, other C4 and
aromatic gasoline are separated in the end. The total products yields from
naphtha cracking differ depending on the paraffin and aromatic content of
naphtha (full range, light, etc.) and severities (high, moderate and low).

Generally, steam cracking of ethane and other feedstocks also requires three
sections that are similar to those in the case of naphtha cracking process [5]. However,
o

800 C and ca. 1 second residence time [13]. The degree of severity is described by the P/E ratio (propylene/ethylene).
A P/E around 0.7 is low severity and any value below 0.5 is high severity. In Western Europe, the average severity for
steam crackers is around 0.52 [5]. Severity is strongly restrained by metallurgy of the tubes and rapid coking tendency in
the coils.
1

Fouling is a complex science and is still an unresolved problem in the process industry. Simply explained, it is the
degradation in heat transfer (or increase in the thermal resistance) due to a buildup of polymers or coke on the heat
transfer surface. It also leads to higher hydraulic resistances that result in higher energy use [15].

the processes differ depending on feedstock properties and design arrangement, which
often concern fractionation and separation sections [19]. For instance, ethane cracking
requires slightly higher temperature in the furnace, higher capacity of C2 splitter but less
infrastructure facilities. Storage tanks or recovery equipment for propylene, butadiene
and BTX aromatics are not needed, but an ethane vaporizer and super-heater are
required.
An additional issue is about coking. Regular decoking is required in various parts of
the pyrolysis section. Before decoking, the furnace first has to be shut down. Then,
high pressure steam and air (sometimes hydrogen) are fed to the furnace while it is
heated up to 880-900 oC, or even up to 1100 oC. Coke on the inner surfaces of the wall
and tubes is either burned off, washed away with high pressure water or be removed
mechanically. Decoking process can take 20-40 hours for a naphtha cracker [20].
Depending on the feedstocks, coil configuration and severity, decoking for steam
cracking furnaces is required every 14-100 days in average [5]. Typically, a naphtha
pyrolysis furnace is decoked every 15-40 days. Maximum cycle time is 60-100 days [5,
20]. Decoking is also required for quench towers, TLE and other sections.
4

Definitions

Energy indicators used in this article are defined as follows. The total energy use
(per unit for a specific process) is our focus in this article. It does not exported energy
(e.g. steam). The total energy use includes energy use in olefin processes and for
additional imports (if applicable).

Energy use in olefin process is the sum of fuel, steam and electricity in primary
terms that are used for reactions (converting feedstock into olefins) and all the
subsequent processes (e.g. compression and separation). This definition is
referred to as process energy use. Process energy use is usually defined as
the energy use in an industrial process. Process energy use in the case of
naphtha/ethane steam cracking is the sum of energy loss and thermodynamic
theoretical energy requirement1. Process energy use is typically expressed in
terms of specific energy consumption (SEC). These two terms are commonly
used to measure the energy efficiency of ethane/naphtha steam crackers. In this
article, the total energy use of steam cracking is the same as its process energy
use or SEC, therefore, these three terms are used interchangeably only for
steam cracking in this article.

For several alternative, non-steam cracking processes (to be discussed later),

however, energy use in olefin process is only part of the total energy use. Some
of these processes import oxygen, hydrogen, electricity and/or steam. Primary
energy uses in the production of these imports are also accounted as part of the
total energy use. All of these energy uses are expressed in SEC as well.

Energy loss represents the difference between the total energy input and total energy output. Thermodynamic
theoretical energy requirement is the minimum energy input requirement for converting naphtha to end products. It is the
difference between the total calorific value of products and the calorific value of naphtha at ambient temperatures. The
former is larger than the latter because the overall naphtha-based steam cracking reactions are endothermic.
Thermodynamic theoretical energy requirement is needed to produce products at certain yields from a given feedstock
and it can neither be changed nor avoided. Therefore, process energy use can only decrease by reducing energy loss.
However, since feedstock and product yields vary from process to process, thermodynamic theoretical energy
requirements vary as well. In order to compare energy efficiencies across different processes, we believe process energy
use for steam cracking (thermodynamic theoretical energy requirements and energy loss together) can be used as a basis
for comparing energy efficiency in this article. Its calculations for steam cracking will be explained later

All energy figures are in terms of primary energy. Final energy figures for electricity
and steam have been converted to primary energy using efficiency factors 40% and 85%
respectively. Energy use in catalyst and equipment production is not included. Energy
contents of products (or calorific values) are calculated based on their low heating value
(LHVs) collected in [21].
The degree of energy efficiency is measured by the expression of SEC, GJ/t. This
article uses several expressions of SEC, e.g. GJ/t feedstock, GJ/t ethylene or GJ/t high
value chemicals (HVCs). In this paper, GJ/t ethylene means that all energy use is
allocated to ethylene only and all other byproducts are hence produced for free in
terms of energy use. This is not always the best indicator. For example, if ethane
cracking is compared with naphtha cracking, it will not be fair to use GJ/t ethylene for
comparison. Ethylene yield from ethane cracking is much higher than from naphtha
cracking, but naphtha cracking also yields considerable amounts of other valuable
byproducts (Table 2). For this reason, we believe GJ/t HVCs is a better indicator. HVCs
include light olefins (ethylene, propylene and butadiene) and non-olefins. Non-olefins
are aromatics and other C5+ in the case of steam cracking. While the mass of light
olefins is fully taken into account, the mass of non-olefins is weighted with 50%1. The
reason is that these non-olefin products are usually priced approximately half as much
as light olefins2 [22]. Our estimates for energy savings refer to savings on total energy
use in terms of GJ/t HVCs.
This paper presents an exergy analysis for naphtha-based steam cracking. Exergy
of an energy carrier refers to the maximum amount of work that can be extracted from
an energy carrier. It is instructive to study exergy losses here because exergy analysis
can locate where energy savings for a process are possible. Exergy loss in the naphthabased steam cracking is considered equal to energy content of combusted fuels at
ambient temperature.
All CO2 emissions from the use of fuel-grade byproducts and external energy
sources are counted. In this article, yield refers to final yield (after separation, recycling,
etc.). It is defined as a percentage of desired products divided by hydrocarbon
feedstock (oxygen not counted) on the mass basis, unless otherwise specified.
Chemistry literature often uses per-pass yield on the mol basis. It will be noted where
this definition is used in this paper.
5

Energy Analysis of naphtha/ethane steam cracking

Our energy analysis is aimed at searching for the areas for energy efficiency
improvement. This section will first set a basis for further comparison of the total energy
use in steam cracking, then it will show where energy and exergy are used in a typical
naphtha steam cracker and finally it will discuss energy integration.

It is different from the definition of HVCs used in [5] where ethylene, propylene, butadiene, benzene and hydrogen are
weighted with 100%. However, this does not lead to large differences in terms of SECs since the yield of non-olefins from
steam cracking is small (e.g. aromatics yield max. 10%). Our definition of HVCs is useful to compare steam cracking with
alternatives, e.g. catalytic cracking from which aromatics yield is high (15-30% see Table 5).
2

Aromatics (pyrolysis gasoline) market prices are ca. $190/t in 2002-2003 [3, 22].

5.1

Typical Specific Energy Consumption

It is a difficult task to identify a SEC (GJ/t HVCs or GJ/t ethylene) that represents
current process energy use by a typical existing naphtha crackers. Most data available
are in SECs in terms of GJ/t ethylene and do not give further data on yields and
methodologies. They are rather old, incomplete or within a very wide range. The world
average SECs (excluding Japan and Korea1) in 1995 was ca. 30-36 GJ/t ethylene for
naphtha crackers [23]. If we consider that an efficiency improvement rate is 1.7% per
year for typical steam crackers in the past thirty years [5] and typical yields of HVCs in
Table 2 are valid, then the SECs for a typical naphtha cracker should be approximately
within the range of 26-31 GJ/t ethylene and 14-17 GJ/t HVCs.
Based on Table 2, calculations show that the thermodynamic theoretical energy
requirement (see definition) for naphtha cracking is ca. 8 GJ/t ethylene or ca. 5 GJ/t
HVCs. In the case of ethane steam cracking, this figure is ca. 5 GJ/t ethylene or ca. 5
GJ/t HVCs. Therefore, the SEC for a typical naphtha cracker is three times of the
theoretical energy input needed to convert naphtha to final products. As earlier defined,
SEC in the case of naphtha steam cracking is the sum of energy loss and
thermodynamic theoretical energy requirement. So the energy loss in a typical naphthabased steam cracking process is at least 17 GJ/t ethylene or 8 GJ/t HVCs. In this case,
the energy loss is approximately equal to exergy loss since the energy discussed here is
the energy content of fuel-grade byproducts combusted in the naphtha/ethane steam
cracking.
5.2

Breakdown of SEC and Exergy Losses

Data for a breakdown of SEC and exergy losses found in literature are
summarized in Table 3. For energy analysis, both thermodynamic theoretical energy
requirement and energy loss are considered. Pyrolysis accounts for ca. 2/3 of the total
SEC of naphtha crackers. The remaining third is consumed by compression and
separation sections. The compression section (ca. 15% of the total energy use in
naphtha cracking) uses slightly less energy than separation section (ca. 1/5 of the total
energy use in naphtha cracking).
For exergy analysis, only exergy loss (17 GJ/t ethylene) due to fuel combustion is
considered. With respect to exergy in pyrolysis section of naphtha crackers, ca. 75% of
the total exergy losses are estimated to occur in the naphtha pyrolysis section. Fuel
combustion is predictably the main cause. These large exergy losses can be illustrated
by the high temperature drops across heat exchangers, which are mostly in the range of
100-300 oC and even near 500 oC in the TLEs. Throughout the whole pyrolysis process,
the total temperature drop is more than 1100 oC and the total pressure drop is over
seven mpa [25].
With respect to exergy use in the rest of sections in a naphtha cracker, the large
losses occur in propylene refrigeration, de-ethanization/C2 splitter and compression.
Exergy losses that occur in the compression and separation sections mainly are caused
by the production of electricity used in refrigeration and compression. All these exergy
losses are not surprising if the conditions in separation and compression sections are
considered. As the process description has indicated, most of the conditions for

The SECs of naphtha steam crackers in Japan and Korea in 1995 are exceptionally low, namely ca. 25 GJ/t ethylene
[23]. About 40% of steam crackers in Europe have SECs at ca. 31-35 GJ/t ethylene [5]. Naphtha and gas oil steam
crackers in the US have SECs at ca. 32 GJ/t [24].

refrigeration are very cryogenic: low temperatures (as low as -150 oC) and high pressure
(up to 450 psia).
Ethane cracking has a similar distribution of energy consumption. However, an
important difference from naphtha cracking is that the contribution of SEC in the
pyrolysis section of ethane cracking (ca.1/2) is less by percentage than that in the case
of naphtha cracking (ca. 2/3). In turn, the contribution of SEC in compression and
separation sections is slightly higher in the case of ethane cracking than that in the case
of naphtha cracking. The chiller that condenses and separates ethylene and ethane
uses up to ca. 21% of the total energy consumption [26]. As our process description
mentioned, ethylene and ethane have similar boiling points, which explains why this
separation task is very energy consuming.
As mentioned in the process description of steam cracking, additional energy used
in decoking/defouling, shutdowns/restarts and related maintenance for various sections
of a steam cracker could consume up to ca. 1-2% of the total energy use in the existing
processes [27]. This additional energy use in decoking and defouling is usually not
counted as part of SEC in steam cracking. Shutdowns also directly lead to large
monetary losses. Therefore, it is not surprising to hear that the greatest challenge for
steam-cracker engineers today is to improve the on-stream factors (intervals between
shutdowns) by reducing coke formation and to extend furnace life between tube
replacements [28].
5.3

Energy Integration

In the case of naphtha cracking, process energy used in the pyrolysis section is
provided through combustion of fuel gases, which are fuel-grade byproducts in
significant volumes. These byproducts, together with flue gases (not fuel gases) and
waste heat, can meet ca. 95% of process energy demand in naphtha steam crackers
[24]. These fuel-grade byproducts amount to ca. 20-25% of the energy content of
naphtha (ca. 10-12 GJ out of LHV 44 GJ/t naphtha). Energy needed for compression
and separation sections is provided by steam, which can almost all be produced from
heat exchangers, or so called Transfer Line Exchangers (TLEs). Typically, steam is in
balance, which means that there is no net steam import or export. A small amount of
electricity is provided from external sources [29]. Electricity is used primarily for running
cooling water, quench oil pumps and sometimes methane compressors [24]. It amounts
to ca. 1 GJ/t ethylene [24]. Backflows to refinery and energy export together can be up
to ca. 9-10 GJ/t ethylene for naphtha cracking [24]. In contrast to naphtha cracking,
ethane cracking is not self sufficient in terms of energy and therefore requires energy
import (15% of the total SEC through various energy carriers) [30].
6

Latest Developments of Naphtha Steam Cracking

In search for alternatives, we draw a family portrait of olefin technologies sorted by

feedstocks (Figure 2). We have chosen a number of the latest technologies based on
the following criteria: using conventional or heavy feedstocks, undergoing active
research and being highly visible in recent publications, recently emerging or being
commercialized and possibly having significant impacts on energy use. In the following
sections, these technologies will be discussed in two categories: (6.1) state-of-the-art
naphtha cracking processes (Table 4); (6.2) advanced technologies in specific sections
of naphtha steam cracking.
8

6.1

State-of-the-Art Naphtha Steam Cracking1

Table 4 is an attempt to summarize state-of-the-art technologies for naphtha

steam cracking, which is sorted by licensors. These technologies are offered as the
most standard, widely accepted processes to olefin producers if they want to build a new
olefin plant today. Table 4 contains only limited, public available information. For the
separation section, only information on the de-methanization for each licensor was
available. Regarding pyrolysis furnaces, most technologies focus on optimization design
of furnace coils, which are located in the radiant section where cracking occurs (see
process description in section 4). The goal is to improve heat transfer, raise severity,
minimize coking and maximize olefin yields. As Table 4 shows, small, double coils and
double radiant cells seem to be common features. With respect to improvements in
separation processes, front-end de-methanization reduces refrigeration needs and
therefore energy demand. For example, ABB Lummus claims a 75% cut in refrigeration
needs [31]. However, traditional energy-consuming refrigeration and distillation as the
main separation method remain unchanged. Further, no significant changes in the
subsequent sections (compression and C2, C3 and C4 separation) are reported as part of
state-of-the-art naphtha steam cracking technologies.
These processes in Table 4 could reach SECs in the range of ca. 18-25.2 GJ/t
ethylene, which is equivalent to a saving of ca. 20% on current average SEC (26-31 GJ/t
ethylene). Gas turbine mentioned in Table 4 is not being commonly offered by every
licensor. It will be discussed again in the next section. Without considering gas turbine,
we consider the average SECs for state-of-the-art naphtha steam cracking is ca. 20-25
GJ/t ethylene and 11-14 GJ/t HVCs. HVCs yields used in the calculation are based on
data reported by ABB Lummus2. The SEC figures (11-14 GJ/HVCs) by state-of-the-art
naphtha cracking technologies are still far more than the absolute thermodynamic
theoretical energy requirement for naphtha to olefin conversion mentioned earlier (5
GJ/HVCs).
In addition to Table 4, we observed a trend that the sizes of state-of-the-art
crackers are increasing. While the current average steam cracker is around 450,000500,000 tons ethylene per year [5], new naphtha crackers can produce over one million
tons of ethylene annually (tpa). Technip built a plant with ethylene capacity of over 1.2
million tpa in Iran [32]. KBR (Kellogg Brown & Root) claims that they are able to build a
two-million tpa ethylene plant [33]. The same trend goes with ethane crackers as well.
Stone & Webster built an ethane cracker for NOVA in Canada with ethylene capacity of
1.27 million tpa. Technip claims the SEC of their mega cracker is 20 GJ/t ethylene as
opposed to the average 30 GJ/t ethylene3 [32].

State-of-the-art is technologies that would be used if a new plant is to be built nowadays. For example, those process
introduced in the petrochemical processes 2003 in [31], which are commonly offered by licensors.
2

ABB Lummus steam cracking technology is said to be used by over 40% of the worlds olefin plants [31].

Technip also claims that their mega crackers have lower product losses (0.25% in comparison with the average 1%),
lower CO2 emission (half of the average 1.6 t/t ethylene in Table 2) and lower operational cost advantages because of
economy of scale [32]. Technip also claims that the maximum capacity may have been reached mainly due to the limits
of compressors.

6.2

Advanced Naphtha Steam Cracking Technologies

Advanced technologies in specific sections in a naphtha cracker are not being

offered by major licensors as part of standard commercialized processes. In fact, some
of them are commercially available, but due to high costs, most of them are not yet
widely implemented. Others are new and their technical and economic feasibility have
yet to be proven.
With respect to the pyrolysis section, there are a few significant innovations and all
of them are aiming at improving heat transfer and raising severity. There are circulating
solids/particles (such as sand, coke and other carriers), circulating beds [34], selective
radiant coils (which allows better control of P/E ratio by adjusting combustion gas) [35],
ceramic coated tubes/coils and other advanced furnace materials [28, 36]. Here we only
discuss Advanced furnace materials. Reducing coking can greatly improve heat transfer
in furnaces. Traditionally, coking can be partially inhibited by a sulfur-compound based
chemical treatment of inner walls of tubes/coils. Advanced tubes and coils in various
shapes (e.g. cast-fins) are coated with glass, ceramics (aqueous salt of IA/IIA metals,
silicon and phosphorus compounds) and they do not need chemical treatment [28, 37,
38]. Coating can also have catalytic effects for olefins selectivity [39]. Also, coating
could allow higher severity and thereby enhance ethylene yields. Sintered silicon
carbide (SiC) ceramics, for instance, offer maximum skin temperature up to 1400 oC ,
high conductivity and low surface catalytic activity [40-42]. Conventional pyrolysis tubes
made of Cr-Ni alloys allows the maximum skin temperature only up to 1100 oC [41]. It is
estimated that these advanced materials could lead to up to ca. 10% savings on current
average SEC, or ca. 2-3 GJ/t ethylene1.
An additional new technology is gas turbine integration. Gas turbine integration
results in the export of both steam and electricity. Also, it produces hot combustion gas
for feedstock heating in a pyrolysis furnace. It can possibly save 13% (ca. 3 GJ/t
ethylene) on the SEC of state-of-the-art steam cracking technologies [43] [44]. If both
advanced furnace materials and gas turbine are applied, ca. 20% energy saving (ca. 4
GJ/t ethylene) on the SEC of state-of-the-art naphtha steam cracking is possible.
With respect to compression and separation section, possible improvements are:
Vacuum Swing Adsorption Process (VSA), mechanical vapor recompression (MVR),
advanced distillation columns, membrane and combined refrigeration systems. VSA
uses solid sorbents for selective light olefin adsorption (such as ethylene and propylene)
over paraffin (such as ethane and propane). MVR could be used in a conventional
propane/propylene splitter. It can lead to ca. 5% (ca. 1 GJ/t ethylene) saving on the
SEC of state-of-the-art steam cracking [45].
Advanced distillation column technology has been studied since 1930s as
thermally coupled column. One type of such columns is divided-wall distillation
columns for butadiene extraction. It could save ca. 16% on the SEC in the conventional
butadiene distillation section [46]. Another type of such advanced distillation column is
Heat Integrated Distillation Column (HIDiC). Two variations of HIDiC developed in the
Netherlands are called Plate Fin and Concentric [47]. These advanced columns improve
heat transfer by building heat exchangers between stripping and rectifying sections.
They can be applied in ethylene/ethane (E/E) splitter and propylene/propane (P/P)
splitter. It is generally estimated that HIDiC saves ca. 60 to 90% energy (or 0.1-0.3 GJ/t
ethylene) on the SEC of a conventional P/P distillation column, which is known for poor
1

This estimate is based on personal communications quoted in [35].

10

energy efficiency (ca. 20-30%) [47-49]. HIDiC is even possible to save ca. 50% (ca.
0.15 GJ/t ethylene) on the SEC in modern distillation columns with heat pumps [47].
Membrane is another long-known technology, but it is rarely applied in steam
cracking. Membrane materials are often made of polymer (e.g. polypropylene) or
inorganic materials. Membranes can be possibly applied in separation of olefin/paraffin
(C2/C3), gases (hydrogen recovery1, acids, etc.) and coke/water (water purification) [51].
Membranes could combine high selectivity with a high permeability. With regards to the
membrane application in the C2 and C3 separation alone, ca. 8% (1.5 GJ/t ethylene)
savings on process energy is expected [52]. However, membrane separation is widely
believed as an immature technology because it is unable to withstand severe operating
conditions and needs regular replacement (due to erosion, etc.). Therefore, membrane
is not yet licensed by any steam cracking licensors.
Energy integration of a steam cracker with another industrial process can also
possibly save energy. Combined refrigeration synchronizes the cryogenic natural gas
liquid plant, natural gas liquid fractionation and ethylene plants into a single unit [53]. It
is claimed that the total refrigeration requirement by an ethylene plant is reduced by 6080%, or ca. 1 GJ/t ethylene can be saved [53].
Since some of the technologies mentioned above could be applied in the same
process (e.g. HIDiC columns and membrane for C2/C3 separation) and most of them are
not yet mature, it is not possible to simply add up all the energy savings together.
Considering the distribution of SEC described in Table 3, we roughly estimate that
advanced steam cracking technologies altogether could lead to up to ca. 15% of energy
savings (ca. 3 GJ/t ethylene) on the SEC of state-of-the-art steam cracking.
7
7.1

Catalytic and other Alternative Technologies

Energy Use

An alternative to conventional steam cracking comprises catalytic and other

alternative olefin technologies, which can process conventional or heavy feedstock.
Table 5 is a list of these technologies in the order of feedstock weight from light (left) to
heavy (right). Note that technologies in Table 5 only differ from the pyrolysis furnace of
a steam cracker. The rest, including compression and separation sections, are assumed
to be similar to those of state-of-the-art steam cracking. The first three technologies use
gas feedstocks. Gas stream technologies use gases as heat carriers to provide
enthalpy needed for pyrolysis [54, 55]. Shockwave technology uses steam at
supersonic speed as heat carrier and the process is volumetric, not limited by heat
transfer through metal walls and tubes as for the conventional steam cracking [54]. It
uses ca. 45% (primary energy use for steam production included) less than the SEC of
the state-of-the-art steam cracking [56]. Olefin producers are very concerned about the
overall system complexity that result from large requirement of steam (ca. 5-10 times the
steam requirement by conventional steam cracking) and subsequent energy recovery
from waste steam [54]. R&D on shockwave technology was stopped in 1998.
There are two oxidative dehydrogenation processes, both for processing gas
feedstocks. Both processes require oxygen with high purity (ca. 90%). Ethane oxidative

Hydrogen recovery may have been among the first wide-scale commercial application of membrane [50].

11

dehydrogenation has ca. 35% potential saving1 (primary energy use in oxygen
production included) on the SEC by state-of-the-art ethane cracking [57]. Another
process is propane oxidative dehydrogenation. This process produces little ethylene.
Ethylene yield from steam cracking of propane is up to 45% and propylene yield is 12%
[30]. Propane oxidative dehydrogenation has potential to lead to ca. 45% (primary
energy use in oxygen production included) savings on the SEC by conventional propane
steam cracking, which is 15-18 GJ/t HVCs.
The rest of technologies in Table 5 use naphtha or heavy feedstocks. SEC by
catalytic cracking of naphtha is estimated to be within 10-11 GJ/t HVCs. This is also ca.
10-20% less than the SEC by the state-of-the-art naphtha cracking (11-14 GJ/t HVCs).
Some of these processes, developed by LG (a major Korea chemical company) and
AIST (a Japanese research institute), are reported to be commercialized soon.
Hydro-pyrolysis (non-catalytic) could save ca. 9% (primary energy use in hydrogenmethane fraction included) less than the SEC by the state-of-the-art naphtha cracking.
The reasons for such energy savings include several factors: higher yields, lower
temperature in the furnace (heat coefficient of hydrogen higher than methane or fuel oil),
low coking and less steam requirement [59].
Byproduct upgrading technologies produce olefins by processing the byproducts
(ranging from C4 to C9) from conventional steam cracking or from refinery [22]. As an
add-on process to naphtha cracking, byproduct upgrading technologies can raise the
total propylene yield of naphtha cracking from the average 15% to 30%. This process
has a potential saving of ca. 7-10% less than the SEC by the state-of-the-art naphtha
cracking.
Using heavy feedstocks, such as crude oil, the catalytic pyrolysis process (CPP)
saves ca. 12% on the SEC of the state-of-the-art naphtha cracking. Because CPP
feedstock can be crude oil and other heavy feedstock, energy use in naphtha production
is avoided, which is about ca. 2-3 GJ/t naphtha [49] If this is taken into account in the
comparison with naphtha steam cracking, the energy savings by CPP would be ca. 20%.
Another important reason for energy saving is the mild reaction conditions in CPP. Its
reaction temperatures are around 650-750 oC, which is 150-350 oC lower than steam
cracking [60, 61].
The energy savings estimated here are due to improvement of energy efficiency in
the pyrolysis section. If the advanced separation technologies (mentioned under 6.2)
are also applied, then the energy savings by catalytic olefin technologies on the SEC by
state-of-the-art naphtha cracking could be up to ca. 40%. Among the alternative olefin
technologies discussed, gas stream and hydropyrolysis (non-catalytic) have not been
actively pursued by the industry in recent years. However, catalytic olefin technologies
are under intensive R&D, especially in China and Japan.

However, if the CO2 emission from oxygen usage is included, the total CO2 emission by ethane oxidative
dehydrogenation is 0.31 ton CO2 per ton ethylene produced. This is 15% higher than that from ethane cracking. Ethane
cracking emits less due to combustion of hydrogen although it uses more energy per ton of ethylene than ethane oxidative
dehydrogenation [57]. Oxygen production (if using electricity) requires primary energy ca. 3-4 GJ/t oxygen [58]. Its
emission factor is assumed as 60 kg CO2/GJ. In the future, this CO2 emission factor could be reduced by membrane or
other efficient oxygen production processes.

12

7.2

Reactors and Catalysts

It is interesting to discuss further about possibilities for energy saving by these

catalytic olefin technologies just mentioned1. The emergence of catalytic olefin
technologies is in line with the recent discussion on energy saving through process
intensification2. This is reflected by the reactors and catalysts used in catalytic olefin
technologies. The reactors of new catalytic technologies3 in Table 5 often share similar
reactor design with conventional FCC reactors used in refineries (fixed or fluidized bed
catalytic cracking reactors).
Chinas SINOPEC has named its catalytic olefin
technologies (e.g. CPP) as FCC family techniques [64]. FCC reactors are smaller than
pyrolysis furnaces. Also, moving beds and catalysts used in FCC enable intensive
contact between catalysts, reactors and feedstocks (by maximizing contact surface) and
consequently, such intensity leads to efficient heat transfer. Unsurprisingly, FCC
reactors4 are known for using less energy in terms of SEC/t feedstock (SEC ca. 2-3 GJ/t
feedstock) [49] than steam cracking furnaces (SEC ca. 5-9 GJ/t ethane or naphtha) [49].
Because catalytic reactors usually operate under lower temperatures than those for
steam cracking, it is possible to use recovered waste heat (combined with fuel
combustion) as sources of process energy [25].
The use of catalysts is commonly known for energy saving. Zeolite FCC catalysts
adopted by US refinery in 1977 have helped save 200 million barrels of crude oil (30
million tons) in the US alone [66]. Similarly, many of catalytic technologies mentioned in
Table 5 use zeolite (other also use metal oxides) catalysts5. Figure 3 illustrates that
catalytic olefin technologies can save activation energy use in conventional steam
cracking. There are three reasons for such energy saving.

First, these catalysts provide an alternative route to steam cracking with the use
of lower activation energy for C-C bonds rupture. In the case of CPP, this means
the cracking can be carried out at moderate temperature and pressure in
comparison with steam cracking [14]. Also, most of the catalysts cannot
withstand extremely high temperatures and pressures as in steam cracking (up
to 1,100 oC and 75 mpa). Consequently, the temperatures for the new catalytic
naphtha cracking processes are 150-250 oC lower than those for steam crackers
(Table 5).

This is not to say all catalytic pyrolysis technologies for olefin production save energy in comparison with the state-ofthe-art steam cracking. We limit our discussions only on those listed in Table 5 that are believed to have energy saving
potentials.
2

The term basically means that better heat and mass transfer in smaller and faster reaction systems with less steps lead
to higher conversion, better efficiency, less waste and safer control systems [62].
3

Catalytic olefin technologies, there are basically two categories: acidic catalytic cracking and thermal catalytic pyrolysis
[63]. Acidic cracking is associated with zeolite catalysts, FCC-like riser/bed reactors and heavy feedstocks. This
technology is being developed by Sinopec/Stone & Webster (in commercial test), ABB Lummus, KRICT, LG, Asahi and
AIST. Thermal catalytic pyrolysis is associated with various kinds of metal oxide catalysts and naphtha. The reactors are
often similar to tubular furnaces used in steam cracking, but FCC-like reactors are also being tested. This technology is
being developed by VNIIOS (in commercial test), Toyo, IIT, Stone & Webster, Idemitsu, KRICT and LG.
4

FCC reactors operate under low temperature: ca. 450-600 C, which is 200-400 C less than steam cracking [65].
However, it is commonly known that FCC ethylene yield usually only is 1-2% and propylene yield is 5% while naphtha
yield is over 50% and cycle oil yield is 20% [49].
5

Zeolite catalysts are complex alumino-silicates and are large lattices of aluminum, silicon and oxygen atoms. In the case
of FCC, zeolite catalysts lead to formation of carbonium ions. These ions then reorganize and lead to various FCC
products. In the case of catalytic olefin technologies, the combined use of zeolite and other catalysts lead to formation of
both carbonium-ions and free-radicals [64, 67]. They are then reorganized and eventually lead to light olefins, aromatics
and other products [14].

13

Second, catalysts improve selectivity to desired products, such as propylene [68].

Even if the same operating conditions as those of steam cracking are applied for
catalytic cracking, the total olefin yield by LGs catalytic pyrolysis technology is
still enhanced by at least 15% [68].

Third, coke formed during the cracking process is constantly removed by

catalysts that are in turn de-coked through catalyst regeneration (or catalyst
decoking). As said earlier, coke lowers energy efficiency by hindering heat
transfer.

Earlier attempts to catalytically convert heavy hydrocarbons to light olefins often

showed that the use of catalysts is often problematic because of thermodynamic
equilibrium limitations, coking, low yields of olefins and high yield of low-value
byproducts1 [64, 69]. The new catalytic technologies in Table 5 have made some
progresses in solving these problems, but continuous improvement is still needed.

7.3

First, regarding the problem with the equilibrium limitation, oxygen is used to
drive the reaction toward the desired direction and to take advantage of heat
generated by oxidation. As a result, excessive heating and high pressure are not
required and thereby energy efficiency is improved [65]. At the same time,
oxygen can also burn off coke on the catalysts. Also, reactors using inorganic
catalytic membranes could also separate oxygen, ethane/naphtha, hydrogen and
other products (reducing undesired reactions) and improve the conversion of
equilibrium limited reaction [70, 71].

Second, older metal oxide catalysts were prone to coking and quickly deactivate.
Therefore, high temperatures and short residence time were required to hinder
coking. High temperatures (800 oC or above) and extremely short residence time
(in milliseconds), however, are often very harsh on catalysts and result in quick
deactivation of catalysts and short lifetime. Recently, new zeolites catalysts (e.g.
metal, silica and hybrid) have shown to have less coking and to be more effective
under higher temperatures [61, 72]. One recent patent on catalytic olefin
technologies claims that new catalysts can reduce CO2 and methane contents in
the air stream from catalyst regeneration by 90% and 50% respectively in
comparison with the CO2 and methane content in the air stream from steam
cracking [65].

Third, older catalysts often show strong selectivity to aromatics and heavy
hydrocarbons instead of light olefins. New catalysts, such as Ga-P zeolite,
suppress aromatization and provide relatively high yield of ethylene and
propylene [73].
Short and Long-Term Prospects

According to major worldwide licensors and research institutions we have contacted

through 2002 to 2004, currently none of these catalytic olefin technologies listed in Table
5 are fully mature and economically competitive in comparison with state-of-the-art
1

Coke can be significant even at high reaction temperature. It can currently only be burned through catalyst generation
and is very problematic if it remains in the final products. Catalytic olefin technologies often yield large amount of
methane and hydrogen, which need much energy at cryogenic conditions to be separated. Other low-value byproducts,
such as aromatic-rich gasoline is difficult to be used due to instability caused by olefins, but additional processing will lead
to high costs [64].

14

steam cracking technologies. Nevertheless, it is of our interest to discuss the short and
long-term prospects of catalytic olefin technologies.
In the short term, catalytic olefin technologies appear to be driven by two economic
factors: strong demand for propylene and low cost feedstock [74, 75].

First, propylene demand is an economic factor that is often discussed. The three
catalytic technologies in the middle of Table 5 are devoted to produce propylene
and are sometimes referred to as propylene on purpose [11]. For the same
reason, conventional FCC used in refineries (cracking heavy feedstocks) also
becomes attractive for R&D since it yields considerable amount of propylene (up
to wt. 17%) and is likely to supplement propylene supply unfulfilled by steam
cracking [74, 76].

The second economic factor is feedstock. Heavy feedstocks (heavier than

naphtha), such as gas oil and heavy residues indicated in the center of Table 5,
are cheaper than naphtha and ethane and they can also yield multiple high value
byproducts [65]. Such feedstocks are attracting much attention in the US,
Europe and Asia. Cracking heavy feedstock can enhance competitiveness
compared to ethane cracking in the Middle East. Therefore, the overall
economics for upgrading heavy feedstock to high value olefin products (in
particular propylene) looks quite attractive.
Besides unsolved technical
problems, whether the production volume by using these new technologies is
able to increase further will be decided partially by propylene market pull and
partially by cost competition between conventional and heavy feedstocks.

In the long term, more and more R&D can be expected to be devoted to catalytic
olefin technologies because of their potentials in energy saving as well as upgrading
low-value heavy feedstocks. Catalysis has brought tremendous progresses to many
fields in the chemical industry, but unfortunately it has not been capitalized in light olefin
production. Steam cracking essentially is a non-catalytic and non-selective process.
Catalysts have never been widely used in the pyrolysis section in steam cracking to
optimize energy efficiency. The application of catalysts in cracking naphtha and ethane
has only become attractive since the beginning of 1990s. Beside those institutions in
Korea, Japan and China (mentioned under Table 5), major licensors (e.g. Stone &
Webster and ABB Lummus) and olefin producers (e.g. ExxonMobil and BP) are also
filing patents on catalytic olefin technologies. Recently, catalytic processes developed
by AIST, Sinopec/Stone & Webster and VNIIOS are said to be already under
commercial tests [63]. Adoption of FCC-like catalytic olefin technologies has been
expected since more than ten years ago [25]. Whether these new processes can
replace steam cracking will depend on how well they mature both technically and
economically in the next 20 to 30 years.
In a word, after reviewing alternative technologies in Table 5, we conclude that there
is a strong rising interest in applying special reactors and catalysts to control yield and
thereby to improve energy efficiency, but the future development of catalytic olefin
technologies will be strongly affected by maturity of catalytic technologies, market pull
and feedstock cost competition.
8

Conclusion

Issues concerning the reduction of energy use, costs and emissions by olefins
production initiated this analysis of olefin technologies. The findings from our energy
15

analysis indicated the most important sections in terms of the energy use, e.g. pyrolysis
section alone accounts for ca. 65% of total energy use and ca. 75% of the total exergy
losses. This paper then discusses the latest olefin technologies that still use
conventional feedstocks. An overview of state-of-the-art naphtha cracking technologies
offered by licensors shows that ca. 20% savings on the current average energy use are
possible. Advanced naphtha steam cracking technologies in the pyrolysis section (e.g.
advanced coil and furnace materials) may together lead to up to ca. 20% savings on the
energy use by state-of-the-art technologies. Improvements in the compression and
separation sections may together lead to up to ca. 15% savings on the energy use by
state-of-the-art technologies. Alternative olefin technologies apply special reactors,
catalysts or additional materials (oxygen, hydrogen, etc.) to crack conventional and
heavy feedstocks. In particular, catalytic olefin technologies can lead to higher yields of
valuable chemicals (e.g. propylene) under lower reaction temperatures. Due to energy
efficiency improvement in the pyrolysis section, catalytic naphtha cracking could possibly
save up to ca. 20% on the energy use by the state-of-the-art naphtha steam cracking is
possible.

16

Acknowledgement
This PhD project is financed by Energy Research Foundation of the Netherlands
(ECN) and Utrecht Energy Research Center (UCE). Also, special thanks to C. Bowen at
Stone & Webster, H. Chang at Tamkang University in Taiwan, J. Hugill at ECN, A.
Laghate at Technip-Coflexip, P. Pujado at UOP LLC and J. Siddall at Dow Chemicals.

17

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Technology, vol. 5, pp. 119, 2000.

[54]

T. Mattick, Personal communications on shockwave technology in January of

2003, . Seattle, Washington: University of Washington, 2003.

[55]

P. Pujado, D. Greer, J. Andersen, T. Foley, and V. Bhirud, The role of new

technology in the light olefins industry, presented at Spring National Meeting of
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[56]

Knowlen, Petrochemical pyrolysis with shock waves, AIAA Paper 95-0402,

1995.

[57]

J. Siddall, Catalytic Autothermal Partial Oxidation, in Dow Chemical, 2000.

[58]

IKARUS, Personal communication with Linde AG.

Quoted in IKARUS
(Instrument for climate changing gas reduction strategies). Internal Report.,
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[59]

M. Taniewski, Personal communication in May of 2003 and February of 2004, .

Poland: Silesian Technical University in Poland, 2004.

[60]

C. Xie, X. Wang, and e. al, Commercial trial of catalytic pyrolysis process for
manufacturing ethylene and propylene, presented at The 17th World Petroleum
Congress on Sept 1-5, 2002, Rio de Janeiro, Brazil, 2002.

[61]

USPTO, Process for production of ethylene and propylene by catalytic pyrolysis

of heavy hydrocarbons (US Patent 6,210,562), : China Petrochemical
Corporation and RIPP, 2001.

[62]

F. M. Dautzenberg and M. Mukherjee, Process intensification

multifunctional reactors, Chemical Engineering Science, pp. 251, 2001.

[63]

S. S. Han, J. N. Kim, C. W. Lee, and Y. K. Park, Catalytic Cracking of Heavy

Naphtha and Olefin Separation in Atmospheric Temperature, . Korea: Advanced
Chemical Technology Division, KRICT, 2002.

[64]

R. Deng, F. Wei, Y. Jin, Q. Zhang, and Y. Jin, Downer Catalytic Pyrolysis (DCP):
a Novel Process for Light Olefins Production, Chemical Engineering
Technology, vol. 25, pp. 711-716, 2002.

[65]

USPTO, Hybrid catalyst for deep catalytic cracking of petroleum naphthas and
other hydrocarbon feedstocks (US Patent application number 20040014593), :
Concordia University, 2004.

[66]

UYSEG, FCC Cracking Saves Energy, : The University York Science Education
Group, 2004.

21

using

[67]

Y. Yoshimura, K. Murata, F. Mizukami, and e. al, Catalytic cracking of naphtha

to light olefins, Catalysis Surveys of Japan (also available for download at
http://www.kluweronline.com), vol. 4, pp. 157-169, 2001.

[68]

S. M. Jeong, J. H. Chae, and e. al, Catalytic pyrolysis of naphtha on the KVO3

based catalyst, Catalysis Today, pp. 257-264, 2002.

[69]

L. Laszlo, Oxidative conversion of lower alkanes to olefins, , F. v. Vught, Ed.:

University of Twente, 2002.

[70]

G. Madia, G. Barbieri, and E. Drioli, Theoretical and experimental analysis of

methane steam reforming in a membrane reactor, Canadian Journal of
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[71]

M. Alfonso, M. Menndez, and J. Santamara, Oxidative dehydrogenation of

butane on V/MgO catalytic membranes, Chemical Engineering Journal, pp. 131138, 2002.

[72]

USPTO, Production of naphtha and light olefins (US Patent application number
20020063082), : ExxonMobil Inc., 2002.

[73]

USPTO, Production of light olefins from oxygenate using framework galliumcontaining medium pore molecular sieve (US Patent application 20030018231),
: ExxonMobil Inc., 2003.

[74]

CMAI, World Propylene Supply Study, Chemical Market Associates, Inc.,

Houston, TX, USA 2001.

[75]

S. J. Zinger, Propylene: A Valuation Evaluation, presented at World

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[76]

K. Sundaram, T. Chan, and R. Venner, Propylene production from FCC

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[77]

C. Jennings, Adding value through growth and innovation: NAFTA region olefins
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[78]

G. M. Wells, Handbook of petrochemicals and processes, 1991.

[79]

D. J. Gielen and B. J. Groenendaal, The Future of the Petrochemical Industry,

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[80]

M. Steinberg, P. T. Fallon, and M. S. Sundaram, The Flash Pyrolysis and

Methanolysis of Biomass for Production of Ethylene, Benzene and Methanol.
New York: Marcel Dekker Inc, 1992.

[81]

ABB-Lummus, Metathesis: Refinery and Ethylene Plant Applications, presented

at ARTC Petrochemical Conference, February 12-14, 2001, Malaysia, 2001.

[82]

M. Tallman, KBR's Superflex process to upgrade F-T liquids at Sasol,

presented at 5th EMEA Petrochemical Technology Conference, Paris, June 2326, 2003, 2003.

[83]

H. V. Bolt, Linde Propylur Process Integrated into a steam cracker, presented at

5th EMEA Petrochemical Technology Conference, June 23-26, Paris, 2003.

[84]

Sud-Chemie, Catofin propane dehydrogenation for propylene, , 2003.

22

[85]

Uhde, The Uhde Star Process: oxydehydrogenation of light paraffins to olefins,

: Uhde, 2003.

[86]

D. Nakamura, Special report: Ethylene capacity rising, margins continue to

suffer, Oil & Gas Journal, 2002.

[87]

K. G. Spletter and W. P. Ruwe, Gulf coast ethylene margins begin in this issue,
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[88]

WEC, Energy Efficiency Improvement Utilizing High Technology, An

Assessment of Energy Use in Industry and Buildings, Report and Case Studies,
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[89]

DOE, Ethylene process design optimization, : US Department of Energy, 2001.

[90]

M. Neelis, M. Patel, and M. D. Feber, Improvement of CO2 emission estimation

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[91]

H. Chang, Personal communication on exergy analysis of separation processes

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[92]

A. Laghate, Personal communications in March and June of 2003, . Zoetmeer,

The Netherlands: Technip-Coflexip, 2003.

[93]

C. Bowen, Personal Communication in June of 2003, . Houston, TX: Stone &

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[94]

C. Bowen and J. A. Reid, Emerging Olefins Technology, presented at American

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[95]

KBR, Selective cracking optimum recovery ethylene (SCORE) process, :

Kellogg Brown & Root with ExxonMobil, 1999.

[96]

IDEE,
Kraakscherpteregeling
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selectiviteitsbeheering
etheenfabriek, NOVEM, Utrecht, The Netherlands 2000.

[97]

USPTO, Catalytic oxidative dehydrogenation process (US patent 6,452,061), :

Regents of the U. of Minnesota (Minneapolis), 2003.

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M. Huff and L. D. Schmidt, Ethylene Formation by Oxidative Dehydrogenation of

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[99]

ChemicalWeek, LG Develops Catalytic Naphtha Cracking Process, , May 22,

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[100]

VNIIOS, Catalytic pyrolysis of petroleum fractions to produce ethylene and

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S. J. Stanley and K. Kukandar, Improving Ethylene Plant Economics with

Metathesis, presented at AlchE 2001 Ethylene Producer Conference, New
Orleans, USA, 2001.

23

in

Figure 1 Typical Flow Diagram for a Naphtha Steam Cracker1

A. Pyrolysis Section

Naphtha

Pyrolysis Furnace

Transfer Line Exchange

(producing steam)

Cracked gas

B. Fractionation and
Compression Section

Oil/water quench tower

and oil fractionator

Multi-stage compressor, acid removal

and caustic scrubbing

Scrubbed products

C. Recovery and Separation Section

Drying, pre-cooling
and refrigeration
De-methanizer

De-ethanizer acetylene hydrogenation

(acetylene converter) and C2 splitter

De-propanizer
and C3 splitter

Ethylene

Propylene

Butadiene
De-butanizer and
C4 extraction

Backflows to refinery

Fuel gases

Figure was drawn based on [5, 77].

24

BTX
C4 raffinates, C8+
fraction and fuel oil

Crude oil

Natural gas

REF

SEP

OC

Off
gases

Pro-

Gas oil

Ethane

pane

naphtha

LPG

REC

PD

Heavy
oil

DCC

CC

SC

Coal

HP

SR

Ethane

GS

OD

C4 +

OU

Biomass (wood, etc.)

GAS

FP

HTUL

FEM

RCY

FT

Methanol

Ethanol

DH

SC

BATH

Olefins (ethylene, propylene and other products, depending on different situation)

Figure 2 Family Portrait of Olefin Technologies: Current and Future

BATH:
CC:

Bio acid acetone to hydrocarbons (such as olefins) [6];

Catalytic Cracking or catalytic pyrolysis;

DCC: Deep catalytic cracking, etc. (see Table 5);

DH:

Dehydration process (such as methanol to olefins, methanol to propylene and ethanol dehydration); [13, 78];

FM:

Fermentation [79, 80]:

FP:

Flash pyrolysis, sometimes in the presence of methane [80];

FT:

Fischer Tropsch synthesis (using syn-gas CO and H2 mixture to synthesize methanol or other products) [6];

25

CO2

HG

Bio acid and

acetone

Syngas

Naphtha

OM

LIQ

Organic Waste

GAS: Gasification; LIQ: after gasification, then liquefaction [6, 79];

GS:

Gas stream reactor technologies, such as shockwave reactors (Table 5)

HG:

Hydrogenation [6, 79];

HP:

Hydro-pyrolysis (see Table 5);

HTUL:

Hydro-Thermal Upgrading Liquefaction which produces naphtha from biomass feedstock [6, 79];

OC:

Oxidative coupling via ethane [6];

OD:

Oxidative dehydrogenation [6];

OM:

Olefin metathesis, e.g. ABB-Lummus Olefin Conversion Technology, IFP-CPC meta-4 [81];

OU: Olefins Upgrading (conversion of C4- C10) to light olefins, such as Superflex [82], Propylur [83] and Olefins
Cracking [22].
PD:

Propane dehydrogenation [84, 85];

RCY: Re-CYcling pyrolysis using organic waste, such as discarded plastics, used rubber, etc.[6, 79];
REC: Recovery of refinery off gases, which contains ethylene, propylene, etc.. [79];
REF: Oil refinery process. Distillation produces naphtha and heavy oil. Catalytic cracking produces off gases. Cryogenic
and absorption produces ethane and LPG;
SC:

Steam Cracking (conventional);

SEP: Gas Separation Process which produces methane, ethane and propane;
SR:

Steam Reforming of natural gas, a process which in this case produces methanol

26

Figure 3 Simplified Energy Profile of Conventional Steam Cracking and Catalytic Olefin Technologies

Energ

Energy saving!
Process energy required in a pyrolysis
furnace

Activation
Energy

Process energy required in a reactor

In

the

case

of

catalytic

olefin

Activation
Energy

Thermodynamic

Olefins
byproducts

energy

Ethane, naphtha
feedstocks

or

and

other

Progress
Process
27

of

Cracking

Table 1 Estimated Global Energy Use and CO2 Emission by Current Olefin Productiona
World

US

Total feedstock (Million tons)b

300

85

Europe (including new EU member

states and FSU)
90

Breakdown of
Feedstock (wt. %)

naphtha 55,
ethane 30,
LPGc 10,
gas oil 5

ethane 55,
naphtha 23,
propane15,
gas oil 5

naphtha 75,
LPG 10,
gas oil 9,
ethane 5

Ethylene capacity
(Million tons)

110-113

28-30

30-32 (23-24 by
Western Europe)

Propylene capacity
(Million tons)

53-55

16-17

17-18

2-3

0.5-0.6

0.7-0.8

180-200

43-45

53-55

Total energy use

(fuel combustion and utilities
included) (EJ)d
Total CO2 emissione
(fuel combustion, decoking and
utilities included) (Million tons)
a

We estimated energy use on the basis of current production level. The annual growth rate of olefin production for 2003-2004 is assumed at 3.5% [11].

Feedstock, ethylene and propylene production data are based on [86, 87]; US figures come from [24].

LPG is a mixture of ethane, ethylene, propane, propylene, butane and butylenes.

Since the world production between 1994 and 2004 went up from 50 to over 110 million tons of ethylene per year, we estimated that global energy used in olefin production has more
than doubled from 1EJ in 1994 [88]. US. Department of Energy put the global process energy used in ethylene production as 2.6 EJ when the global ethylene production is 93 million
tons in 2000 [89].
e

CO2 emission and process energy use are based on [5, 30]. Decoking is based on [36]. US figures are lower than those of Europe due the fact that heavy feedstock uses more
energy use in total.

28

Table 2 Overview of Two Currently Most Used Conventional Feedstocks in Olefins Production
Ethane
Naphtha

SEC (GJ/t HVCs)

17-21 (typical)
15-25 (maximum)
16-19 (typical)

26-31 (typical) and

20-40 (maximum)
14-17 (typical)

CO2 emission (t CO2/t ethylene)b

1.0-1.2 (typical)

1.8-2.0 (typical)

CO2 emission (t CO2/t HVCs)

1.0-1.2

1.6-1.8

Ethylene yield (wt. %)c

80-84%

29-34% (30% typical)

Propylene yield (wt. %)

1-1.6%

13-16%

Butadiene yield (wt. %)

1-1.4%

4-5%

Aromatics and C4+ yield (wt. %)

2-3%

10-16%

HVCs yield (wt. %)

82% (typical)

55% (typical)

Methane yield (not counted as HVCs) (wt. %)

4.2%

13-14%

Hydrogen yield (not counted as HVCs) (wt. %)

4.3%

1%

Backflows to refinery (wt. %)

0%

9-10%

Losses (due to fouling, coking, etc.) (wt. %)

1-2%

1-2%

SEC (GJ/t ethylene)a

Energy use is based on [24, 30]. SEC here only refers to process energy use in pyrolysis and separation.

Emission is calculated based on [30, 90]. Emission is a result of fuel combustion and utilities, both of which use fossil fuel. Ethane cracking results higher hydrogen and ethylene
content, therefore less CO2 emission per ton of ethylene, than naphtha cracking does.
c

Yield data is based on [30, 31]. Yields are on the mass basis and are all final yields.

29

Table 3 Breakdown of Specific Energy Consumption (SEC) and Exergy Losses in Steam Cracking Process
Ethane
a

Heat of
reaction

SEC

SEC

[26]

[29]
c

23%

Pyrolysis

Steam,
heating &
losses
Fractionation and
Compression

Separation

Naphtha

65%
24%
22%d

31%

15%e

20%

Exergy loss
Our
b
estimation
Fuel combustion and
heat transfer to the
furnace
Heat exchange with
steam, TLEs and heat
loss to flue gas
f
Fractionation and
Compression
De-methanization
De-ethanizer and
C2 splitter
C3 splitter
De-propanization/
De-butanization

75% (or
15 GJ/t
ethylene)

[25]
73%

N/A
27%
19%

25% (2 GJ/t
ethylene in
compression
and the rest
of
separation
processes)

12%
23%
N/A

100%

100%

Total exergy losses

100% or
17 GJ/t
ethylene

2%
10%

Ethylene refrigeration
Propylene refrigeration
Total process
energy use

[91]
[18]

100% (only
pyrolysis
section)

5%
30%
100% (only
compression and
separation)

All energy figures in the table is in primary energy terms. Generally speaking, the contribution of electricity is very small ca. 1 GJ/t ethylene [24]. Steam is produced internally and is
in balance. Almost all process energy (including steam) originates from combustion of fuel-grade byproducts and extra fuel (only in case of ethane cracking). The distribution of
byproduct/fuel energy contents is represented by the percentages in the table.
b
Our estimate on the pyrolysis section is based on [25]. Our estimate on the compression and separation sections is based on [18, 91].
c
Another figure for heat of reaction given in [8] is 21%. Energy use for heat of reaction refers to the energy used to convert feedstocks into desired products.
d
Another figure for compression given in [8] is 16%.
e
Another figure for compression given in [8] is 13%.
f
Data on the exergy loss in fractionation and quench towers is not found. We roughly estimated the exergy loss here is below 0.2 GJ/t ethylene.

30

Table 4 State-of-the-Art Naphtha Steam cracking Technologies sorted by Licensorsa

Technip-Coflexipb

Coil related
furnace
features

Radiant coils
pretreated to reduce
coking with a sulfursilica mixture

De-methanizer
separation
features

Double
de-methanizing
stripping system

De-methanizer with low

refrigeration demand

Front-end demethanizer and

hydrogenation

Gas Turbine

N/a

Ca. 3 GJ/t
ethylene saved

N/a

Offered but no data

N/a

Ethylene Yield
(wt. %)

35%

34.4%

35%

N/a

38%

18 (with gas turbine);

21 (typical)

21 (best)

20-25

No data

SEC
18.8-20 (best)
(GJ/t ethylene)g or 21.6-25.2 (typical)

ABB Lummusc

Linde AGd

Stone & Webstere Kellogg & Brown Rootf

Licensors

Double pass radiant

Twin-radiant-cell
Coil design (straight,
Twin-radiant-cell
coil design; online design (single split) is
small diameter), low
design and quadradecoking reduces 13m (shorter than the
reaction time; very high
cracking
average length 25m)
emissions
severity

De-methanization
Absorption-based
simultaneous mass
demethanization system
transfer and heat
with front-end design
transfer

For the conventional naphtha steam cracking, ethylene yield is typically 30%. HVCs yield is typically 55%.
Technip data come from [31, 92]. According to Technip, SECs vary depending on the processing scheme, extent of heat integration amd climatic conditions [92].
c
ABB data come from[31]; Other yields are 14.4%, butadiene 4.9% and aromatics 14%. The total HVCs yield is 60.7%. Gas turbine data based on [43].
d
Linde data come from [31];
e
Stone & Webster data come from [31, 93, 94];
f
Kellogg & Brown Root come from [31, 95];
g
The average SEC in the industry today is around 26-31 GJ/t ethylene for naphtha cracking.
b

31

Table 5 Catalytic and Alternative Olefin Technologies Using Conventional and Heavy Feedstocks
Gas Stream
b
Technologies

Ethane Oxidative
c
De-hydrogenation

Propane Oxidative
d
dehydrogenation

Catalytic cracking of
e
naphtha

Hydro-pyrolysis of
f
naphtha

Byproduct upgrading
g
(C4-9)

Feed
stock

Ethane and other

gas feedstock

Ethane and oxygen

Propane and oxygen

Naphtha

Naphtha

C4-C9 (from steam cracking,

refinery, etc.)

Olefin
s

Ethylene

Ethylene

Propylene

Ethylene/propylene

Ethylene

Propylene

Ethylene/propylene

React
or

Shockwave,
combustion gas;
shift syngas;
plasma; etc.

Alloy Catalyst Reactor

with hydrogen co feed

Both a stem reformer

and an (oxy-reactor);
or, cyclic fixed-bed

Fluidized bed

Reactors with
hydrogen co feed
but less steam

Fixed or fluidized bed

Riser and transfer line

reactor

N/a

Mordenite zeolite

Zinc and calcium

aluminate based

Zeolite (or various

metal oxides)

N/a

Zeolite

Acidic zeolite

580-650

600-700

N/a

CPP: ca. 35 GJ/t ethylene

and ca. 12 GJ/t HVCs

UOP: propylene yield from

steam cracking is 30% and
HVCs yield 85%

CPP: ethylene 21%,

propylene 18%, C4 11%,
aromatics 15% and HVCs
yield 60%

Commercially available

Lab and near

commercialization

Cataly
sts
Temp.
o
C
Total
energy
i
use

625-700

900-1100

550-600

600-650

785-825

Shockwave:
ca. 8-10 GJ/t
ethylene/HVCs

Dow: ca. 10-12 GJ/t

ethylene/HVCs

Uhde: ca. 8-10 GJ/t

propylene; ca. 8-10
GJ/t HVCs

Yield
(wt.
j
%)

Shockwave:
highest ethylene
yield ca. 90%

Dow: ethylene yield

on the mass basis is
ca. 80%

Uhde: propylene yield

on the mass basis is
ca. 84%

KRICT: ca. 19 GJ/t

ethylene and ca. 10
GJ/t HVCs
KRICT: ethylene 38%,
propylene 17-20%,
aromatics 30% and
HVCs 73%

Blachownia: ca. 1620 GJ/t ethylene and

ca. 10-13 GJ/t HVCs
Blachownia:
Ethylene yield 3640% and HVCs yield
70%

Curren
t
status

Lab

Lab

Commercially
available

Pilot plant

Commercially
available

Catalytic Pyrolysis
h
Process (CPP)
Crude oil, refinery heavy
oils, residues, atmospheric
gas oil, vacuum gas oil

Steam cracking has large, tubular fired furnace; feedstock is indirectly heated; no catalysts use in pyrolysis; temperature 750-1100 C; no hydrogen or oxygen need. Process energy
by the average naphtha cracking technology is ca. 9 GJ/t naphtha.
b
Gas stream data come from [55]. Shockwave data come from [56]. Combustion gas could save 0.3 GJ/t ethylene [96].
c
Per pass ethylene yield on the mol basis is typically ca. 30%. Data is based on [97, 98]. Oxygen production needs 3-4 GJ/t oxygen and this is accounted.
d
Per-pass propylene yield on the mol basis is typically ca. 30-40%. Data is based on [84, 85]. Oxygen production needs 3-4 GJ/t oxygen and this is accounted. Propane steam
cracking has a SEC of 20-25 GJ/t ethylene and 15-18 GJ/t HVCs with the yields of ethylene 42% and propylene 11% [30]. Other similar processes include Oleflex by UOP, Catofin by
ABB Lummus, etc.
e
KRICT data is based on [63]. Also, LG claims ethylene up by 20% yield and propylene yield up by 10% and 10% energy savings on the current SECs of naphtha cracking in Korea
[68, 99]. The SEC 7.5 GJ/t naphtha is assumed based on [67]. Other processes are: AIST ethylene/propylene yield together 60-70% and 20% energy savings per ton of ethylene and
propylene is claimed [40, 67]. VNIIOS ethylene yield 30-34% and propylene yield 18-20% [100]; Asahi ethylene 22%, propylene 20-40% [34].
f
Hydro-pyrolysis was used in Blachownia Chemical Works in Poland, which claims a 20% increase of the average ethylene yield and ca. 30% less energy use [59]. The technology is
not offered by major licensors.
g
Olefins upgrading data is based on [82] and [22]. A similar industrial process is Metathesis [101]. Metathesis is an olefin conversion process, which in this case converts ethylene
and butane-2 to propylene [13]. It is basically an extension of naphtha cracking to increase the yield of propylene.
h
CPP data comes from [60, 61, 94]. The SEC 7.5 GJ/t feedstock is estimated. A review of several similar processes can be found in [64].
i
Typically, current ethane cracking has an average SEC 17-21 GJ/t ethylene and 16-19 GJ/t HVCs. Naphtha cracking has a SEC 26-31 GJ/t ethylene and 14-17 GJ/t HVCs. The
state-of-the-art naphtha cracking has 20-25 GJ/t ethylene and 11-14 GJ/t HVCs.
j
Typically, ethane cracking has 81% ethylene yield. Naphtha cracking has 30% ethylene and 15% propylene yield.

32