Process Economics Program Report 29G
Published: April 2001
The prospects for ethylene demand remain strong but much of the future increase in
production capacity may come from incremental enhancement of existing plants, rather than from
new "grass-roots" production facilities. Steam cracking for ethylene originated as early as the
1920s and was commercialized in the 1950s. The importance of ethylene continues to drive
research and development of this technology along with the exploration of nonconventional
technologies in order to achieve higher yields of olefins and lower capital and operating costs.
However, as recently discussed in PEP Report 29F, Ethylene by Nonconventional Processes
(August 1998), it is unlikely nonconventional processes will replace steam cracking for ethylene
production in the foreseeable future. This study examines potential improvements in
conventional steam cracker operations with emphasis on improving the competitive edge of
existing plants.
Ethane, LPG and naphtha are the dominant steam cracker feedstocks. Natural gas
condensate is abundant in North America and the Middle East while naphtha is commonly used
in Asia and Europe. Since the 1970s many new ethylene plants have been built with feedstock
flexibility. In PEP Report 220, Ethylene Feedstock Outlook (May 1999), SRIC currently projects
that generally ethylene feedstocks supply will be adequate over the next decade even
considering that the demand for ethylene is increasing twice as fast as petroleum refining (4-
5%/year versus 2%/year).
Significant technological developments exist for all sections of the ethylene steam cracker
that could be implemented in plant revamps. Examples include new large capacity yet compact
and efficient furnaces; coke inhibition technology; larger, more efficient compressors;
fractionation schemes; mixed refrigerants; and advance control and optimization systems.
This report should provide a useful overview of process
developments since PEP Report 29E, Ethylene, issued in 1991 for
people involved in research and development or planning investment in new ethylene
plants as well as those involved with planning, managing, operating, and designing
existing plants.
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