1 Ethylene Plants

< >1MAN Turbo AG

MAN Turbo Compressors and Steam MAN Turbo Compressors and Steam Turbines for Ethylene PlantsTurbines for Ethylene Plants

May 2010May 2010

< >2MAN Turbo AG BuchkremerTurbomachinery for Ethylene Plants 29.04.2010

References

Application References References for Manufacturing of Large ImpellersReferences for Resulting Dimensions and WeightsReferences for Large Steam Turbines as mechanical drive


Casings in Service

38 Cracked Gas 28 Propylene / Propane

Refrigeration27 Ethylene / Ethane

Refrigeration 8 Recycle Gas 3 Other Service

28 Steam Turbine Drivers

132 Turbomachines in Ethylene Plant Service

Ethylene PlantsApplication References

Latest Reference: Complete Set of Machines for a has been500 kta Ethylene Plant delivered


Schwechat Refinary, Austria, 2005

350 kta Extension of Ethylene Plant


350 kta Extension of Ethylene Plant

Schwechat Refinary, Austria, 2005


Tiszaujvaros Kombinat, Hungary, 2004

250 kta Ethylene Plant - LINDAETH



250 kta Ethylene Plant - TISKO



250 kta Ethylene Plant - TISAETH



250 kta Ethylene Plant - TISPROP


600 kta Cracked Gas Compressor no. 1

TERNKO 4

LP RH100/02D RH100/02D MP RH100/04ST DK080/170

flow 165 504 m3/hp1 1.4 barp2 14.8 barspeed 5 200 rpmcomp. rated 20 170 kWturbine rated 22 187

DOW Benelux LHC-3 Terneuzen, NL, 2000


TERNKO 5

HP RH040/03ST DK035/080

flow 13 044 m3/hp1 11.7 barp2 38.4 barspeed 12 409 rpmcomp. rated 6 987 kWturbine rated 7 686 kW

600 kta Cracked Gas Compressor no. 2



600 kta Ethylene Refrigeration Compressor

TERNAETH

Type RH063/06ST DG040/040

flow 26 820 m3/hp1 1.04 barp2 16.0 barspeed 8500 rpmcomp. rated 6 780 kWturb. rtd 7 458 kW

T1 -102°CSidestream (480%) @ 4 barExtraction (43%) @ 10.3 bar

!!



600 kta Propylene Refrigeration Compressor

TERNPROP

type RH100/06ST DK080/170

flow 88 126 m3/hp1 11.7 barp2 38.4 barspeed 4 058 rpmcomp. rated 16 481 kW



600 kta Steam Turbine Driver

TERNKO 4 /TERNPROP

ST DK080/170

p1 91 barpex 13 barp2 0.1 barRated 22 187 kW

Identical steam turbine for TERNKO 4 and TERNPROPonly 1 spare rotor required



Cracked Gas Compressor

MOSSKO

LP RH100/03DMP RH100/06HP RH050/08

flow 111 850 m3/hp1 1.5 barp2 38.9 barspeed 4 670 / 8 550 rpmcomp. rated 28 000 kW

Gas Turbine driven (Frame 5)with helper steam turbineintermediate gear box

Esso Mossmorran, GB, 1981


Propane Refrigeration Compressor

MOSSPROP

LP RH112/02DMP RH112/02DHP RH112/02

flow 144 223 m3/hp1 1.1 barp2 12.6 barspeed 3543 rpmcomp. rated 28 000 kW

3 casing design

Esso Mossmorran, GB, 1981


Delivered in late 2009

ILAM 500 kta Ethylene Plan


ILAM Cracked Gas Compressor


ILAM Cracked Gas Compressor

Ø 500 kta Cracked Gas CompressorØ MAN TURBO condensing steam turbineØ welded compressor casingsØ HP casing horizontally split with hydro

test pressure of 78,3 bargØ compressor nozzle loads 3 x NEMA


ILAM Propylene Compressor


ILAM Propylene Compressor

Ø MAN TURBO condensing steam turbineØWelded Compressor CasingØ compressor nozzle loads 3 x NEMA


ILAM Ethylene Compressor


ILAM Ethylene Compressor

Ø MAN TURBO condensing steam turbineØ stainless cast steal compressor casingØ compressor nozzle load 3 x NEMA


Cracked Gas Compressor (CGC)Ethylene RefrIgeration Compressor (ERC)Propylene Refrigeration Compressor (PRC)Binary Refrigeration Compressor (BRC), for ABB Lummus instead of ERC

ST ST

Propylene refrigerationcompressor

Ethylene refrigerationcompressor

Amine treatmentCaustic washing

ST 1 1 2 3 4 5

30 - 40 bar

Drying

Cracked gas compressor

Cold box- 50 °C - 105 °C

Compressor Casings


Casing Design ExampleRH090/06 – 39 barg (I)

• Largest fabricated casing built by MAN Turbo to date (~2.6 m)

• 5 nozzle design


Casing Design ExampleRH090/06 – 39 barg (II)

• Initial analysis shows possible leakage • shift bolt pattern closer to shaft bore location

• high local peak-stresses in support strut region • new strut design with less stiffness in the surrounding regions incl. experimental verification

⇒Hydrostatic pressure test successful – First Time Right

leakage path

shift bolt hole

strain gauge measurement at support strut


• All surface stresses below yield• No peak stresses on outside surface• Tightness confirmed

1.3 Mt/a CGC-HP:Surface stresses

⇒ CGC-HP Casings with horizontal split available even for large Ethylen Plantswith high discharge pressures (up to 66 bar water test)

Current ImprovementsStudy of 66 bar Charge Gas Compressor (HP) with Horizontal Split Casing

Casing Scaling:Ethylen 1 Mt/a → RH100 (Impeller ~ 950 mm)

Ethylen 1,3 Mt/a → RH110 (Impeller ~1100 mm)

Modell:

Results:


Ø 3-D and 2-D impeller

Ø cover disc brazed or welded

Ø 40° / 50° / 60° outlet

Ø A 182 (X3CrNi13-4)

Ø 17-4 PH

Impeller Design


NACE MR0175

H2S-Anteil CO2-Anteil Druck (absolut)[Mol-%] [Mol-%] [bar]

EINGABEWERTE: 0,006 0,045 18,6

SSC Regionen nach NACE (Stand heute)

3

3,5

4

4,5

5

5,5

6

6,5

7

0,00001 0,0001 0,001 0,01 0,1 1 10p H2S [bar]

pH

>100°C20°C

Re gion 0

Region 3

Region 2

Region 1

1

10

100

10001 10 100 1000 10000 100000 1000000

Mol-% H2S in gas

Tota

l abs

olut

e pr

essu

re [b

ar]

0,0001 0,001 0,01 0,1 1 10 100

ppm H2S in gas

Sulfide Stress Cracking Region

SSC Regionen nach NACE 2002

Ausdruck DiagrammSCC Regionen nach NACE (Stand heute)

Ausdruck DiagrammSCC Regionen nach NACE (Stand 2002)

MAN Diesel & Turbo selects impeller material according the latest NACE -Standard


Compressor RASRA 1-2Type AR115/10Steam Turbine Driven

Year of Order 2003Suction Flow 690,000 m3/hSuction Pressure 1.000 barDischarge Pressure 8.3 barPower 55600 kW

Large ImpellersReference – RASRA

44 Impellers with a diameter of 1600 mm or larger


RIK 140

Large Impellers Reference RIK 140


Compressor fouling

Basic causes for compressor fouling:

- Feedstock:High valency hydrocarbons and untreated gas components tend to polymerization.

-Temperature:The rate of polymerization increases rapidly at temperatures greater than 85°C (depending on feed stock)

- Pressure:Fouling increases almost proportionally to pressure

- Surface finish: smooth surfaces are less prone to fouling


Polymerized deposits

volute diffuser


Fouling deposits


Production: At a given speed the discharge head / volume flow characteristic is lower. The efficiency curve tails off accordingly. Increasing the speed can counteract this, howeverthe original volume is now achieved at a less favourable efficiency level and at a higher temperature.The speed of polymerization increases and the fouling process accelerates as a result.

Consequences of polymerized deposits in the compressor for the operator with respect to the efficiency rating and availability

head

drop

of

effic

ienc

yte

mpe

ratu

rin

crea

se

100% point

speed compensation

clean compressor atnormal speed

when fouling ispresent

Clean compressor atnormal speed

when fouling is present

clean compressor atnormal speed

actual suction flow

∆V

constantdischargepressure

85°C

95°C

Consequences of polymerization


Washing system example 3

Water injection in the return channels is used currently.

To optimize

- nozzle type- flow quantity- configurationa CFD engineering is put into execution.


Ø cast steel casing (low temperature)

Ø impeller inline arrangement

Ø internal side stream

Ø DGS in tandem arrangement

Design Refrigeration CompressorTERNPROP - Cross Section


Sideloads

Ø location upstream return channel allows forproper mixing of the two streamsØ cast design allows for very large side streamwith only small increase of bearing span


Example LP-Compressor of Cracked Gas Train BP GrangemouthModified Parts: Shaft (Red)

Impellers (Blue)Diaphragms (Yellow)Labyrinths (Green)

ESSO / EXXON MOSSMORRAN, GBOriginal Delivery 1981CG Compressor Increase by 27 %(1988)Ethylene Compressors Increase by 26 % (1996)Propane Compressor Increase by 39 %(1996)

BP CHEMICALS GRANGEMOUTH, GBOriginal Delivery 1991CG Compressor Increase by 25 %(1997)

SOW / BSL BOEHLEN, GEROriginal Delivery 1972Refurbishment andConversion to Dry Gas Seals (1994)Cracker Capacity Increase by 35 %(1996)

Experience in Ethylene PlantsCapacity Increase


References for Resulting Dimensions and Weights

Works assembly of a large moduls (500 tons) for a GTL plant


References for Resulting Dimensions and Weights

§ Field installation of an 80 MW compressor train for a GTL plant


Steam TurbinesTypically 110 bar, 530 °C or 75 bar, 470 °C

45 bar

18 bar

Turbine ERCTurbine PRC

Turbine CGC


Steam Turbine package

Ethylene Plants –Large Steam Turbines


ü single source supply, compressors and steam

turbines from same factory

ü design generally acc. to API 617 / 612

ü MAN Turbo has experience with ethylene plants

for various licensees

ü MAN Turbo has as well recent references

ü MAN Turbo has large train capability

in factory and test bed

ü Up-rating and service capability

MAN Turbo Competence in Ethylene Plants - Conclusion

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1 Ethylene Plants