Webinar Steam Cracker Optimization Tips for Improving Efficiency and Reducing Costs

welcome everyone thank you for joining us on today's webinar steam cracker optimization tips for improving efficiency and reducing costs I'm alicyn sterling a marketing manager for Emerson micromotion I'm pleased to welcome you to our first webinar in the Emerson flow expert series before we begin today wanted to take a moment to acquaint you with your webinar console environment you'll notice that on your screen you'll have a presentation window on the left side a Q&A chat window in the upper right hand corner media player controls from the bottom and then in the middle there's a resource box with links to related content that you can view and download during the event you can also resize move or minimize any of these windows during the event to set your viewing preferences and at the bottom of the display you'll notice a row of icons that gives you some added capabilities where you can choose to share this webinar obvious any social channels that you like you can also through the contact us button request a visit from one of our flow experts throughout the webinar we encourage you to interact with our speaker by typing any questions that you have using the chat panel and we will be answering questions both live and at the end of the event we are also recording today's session and we will make the link to this recording available to you 24 hours post event via email we will also be including in that email to related resource links that you see in your console and today on our webinar we are lucky enough to have joining us Tonya Wyatt a global chemical industries marketing manager for Emerson micromotion Tonya holds a bachelor's degree in chemical and petroleum refining engineering from the Colorado School of Mines she has been with Emerson for 15 years in a variety of roles she is specialized in gas applications including ethylene and ethylene production for several years prior to joining Emerson Tania worked at a chemical company in Texas doing R&D working with polymers she enjoys traveling both for work and leisure and hesitated over 24 country welcome Tania Thank You Allison first of all I just want to say that we have a rather wide range of participants on the call today a so I apologize of some of this background information is kind of a review of what some of you already know but hang in there and hopefully we'll be able to provide some good value for everyone so like Allison said I get to travel a lot for work and I've had the privilege of visiting a lot of chemical companies all around the world I've noticed that there are some scenes that are pretty universal as far as chemical industry challenges those are concerned over improving efficiency and reducing costs I think that has been around for a long time and is pretty universal even outside of the chemical industry and of course there's always an emphasis on safety and environmental compliance more recently I've noticed that there seems to be a growing concern around retaining talent in the workforce as well we're going to be having a series of these webinars and we'll talk about a lot of these different areas of concerns today the webinar is really going to be focused mainly around that first challenge of efficiency and cost reduction so during this webinar we're going to discuss how to optimize the steam to hydrocarbon ratio and we'll talk about some of the benefits of being able to do that we'll talk about how to improve custody transfer measurement and during this webinar I'll share a story about a customer who implemented our flow technology for their seem to hydrocarbon ratio controls and they were able to improve their efficiency by two percent we'll also talk about a chemical company who used micromotion meters for custody transfer of ethylene and they were able to prove after they had the meters been for two years of service that the meter was less than a tenth of a percent different than the laboratory prover then we'll wrap up with some final thoughts I think everyone is concerned about production costs and maintaining profitability while maintaining a safe workplace and ensuring reliable and repeatable data to make better operational decisions you're probably making a lot of improvements in many of these areas that are looking to do it better we want to help your bottom line Emerson can help you maintain a safe workplace and reduce costs associated with safety health and environment with our advanced diagnostic capabilities we can help you meet environmental standards while providing reliable data to help make the right operational decisions we can also help to minimize on plant shutdowns through better process insight and control which leads to lower maintenance costs and increase availability we can help to improve process efficiency and through accurate measurement and control we can help reduce the impact of variability of feeds to improve consistency and production which leads to improve throughput and better quality control with Emerson is your measurement partner we can help you increase ethylene yield and throughput improve plant availability reduce energy costs and ensure safety and compliance we've helped a lot of different petrochemical and you're finding customers have success in these areas we'd love to help you too and we can do that by combining some of our innovative technologies with many years of field experience we've been successful doing just that same thing in some of these areas from the hot section which includes measuring and optimizing fuel gas consumption it includes the steam to hydrocarbon ratio and optimizing that flow control and optimization through the D coking process and the measurement of inhibitors in the quenched our applications mass balance especially around the acetylene reactor and distillation columns and custody transfer measurement of raw materials and final products and finally process control for some of the downstream products made for ethylene this graphic is kind of cool because it reminds us of how much ethylene really ends up being a part of our day-to-day lives as you know ethylene is an important building block for the chemical industry and many final products are derived from ethylene some of those products are poly ethylene ethylene glycol ethylene oxide vinyl chloride monomer so that used to be makem PVC Cyrene polystyrene and a bunch of other products all of these downstream processes have measurement opportunity improvements and we have examples of them demonstrated successes in these areas unfortunately we won't have time to cover all of those today so let's go back and start by talking about the furnace section of the cracker here there are three critical goals the first is to optimize the steam to hydrocarbon ratio and that will help you optimize the conversion of the feedstock while minimizing coking of the furnace tube the second is to do this while using the minimum amount of fuel gas and finally you want to ensure that when it is time for decoding the process is completed in the most effective manner possible so moving beyond the furnace section to recovery the main goal here is to separate the products mass balance is important in this area as well as custody transfer of the end products for the sake of time during this webinar we will really be discussing two of those applications will talk about optimizing the steam to carbon ratio in the furnace section and we'll talk about custody transfer of the final product as you may already know there are essentially four process streams in the front of section during normal operation those are the three seeds the first one being fuel gas for combustion that gets mixed with air the second being the hydrocarbon feed which is typically NASA or ethane and the third is the dilution steam there's also cracked gas coming out of the furnace there are two primary variables on the furnace section that are controlled for optimization of the process these variables are the temperature of the craft gasps which is typically called the coil outlet temperature or sometimes shortened to co t and the composition of the cracked gas during normal operation of the furnace the goal is to optimize the yield to produce the highest value of product and to minimize the coking rate in order to do this the steam the hydrocarbon ratio must be very carefully controlled steam is added to reduce the temperature for the cracking and to help prevent rapid coking however if there's too much steam it lowers the energy efficiency and the productivity when there's too much steam it also requires excess quench reagents it diminishes the amount of hydrocarbon that can be carried through the pipelines and this leads to higher velocities and more pressure loss every hydrocarbon feed has an ideal steamed a hydrocarbon ratio that is optimal for that feed and you can see what that number is in this table here from talking to a lot of different customers we found that being off from the optimal ratio by as little as point zero one can cost three hundred thousand dollars a year in Los fields for every million times per year capacity similarly if you want to reduce the coking rate the coil outlet temperature has to be carefully controlled we found that a deviation of just one degree away from the optimal temperature can cost up to two million dollars per year per million tonne per year capacity as i mentioned accurate measurement of the hydrocarbon feed is required to make sure you have the appropriate steam to hydrocarbon ratio and may detain tight control of the ratio to improve the throughput and the guild of the furnace so traditionally a lot of orphans and turban flowmeters have been used to measure these important points traditional orifice plates can be difficult to install they can have multiple potential leak points and they can cause some maintenance issues especially with the potential for plugged impulse lines they also have multiple sources of uncertainty and the measurement may not be as accurate as it could be or even as you think it is turban leaders can be difficult to maintain jutra moving parts turbo users often start out quite accurate but they wear over time and lose their accuracy and can also cause maintenance issues and downtime in some cases people are using coriolis need meters on main feed lines where there's a lot more flow because they know this measurement point has high value but most of the sub lines are typically using orifice and turban meters you know it's easy to consider the acquisition cost of flow meters and think it's too expensive to go with Coriolis or vortex but don't forget the full cost of ownership and the impact of coking rates and throughput keep in mind too that these reactions are all math based so mass measurement can be valuable here micro motor meters offer superior performance under real-world conditions the elite flow meters provides the best measurement for the hydrocarbon c to help optimize the ratio and improve the conversion while reducing coking they offer up to a quarter percent mass flow accuracy for gas which is unmatched and that accuracy applies over a really wide range of flows plus micro mission offers advanced diagnostics that can give you more confidence that your meter is working correctly and you don't even have to interrupt the process to find this out for safety instrumented systems micromotion also offers both certified and proven and use devices that are good for up to fill three applications our latest trans center is a model 5,700 also has advanced diagnostics that make it easy to capture great zero and it provides automatic data logging give you giving you more insight into your process the transmitter was designed around completely improving the user experience and it has a lot of great features I don't have time to go into all of those today but if you do want more details feel free to use the contact widget on the bottom of your screen and request some additional information about that new product so we've talked about having the correct steam to hydrocarbon ratio and we've talked about the hydrocarbon measurement of that part of the ratio so let's talk a little bit about the same measurement now in traditional designs or fifth place with n pulp wines are typically used for this measurement unfortunately the recycled steams can contain a lot of fine coke particles that can coat or plug the impulse piping it not only results in some unreliable measurement of the steam but it also requires significant maintenance rosemount 8800 vortex meters are ideal for measuring the steam into the furnace they offer high accuracy which is important but even more importantly they have a unique allcast design with no crevices or gaskets this means that the coke lines don't cause any issues with the measurement and it eliminates the maintenance costs associated with plugged in pulse would in addition rosemount offers a dual for text version that can be used for this application the dual cortex can either be used where you have one of the meters being used for process control and the other one used for safety loop or you can use the duo vortex for redundancy in the safety loop in situations where you need like two out of three voting for safety a quad vortex is also available that gives three measurements for the system safety system plus you would have one additional measurement left over that you could use for basic process control one really nice feature about both of these meters is that you only have a single set of straight rim so installation costs are reduced as well rosemount is the only manufacturer with the non plugging vortex design and it really has proven successful on a lot of these furnace applications we'll take a look at an example here this example is of a success at shell more dykes which is in the Netherlands gel is having some problems with high maintenance costs and a lot of reduced plant availability because of the fines and the steam causing plugging of the end pulse lines if they're 40 50 meters so they were looking for some other type of solution that would help them with their maintenance costs and really be easier for them to use they installed 20 rosemount 8800 dual cortex meters on the furnace steam lines and they immediately eliminated the need for cleaning with Rose house unique all welded body design with no crevices or process feels the slides were like no longer an issue at all for them even after eight years they haven't had to remove the sensors for cleaning since then shell has actually retrofit other furnaces and the rosemount vortex has become a standard standard metering solution for this application they saw a two percent efficiency improvement and improve plant availability they also use the dual vortex meter so that one device could be used for process control and the other for the SI absolutes and this saves them significantly on their installation costs for more information you can download and read the proven results it's on your resource list there's a little window for that and it's called the dual vortex steam ethylene paper so if you want to click on that you can download it and look at it later so we've talked about steam and hydrocarbon ratios and that part of the cracker but before we move past the hot section I did want to mention that fuel gas d coking air and inhibitor are also areas where we've seen improvements through using different flow technologies from Emerson if you're interested in learning more about these applications you can have a local salesperson discuss them with you or you can download this article that was published in the hydrocarbon processing but discusses best practices for measurement of an ethylene furnace again you can find it in your resource list and it's listed as ethylene hydrocarbon processing article so the other application example for ethylene that we will talk about today is regarding custody transfer points these may include raw materials or final products there are several custody transfer points in an ethylene plant from the raw materials and the fuels coming in to the final products leaving the plant accurate measurement is important for all of these buying and selling points there's also some of the internal consumption points that can be custody transfer applications things like methane or pie gasps that might be purchased from another part of the process there are many final products that get sold to other users including propylene and ethylene and ethylene can be found in the gas phase dense phase or liquid sometimes the butadiene and the hydrogen are also separated and sold as well each of these dreams represent values and getting accurate measurements may be worth a lot more than you think we're going to take a quick break for a second because I would like to get some information from you I would like to put forth the question of what kinds of technologies are you guys currently using to measure ethylene that could be in the liquid phase gas phase dense phase but if you don't mind clicking on what technology and go ahead and hit submit we'll give you a few seconds here to submit some answers so we sponsors so far so we'll go ahead and take a look at the result and I with one slide too far so bear with me a moment okay it looks like a lot of people actually are using Coriolis leaders so that's good news and we'll talk a little bit about some of the benefits of using Coriolis and also why not all Coriolis leaders are made exactly the same and so some of the benefits of using my promotion meters specifically a lot of you are also using DP and turban meters which really have been kind of the traditional historic version of measurement for a lot of these points so some of the 10 associated with these custody transfer points are really measurement difficulties for the fluids themselves for example there are a lot of products within an ethylene processing unit that are high vapor pressure liquids cryogenic fluids or even supercritical fluids each of these have their own measurement challenges high vapor pressure liquids like propane and butane have a tendency to vaporize in the line and so as you have pressure drops along the line you get from flashing associated with that and you have two phase flow which makes measurement really difficult ethylene can be found in the dense or super critical phase and when it is found in that phase you can experience large very sudden changes in density with just small changes in pressure and temperature so that makes it difficult to convert from volume flow to mass flow ethylene is almost always bought and sold in math so direct mass measurement offers a lot of advantages most of these applications have traditionally used or fifth metering but many historic supercritical ethylene measurement points have also used turban meters along with a density meter there have been studies by consortium of customers using a comparison between turban meters with density meters versus Coriolis leaders and we have those studies available but basically concluding that the coriolis leader would be a lot simpler in the application and provide better accuracy so a lot of these different traditional measurement devices will have poor installed accuracy and they could also have higher maintenance and additional uncertainty associated with those density conversions to mass micrometers measure mass flow directly which eliminates a lot of these challenges however not all Coriolis leaders are equivalent on these difficult applications especially when it comes to two phase flow capabilities my promotion elite meters offer direct mass metering all these products like we mentioned are traded on a mass basis they offer multi variable measurement so micro mission has superior mass flow and density measurement capabilities under real-world conditions so when your pressures and temperatures aren't the same as your lab environment also the volumetric output can be really useful in ensuring that tanks aren't over filled even if the transaction is completed in math we provide maintenance-free operation even under heavy flashing and two phase flow conditions and finally smart meter verification is a feature that enables you to check the meter integrity periodically and minimizes you're proving requirements without interrupting the process at all we'll take a look at an example application for custody transfer of ethylene there is a pipeline company in the Gulf Coast region in the u.s. that was sewing ethylene to a petrochemical company so that they can make polyethylene they were doing this transaction using traditional BP meters the DP meters have limited turndown capabilities and the contract between the supplier and the buyer was written in such a way that if the flow rate dropped below a certain pressure draw the supply would be shut off because the accuracy of the measurement wouldn't be suitable for custody transfer so even when the DT meter was working in the optimal VP range the accuracy of the system was estimated to only be about three-quarters of a percent the line was fairly small the amount of ethylene transferred in the line was between about nine and twelve million pounds per year or four to five and a half million kilograms per year both the buyer and the seller also wanted to be able to prove the integrity of the sensor without shutting down the production after looking at different technology choices the companies agreed to use a micro motion elite meter with smart meter verification so that they could periodically check the health of meter in addition they continuously monitored some of the online health registers through their SCADA system and automatically tied any of those alarms that they would see on the meter to a notification system that would send a text or an email to their technicians after two years of service and running smart meter verification monthly during that time they had a plant turn around and they were able to pull the meter from the line and send it in for proving they found that the meter had a minus point zero six percent difference from the lab premar and this is phenomenal considering the uncertainty of the meter plus the uncertainty of the lab provers to have something matched that closely so based on those results they decided to allow smart meter verification to become their standard operating procedure for proving the meter integrity between the plant turn around they also ended up reducing the frequency of the smart meter verifications quarterly instead of monthly based on their excellent results in addition to that ability to check the meter they were able to get accuracy improvements to plus or minus point three five percent instead of three quarters of percent and they reduce maintenance costs this resulted in a payback of just four months for the entire system so more than just the meter they also did an installation of new pipeline and a whole major skin for more information there's kind of a longer version of this story that was presented at the Texas AM instrumentation symposium available if in your resource list as petrochemical lost production white paper or if you're interested in the Cliff Notes version or more bite-sized version you can click on the ethylene proven results so strappings up with Emerson as your measurement partner we can really help you increase your ethylene yield and throughput improve plant availability reduce energy costs and ensure safety and compliance we've helped many different petrochemical and refining customers have success in these areas we'd love to be able to help you as well with the combination of our innovative technologies and Phil's experience we look forward to helping you improve your bottom line we really would like to have an individual talk with you if you would be interested in that and get into a little bit more detail I hope you found this information to be meaningful before we get into the question and answers I do have one more quick question for you for our poll we're planning on doing more of these webinars in the future and we're interested in which topics might be most beneficial to you so if you could just click on your opinion will just give a few seconds here for everyone to take a look at that okay it looks like we have quite a few responses so let's go ahead and take a look here so it looks like there's actually interested in all of the different areas and the most prominent being the cost effective options for environmental compliance so these are definitely some topics to be on the lookout for in the future we'll try to address some of these as we as we have a chance so thank you again for attending this webinar we do have some time for questions now and please remember that if we don't have time to get you to your questions you can always use the contact me form to request a follow-up visit or you can send an email to me directly my email is listed on the screen so I'll turn it over to Alison now to lead the Q&A session thanks so much Tanya this is a really great presentation with tons of really great information so it's time you mention we're not going to open it up for any questions so please feel free to type in your questions in the Q&A chat panel and your console and tanya leigh more than happy to answer them and as she mentioned it you know we don't get your question or if you prefer you're more than welcome to email Tanya directly and we look forward to chatting with you about your needs so Tanya it looks like we've got a couple questions coming in right away here yeah so let me go ahead and get started on those it looks like the first question is around special calibrations is there any kind of special calibration required for ethylene it's a really good question actually all of our Coriolis meters and the coriolis leaders are used for liquids gases flurries a bunch of different kinds of fluids all of them are calibrated in the factory using water and that calibration is Miss traceable and because we're measuring mass that calibration is actually transferable to all other types of fluids including gases we actually have papers that helps explain that transfer ability they are available on our website if you go to ww mi chiamo ENCOM flash gas there are white papers that explain how that works and again if you want more information on it feel free to contact me it looks like there's also a question here around custody transfer so we talked about ethylene custody transfer and the question is what custody transfer approvals do the micromotion leaders have so my promotion has a lot of different approvals around the world in the u.s. probably the most common custody transfer approval we see is way to measure approval and that one applies to liquid applications but if you're talking about gas applications it's not really a custody transfer approval that AGA 11 is kind of the standard used in the USA and in other parts of the world as well but but AG a report number 11 talks about using need coriolis leaders for natural gas applications and micromotion definitely meets all the guidelines in hea 11 so that's probably the standards that use most often for gas but again around the world there's others like nmi measurement canada and i should probably also mention since we're talking about ethylene that micro-millimeters also meet api chapter 5 point 6 which is about measurement of liquid hydrocarbons but it also includes dense phase of fluids like ethylene so that one is probably the most relevant to that peter also measurement canada i think i mentioned that but we do have that for elite meters up to 4 inch meters on gas applications so good to note that as well um it looks like somebody here is all so asking we didn't really talk about it a lot that we mentioned briefly about fuel gas to furnaces looks like they're saying that they have some changing composition of fuel gas I think that's pretty common with refinery fuel gas if that's what you're using and so we definitely can help out with reducing some of the impact of that variability by measuring directly the math associated with that fuel gas as opposed to the volumetric measurement we end up being able to reduce some of the variability and we have a lot of information that talks about that probably not a good idea to get into it too much here today but we also have some specific gravity meters that are able to look at the specific gravity of the fuel gas and kind of be able to tell you a little bit about their energy content and so we can optimize the combustion control and the efficiency and that way too so great question so one of the questions here is around response time of vortex leaders and I don't know the specific answer to response time for the 8800 more text neater but that is definitely something that we can look into and i will reply to the person who asked that question directly all right well thanks so much Tanya again if you have any questions that we haven't answered please don't hesitate to directly email tania tania da y to emerson calm and she will be more than happy to fall off here if you have any last questions that you can pop them in right out of your Q&A window humble so we just got another one hopping in here yeah the question is around any new ethylene plants being built in North America and there definitely are some plants coming up we have been involved with kind of specking out some of those plants in the future instrumenting some of them and I think there's mixed feelings Justin general around how many of the ethylene plants that were originally planned are going to go forward I think a lot of people definitely with the oil prices changing and everything the advantage for ethane feedstocks is not as much as it used to be but still an advantage and so most of the ethylene projects that were in place are continuing on and some of the ones that were kind of planned and not yet permitted may be delayed a little bit but the general feeling in the industry is that they will continue to be building those ethylene plants so great questions awesome well thank you again Tanya for all this great information this is a reminder you know everyone there's that contact us button at the bottom of your console or of course you can always email Tanya directly and we thank you all for joining us today and to all these great questions again we will be sending out a link to this recording tomorrow in an email along with links to all these resources that you see in your console on behalf of our c'mon yo why it's called everyone here at Emerson mex motion we thank you again for joining us today and taking the time to view a veteran presentations have a great everyone thank you you

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