Model-based, thermo-physical optimisation for high olefin yield in steam cracking reactors

• Published in: Chemical engineering research & design Vol. 88; no. 10; pp. 1305 - 1319
• Main Authors: van Goethem, Marco W.M., Barendregt, Simon, Grievink, Johan, Moulijn, Jacob A., Verheijen, Peter J.T.
• Format: Journal Article
• Language: English
• Published: Amsterdam Elsevier B.V 01.10.2010; Elsevier
• Subjects: Applied sciences; Chemical engineering; Ethane; Ethylene; Exact sciences and technology; Fracture mechanics; Mathematical models; Olefin yields; Olefins; Optimisation; Optimization; Reaction kinetics; Reactor synthesis; Reactors; Steam cracking; Synthesis; Reactor synthesis; Olefin yields; Optimisation; Steam cracking; Reaction kinetics; Temperature distribution; Mixing; Cracking; Kinetics; Reactor; Modeling; Optimization
• ISSN: 0263-8762
• DOI: 10.1016/j.cherd.2010.02.003

The steam cracking practice seems to have reached a stage of maturity which makes it increasingly difficult to improve ethylene yield. In order to determine if there is still scope for yield improvements it is helpful to know what the optimal reaction conditions for the steam cracking process are. This work presents a model-based synthesis approach that enables to determine the optimal thermal and physical reaction conditions for a particular feed, maximising olefin yield. A distributive reaction-mixing synthesis model has been combined with an industrially proven large kinetic scheme, SPYRO ®, which contains over 7000 reactions between 218 molecular and 27 radical species. The model combination allows optimising the following degrees of freedom with respect to olefin yield: feed distribution, product removal, macro-mixing, along a reaction volume coordinate. The reaction temperature upper limit is put at 1300 K, exceeding the current (metallurgical) bound by 100 K. For the cracking of ethane a linear-concave unconstrained temperature profile with a maximum temperature of ∼1260 K proves optimal which is lower than allowed while all ethane should be supplied at the entrance of the reaction volume. For propane and heavier feedstocks an isothermal profile at the upper temperature bound, with dips at the beginning and the middle of the reaction coordinate is optimal, while distribution of the hydrocarbon feed along the reactor coordinate results in higher yields. The theoretical maximum achievable ethylene yield for ethane cracking is found to be 66.8 wt% while in conventional cracking typically 55 wt% is considered to be the maximum value. This optimum is constrained by the pressure which is at its lower bound. The resulting residence time is in the same order as with current technology for ethane cracking. For the more heavy feedstocks these times are one order of magnitude smaller which will be a challenge for designing.