Ethylene Cracker Industrial Case

Innovative tools,

methods and indicators

for optimizing

the resource efficiency

in process industry

“This project has received funding from the European Union’s Seventh Programme for research, technological

development and demonstration under grant agreement No 604140”

DCI Tarragona Ethylene Cracker Industrial Case

Alfred Arias Innovation Support Leader Dow Chemical Ibérica S.L.

SPIRE Workshop on Resource Efficiency Monitoring, Assessment and Optimization

Brussels 27th January 2016

Dow Chemical Company 2

SPIRE Workshop on Resource Efficiency Monitoring, Assessment and Optimization Brussels January 27th , 2016

Founded in 1897 by Herbert H. Dow in Midland, Michigan (USA)

We are a Company leader in science and technology with a annual turnover of MM $57.786 (Year 2014)

We provide more than 5.000 products, services and technologies in 188 sites located in 36 different countries.

We serve customers in more than 160 countries.

We are about 52.000 employees around the world.

In 2001, we acquired Union Carbide Corporation

In 2009, we completed the integration of Rohm and Haas

¿W ho we are…..?

3


Dow Locations

Dow Chemical in Europe 4


Established in 1954 (in Spain in 1960)

Dow Europe (EMEA) represents:

35% of the Total Sales.

29% of the Employees.

Portfolio of more than 6000 Customers

90% of the European Sales are produced in European facilities.

Dow in Europe…

Dow Chemical Ibérica 5


We are the subsidiary of The Dow Chemical Company in Spain and Portugal

We started our activities in the Iberian Region in en Bilbao in 1960 and in 1967 we started up the 1st. LDPE Plant in Tarragona.

Dow Ibérica currently has Production Sites and R+D+i Centers in Tarragona (Catalonia), Ribaforada (Navarra) y Estarreja (Portugal). Headquarters and Sales Offices are located in Madrid.

We generate more that 1500 direct jobs

Dow in Spain and Portugal….

Dow Chemical Ibérica 6


Dow in Spain and Portugal….

- PU Systems Service Center - PU R+D+i Center

- MDI™ (DCI+DAS) Headquarters Sales Offices * R+D+I Centers

-Plastics Excellence -Water Applications Development

*Hydrocarbons and Energy Ethylene

Propylene Pygas

C4 Fraction Octene

*Derivatives HDPE™ LDPE™

DOWLEX™ PRIMACOR™

Polyols Polyglicols

Elastomers (AFFINITY, ENGAGE, INSITE,) Polypropilene (VERSIFY)

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DCI Tarragona. Ethylene Cracker

Ethylene Cracker. Process Overview 8


9


TOP-REF Scope in DCI.

Optimization / Rationalization of Steam Network “Players”:

Fired Equipments (Steam Producers)

Cracking furnaces (Fixed – No Freedom Degree -)

Boiler (Variable – Freedom Degree -)

Large Turbines & Compressors (Steam Consumers)

Efficiency (Soft Sensors)

Steam Grids (Steam Balance)

Steam Grid Balance

Exergy Performance analysis leading to new set-ups

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TOP-REF Benefits for DCI.

Identification of “blind inefficient spots” (mainly from the energy

intensity perspective) and not only focused on the steam grid system

(simplified models might be an enabler)

New and Improved Control Strategies.

Identification / Definition of New or Improved “non-invasive”

hardware as “soft sensors”(i.e. T, P, other measurements).

Identify potential energy saving projects to be included in the Plant

Specific Technology Plan pipeline.

Learning opportunities to realize the value of tools never tested

before in our sector (i.e. LCA).

CO2 footprint reduction (potential impact on ETS incurred cost).

Symbiosis / Leveregeability to other Dow’s Plants and Industrial

Sectors

Conclusions 11


The simulation is validated and capable to simulate an

scenario of 100% naphtha fed and an ethylene production

at nameplate capacity with an accuracy of ±10%.

The economic and energetic study was completed showing

that the SL vent valve is the most inefficient spot (45% of

the total economic losses and 55% of the total energetic

losses).

Some improvements ideas have been identified to

mitigate these losses: better control strategy, steam recovery

and new consumers for the excess of steam.

More to come….. 12


Automation of the simulations.

Connect steam grid simulation with the

Ethylene production plant simulation.

Implementation of additional potential

improvements drawn from: Thermoeconomic and exergetic studies.

“soft sensors” feasibility.

Improved Control Strategies.

Operator decision support tool for KRI’s optimization.

“This project has received funding from the European Union’s Seventh Programme

for research, technological development and demonstration under grant agreement No 604140”

Brussels

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Ethylene Cracker Industrial Case