Ethylene Production From Tennessee Fracked Natural Gas University of Tennessee at Chattanooga ENGR 5910/ENCH /26/2012 Brandon Dodd Valentine Mbamalu

Outline Introduction Design Basis Cracking Reaction Process Flow Diagram Equipment Design Project Economics Conclusion

Introduction

Design Basis Analyze 500,000 metric tons Ethane feedstock per year Feedstock will be considered as 100% Ethane Negligible reaction byproducts not to be considered for this level of design

Ethane Cracking Reaction Byproducts Methane Propane Hydrogen Gas

Generalized Process Flow Diagram

Steam Cracker 170 MW heat duty Modeled as 2 100MW separate pyrolysis furnaces Each furnace 100 MW capacity Operates at 80% capacity.

Transfer Line Exchanger Shell and Tube Model 73 MW Heat Removed from Product Stream 820 m 2 Total Exchange Area 2 Units in Series

Distillation Columns 3 Total Columns 8 stage de-methanizer – 10m high – 3m diameter 20 stage de-ethylenizer – 15m high – 3m diameter 40 stage de-ethanizer – 27m high – 3m diameter

Other Equipment Estimated Quench Tower Compressors Refrigeration Pumps Fans

Unit Cost Summary

Costs – In Millions Capital Costs - $121 – Includes land cost Total Annual Operating Costs - $617 – Utility Cost - $142 – Raw Material Cost - $475 – Labor Cost – estimated $1

Revenue – In Millions Total Yearly Revenue - $960 Ethylene – 560,000 metric tons – $955 Methane – 3000 metric tons – $0.7 Propane – 3000 metric tons – $0.7

Revenue Vs. Cost

Payback Period

ENVIRONMENTAL IMPACT Air pollution Primary – Nitrogen dioxide, Particulate Matters, Volatile Organic Component. Secondary – Ozone. Incinerators

Conclusions Costing based on key component Project is profitable Economic activities will receive boost Jobs and revenue to state and local gov.