Propane plant

The reader should be aware that a few installations have been built during the last 5 years that produce propylene by the dehydrogenation of propane. Plants of this nature are operational or planned for Mexico, Belgium, Russia, Saudi Arabia, South Korea, and Thailand. In most of these cases, the plant is feasible only if there is a large supply of low-valued propane, a significant demand for propylene with an otherwise inadequate supply, and/or a supply of low-... 

Rotary vacuum filters are used in ketone dewaxers and rotary pressure filters are used in propane plants. The principles of operation are the same. A typical filter is shown in Figure 30. 

DeWaxing Aids (DWA) may be used in ketone dewaxing but are always used in propane dewaxing. Typically the DWA doses used in propane plants are 2-3 times higher than in ketone plants. While DWAs are economically justified for use on all grades in the propane plant, performance on light neutrals in ketone plants has typically not been economically justified. 

When gases are rich in ethane, propane, butane and heavier hydrocarbons and there is a local market for such products it may be economic to recover these condensable components. Natural gas liquids can be recovered in a number of ways, some of which have already been described in the previous section. However to maximise recovery of the individual NGL components, gas would have to be processed in a fractionation plant. 

Where the distance to the customer is very large, or where a gas pipeline would have to cross too many countries, gas may be shipped as a liquid. Gas has to be chilled to -160°C in a LNG plant to keep it in liquid form, and is shipped in refrigerated tankers. To condition the gas for liquefaction any COj, HjS, water and heavier hydrocarbons must be removed, by the methods already discussed. The choice of how much propane and butane to leave in the LNG depends upon the heating requirements negotiated with the customer. 

Olefins are produced primarily by thermal cracking of a hydrocarbon feedstock which takes place at low residence time in the presence of steam in the tubes of a furnace. In the United States, natural gas Hquids derived from natural gas processing, primarily ethane [74-84-0] and propane [74-98-6] have been the dominant feedstock for olefins plants, accounting for about 50 to 70% of ethylene production. Most of the remainder has been based on cracking naphtha or gas oil hydrocarbon streams which are derived from cmde oil. Naphtha is a hydrocarbon fraction boiling between 40 and 170°C, whereas the gas oil fraction bods between about 310 and 490°C. These feedstocks, which have been used primarily by producers with refinery affiliations, account for most of the remainder of olefins production. In addition a substantial amount of propylene and a small amount of ethylene ate recovered from waste gases produced in petroleum refineries. 

Since the early 1980s olefin plants in the United States were designed to have substantial flexibiHty to consume a wide range of feedstocks. Most of the flexibiHty to use various feedstocks is found in plants with associated refineries, where integrated olefins plants can optimize feedstocks using either gas Hquids or heavier refinery streams. Companies whose primary business is the production of ethylene derivatives, such as thermoplastics, tend to use ethane and propane feedstocks which minimize by-product streams and maximize ethylene production for their derivative plants. 

The market value of natural gas Hquids is highly volatile and historically has been weakly related to the world price of cmde oil. During the 1980s, the market value of natural gas Hquids ranged from approximately 60% of the price of cmde to 73% (12). In this 10-year interval, several fluctuations occurred in the natural gas Hquid market. Because of the variabiHty of the natural gas Hquid market, the NGL recovery plants need to have flexibiHty. Natural gas Hquid products compete in the following markets ethane propane a Hquefted petroleum gas (LPG) a C-3/C-4 mix and / -butane all compete as petrochemical feedstocks. Propane and LPG are also used as industrial and domestic fuels, whereas 2-butane and natural gasoline, consisting of C-5 and heavier hydrocarbons, are used as refinery feedstocks. 

Commercial VPO of propane—butane mixtures was in operation at Celanese Chemical Co. plants in Texas and/or Canada from the 1940s to the 1970s. The principal primary products were acetaldehyde, formaldehyde, methanol, and acetone. The process was mn at low hydrocarbon conversion (3—10%) and a pressure in excess of 790 kPa (7.8 atm). These operations were discontinued because of various economic factors, mainly the energy-intensive purification system required to separate the complex product streams. 

The economics of the arc-coal process is sensitive to the electric power consumed to produce a kilogram of acetylene. Early plant economic assessments indicated that the arc power consumption (SER = kwh/kgC2H2) must be below 13.2. The coal feedcoal quench experiments yielded a 9.0 SER with data that indicated a further reduction to below 6.0 with certain process improvements. In the propane quench experiment, ethylene as well as acetylene is produced. The combined process SER was 6.2 with a C2H2/C2H4 production ratio of 3 to 2. Economic analysis was completed uti1i2ing the achieved acetylene yields, and an acetylene price approximately 35% lower than the price of ethylene was projected. 

The most important commercial use of ethane and propane is in the production of ethylene (qv) by way of high temperature (ca 1000 K) thermal cracking. In the United States, ca 60% of the ethylene is produced by thermal cracking of ethane or ethane/propane mixtures. Large ethylene plants have been built in Saudi Arabia, Iran, and England based on ethane recovery from natural gas in these locations. Ethane cracking units have been installed in AustraHa, Qatar, Romania, and Erance, among others. 

In 1987 nonmotor fuel uses of butanes represented ca 16% of the total consumption. Liquid petroleum gas (LPG) is a mixture of butane and propane, typically in a ratio of 60 40 butane—propane however, the butane content can vary from 100 to 50% and less (see Liquefied petroleum gas). LPG is consumed as fuel in engines and in home, commercial, and industrial appHcations. Increasing amounts of LPG and butanes are used as feedstocks for substitute natural gas (SNG) plants (see Fuels, synthetic). / -Butane, propane, and isobutane are used alone or in mixture as hydrocarbon propellents in aerosols (qv). 

Essentially all of the methane [74-82-8] is removed ia the demethanizer overhead gas product. High recovery of ethane and heavier components as demethanizer bottoms products is commonplace. The work that is generated by expanding the gas ia the turboexpander is utilized to compress the residue gas from the demethanizer after it is warmed by heat exchange with the inlet gas. Recompression and deUvery to a natural gas pipeline is performed downstream of the plant. A propane recovery of 99% can be expected when ethane recoveries are ia excess of 65%. 

The preparation of polynitroparaftins has been reviewed (75). 2,2-Dinitropropane has been produced ia pilot-plant quantities by Hquid-phase nitration starting from either propane or 2-nitropropane (76,77) (see Nitration). 

Total Hydrocarbon Gontent. The THC includes the methane combined in air, plus traces of other light hydrocarbons that are present in the atmosphere and escape removal during the production process. In the typical oxygen sample, methane usually constitutes more than 90% of total hydrocarbons. The rest may be ethane, ethylene, acetylene, propane, propylene, and butanes. Any oil aerosol produced in lubricated piston compressor plants is also included here. 

A large amount of BTX is obtained as a by-product of ethylene manufacture (see Ethylene). The amount produced strongly depends on the feed to the ethylene plant. This is illustrated in Table 3 for various feeds to a typical large scale plant producing 450,000 t/yr of ethylene (16). Note that only about 1—2% of the ethane/propane feeds end up as BTX and it is almost completely benzene and toluene. As the feed goes up in molecular weight, the yield of BTX increases from 4% with butane feed to about 10% with gas oils, and the BTX proportions go from 72 20 8 respectively, to 44 34 22 respectively. 

Significant products from a typical steam cracker are ethylene, propylene, butadiene, and pyrolysis gasoline. Typical wt % yields for butylenes from a steam cracker for different feedstocks are ethane, 0.3 propane, 1.2 50% ethane/50% propane mixture, 0.8 butane, 2.8 hill-range naphtha, 7.3 light gas oil, 4.3. A typical steam cracking plant cracks a mixture of feedstocks that results in butylenes yields of about 1% to 4%. These yields can be increased by almost 50% if cracking severity is lowered to maximize propylene production instead of ethylene. 

The propylene fractionator operates at a pressure of 1.8 to 2.0 MPa with more than 160 trays required for a high purity propylene product. Often a two-tower design is employed when polymer grade (99.5%+) is required. A pasteurization section may also be used when high purity is required. The bottoms product contains mainly propane that can be recycled to the cracking heaters or used as fuel. Typical tower dimensions and internals for a 450,000 t/yr ethylene plant with naphtha feed are summarized in Table 7. 

Plant capacity, t/yr Ethane Propane Butane Naphtha Gas oil... 

Design considerations and costs of the catalyst, hardware, and a fume control system are direcdy proportional to the oven exhaust volume. The size of the catalyst bed often ranges from 1.0 m at 0°C and 101 kPa per 1000 m /min of exhaust, to 2 m for 1000 m /min of exhaust. Catalyst performance at a number of can plant installations has been enhanced by proper maintenance. Annual analytical measurements show reduction of solvent hydrocarbons to be in excess of 90% for 3—6 years, the equivalent of 12,000 to 30,000 operating hours. When propane was the only available fuel, the catalyst cost was recovered by fuel savings (vs thermal incineration prior to the catalyst retrofit) in two to three months. In numerous cases the fuel savings paid for the catalyst in 6 to 12 months. 

The San Juan plant can process up to 500 MMcfd of gas, and extract 40,000 bbl of EPBC liquids. EPBC liquids include ethane (E), propane (P), butanes (B), and condensate (natural gasoline) products... 

LNG—consisting of ethane, propane, butane, and natural gasoline (condensate)—arrives at the plant for upgrading before it is sent to petrochemical plants and refineries as feedstock. Residue gas is sold to the interstate and intrastate pipeline network. MESA, one of the world s major crude helium producers, also delivers helium to a pipeline operated by the U.S. Bureau of Mines. 

Probably the largest natural gas proeessing straddle plant in North Ameriea is BP-Amoeo s Empress, Alberta faeility. Here, EPBC (ethane, propane, butanes, and eondensate) are extraeted as liquids from natural gas before the gas is delivered to the TransCanada and Foothills (Saskatehewan) pipelines (Figure 8-5). The term straddle plant refers to the faet that the plant straddles the natural gas pipeline and extraets liquid eomponents before passing the natural gas further along the pipeline. 

Thailand s sole producer of methane, propane, and LNG/NGL is operating at least four gas separation plants. From these state-owned sites, the company supplies more than 90% of its production to the domestic market. A small percentage of NGL is exported. 

The various plants each have a daily input capacity of natural gas of 220-350 MMcfd. All operate 24 hours a day, providing an estimated total daily production capacity of 1,000 MMcf of methane, 1,450 t of ethane, 1,414 t of propane, 2,670 t of LPG and 5,700 bbl of NGL. 

At the Corpus Christi plant, liquid supplies of C4, C5, and Cg are delivered by truek and pipelines from nearby refineries. These liquids are proeessed through light end fraetionating units that remove the propane (C5 and Cg), and drop out isobutane and normal butane (whieh is reintrodueed into the stream for reproeessing.)... 

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