MAN Turbo Compressors and Steam Turbines for Ethylene Plants May 2010

MAN Turbo AG

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References

Application References References for Manufacturing of Large Impellers References for Resulting Dimensions and Weights References for Large Steam Turbines as mechanical drive

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

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Ethylene Plants Application References

Casings in Service 38 Cracked Gas 28 Propylene / Propane Refrigeration 27 Ethylene / Ethane Refrigeration 8 Recycle Gas 3 Other Service 28 Steam Turbine Drivers 132 Turbomachines in Ethylene Plant Service

Latest Reference: Complete Set of Machines for a has been500 kta Ethylene Plant delivered

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

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Schwechat Refinary, Austria, 2005

350 kta Extension of Ethylene Plant

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

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Schwechat Refinary, Austria, 2005

350 kta Extension of Ethylene Plant

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 5 >

Tiszaujvaros Kombinat, Hungary, 2004

250 kta Ethylene Plant - LINDAETH

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 6 >

Tiszaujvaros Kombinat, Hungary, 2004

250 kta Ethylene Plant - TISKO

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 7 >

Tiszaujvaros Kombinat, Hungary, 2004

250 kta Ethylene Plant - TISAETH

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 8 >

Tiszaujvaros Kombinat, Hungary, 2004

250 kta Ethylene Plant - TISPROP

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 9 >

DOW Benelux LHC-3 Terneuzen, NL, 2000

600 kta Cracked Gas Compressor no. 1

TERNKO 4 LP MP ST flow p1 p2 speed comp. rated turbine rated RH100/02D RH100/04 DK080/170 165 504 m3/h 1.4 bar 14.8 bar 5 200 rpm 20 170 kW 22 187

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 10 >

DOW Benelux LHC-3 Terneuzen, NL, 2000

600 kta Cracked Gas Compressor no. 2

TERNKO 5 HP ST flow p1 p2 speed comp. rated turbine rated RH040/03 DK035/080 13 044 m3/h 11.7 bar 38.4 bar 12 409 rpm 6 987 kW 7 686 kW

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 11 >

DOW Benelux LHC-3 Terneuzen, NL, 2000

600 kta Ethylene Refrigeration Compressor
TERNAETH Type ST flow p1 p2 speed comp. rated turb. rtd RH063/06 DG040/040 26 820 m3/h 1.04 bar 16.0 bar 8500 rpm 6 780 kW 7 458 kW

T1 -102C Sidestream (480%) @ 4 bar Extraction (43%) @ 10.3 bar

! !

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 12 >

DOW Benelux LHC-3 Terneuzen, NL, 2000

600 kta Propylene Refrigeration Compressor

TERNPROP type ST flow p1 p2 speed comp. rated RH100/06 DK080/170 88 126 m3/h 11.7 bar 38.4 bar 4 058 rpm 16 481 kW

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 13 >

DOW Benelux LHC-3 Terneuzen, NL, 2000

600 kta Steam Turbine Driver
TERNKO 4 / TERNPROP ST p1 pex p2 Rated DK080/170 91 bar 13 bar 0.1 bar 22 187 kW

Identical steam turbine for TERNKO 4 and TERNPROP only 1 spare rotor required

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 14 >

Esso Mossmorran, GB, 1981

Cracked Gas Compressor

MOSSKO LP MP HP flow p1 p2 speed comp. rated RH100/03D RH100/06 RH050/08 111 850 m3/h 1.5 bar 38.9 bar 4 670 / 8 550 rpm 28 000 kW

Gas Turbine driven (Frame 5) with helper steam turbine intermediate gear box

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 15 >

Esso Mossmorran, GB, 1981

Propane Refrigeration Compressor
MOSSPROP LP MP HP flow p1 p2 speed comp. rated RH112/02D RH112/02D RH112/02 144 223 m3/h 1.1 bar 12.6 bar 3543 rpm 28 000 kW

3 casing design

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

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ILAM 500 kta Ethylene Plan

Delivered in late 2009

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

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ILAM Cracked Gas Compressor

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

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ILAM Cracked Gas Compressor

500 kta Cracked Gas Compressor MAN TURBO condensing steam turbine welded compressor casings HP casing horizontally split with hydro test pressure of 78,3 barg compressor nozzle loads 3 x NEMA

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

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ILAM Propylene Compressor

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 20 >

ILAM Propylene Compressor

MAN TURBO condensing steam turbine Welded Compressor Casing compressor nozzle loads 3 x NEMA

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

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ILAM Ethylene Compressor

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 22 >

ILAM Ethylene Compressor

MAN TURBO condensing steam turbine stainless cast steal compressor casing compressor nozzle load 3 x NEMA

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 23 >

Compressor Casings
Cracked gas compressor

ST Cracked Gas Compressor (CGC) Ethylene RefrIgeration Compressor (ERC) Propylene Refrigeration Compressor (PRC) Binary Refrigeration Compressor (BRC), for ABB Lummus instead of ERC

5
30 - 40 bar

Amine treatment Caustic washing

Drying

Cold box
- 50 C - 105 C

ST
Propylene refrigeration compressor

ST
Ethylene refrigeration compressor

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 24 >

Casing Design Example RH090/06 39 barg (I)

Largest fabricated casing built by MAN Turbo to date (~2.6 m) 5 nozzle design

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 25 >

Casing Design Example RH090/06 39 barg (II)

Initial analysis shows possible leakage shift bolt pattern closer to shaft bore location high local peak-stresses in support strut region new strut design with less stiffness in the surrounding regions incl. experimental verification Hydrostatic pressure test successful First Time Right
shift bolt hole

leakage path

strain gauge measurement at support strut

Turbomachinery for Ethylene Plants MAN Turbo AG Buchkremer 29.04.2010 < 26 >

Current Improvements
Study of 66 bar Charge Gas Compressor (HP) with Horizontal Split Casing
Casing Scaling: Ethylen 1 Mt/a Ethylen 1,3 Mt/a Modell: Results: RH100 (Impeller ~ 950 mm) RH110 (Impeller ~1100 mm) 1.3 Mt/a CGC-HP: Surface stresses

All surface stresses below yield No peak stresses on outside surface Tightness confirmed

CGC-HP Casings with horizontal split available even for large Ethylen Plants with high discharge pressures (up to 66 bar water test)
Turbomachinery for Ethylene Plants MAN Turbo AG Buchkremer 29.04.2010 < 27 >

Impeller Design

3-D and 2-D impeller cover disc brazed or welded 40 / 50 / 60 outlet

Turbomachinery for Ethylene Plants

A 182 (X3CrNi13-4) 17-4 PH

MAN Turbo AG

Buchkremer

29.04.2010

< 29 >

NACE MR0175
H2S-Anteil [Mol-%] CO2-Anteil Druck (absolut) [Mol-%] [bar]

EINGABEWERTE:

0,006

0,045

18,6

MAN Diesel & Turbo selects impeller material according the latest NACE Standard

Ausdruck Diagramm SCC Regionen nach NACE (Stand heute)

Ausdruck Diagramm SCC Regionen nach NACE (Stand 2002)

SSC Regionen nach NACE (Stand heute) 7 6,5 6 5,5 pH 5

Re gion 0 Region 1

>100C 20C
1000
Total absolute pressure [bar]

SSC Regionen nach NACE 2002

ppm H2S in gas

10

100

1000

10000

100000

1000000

Region 2

100

Sulfide Stress Cracking Region

4,5 4 3,5 3 0,00001

Region 3

10

0,0001

0,001

0,01 p H2S [bar]

0,1

10

1 0,0001

0,001

0,01

0,1 1 Mol-% H2S in gas

10

100

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 30 >

Large Impellers Reference RASRA

44 Impellers with a diameter of 1600 mm or larger

Compressor RASRA 1-2 Type AR115/10 Steam Turbine Driven Year of Order Suction Flow Suction Pressure Discharge Pressure Power
Turbomachinery for Ethylene Plants MAN Turbo AG Buchkremer

2003 690,000 1.000 8.3 55600

m3/h bar bar kW

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29.04.2010

Large Impellers Reference RIK 140

RIK 140

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 32 >

Compressor fouling
Basic causes for compressor fouling: - Feedstock: High valency hydrocarbons and untreated gas components tend to polymerization. -Temperature: The rate of polymerization increases rapidly at temperatures greater than 85C (depending on feed stock) - Pressure: Fouling increases almost proportionally to pressure - Surface finish: smooth surfaces are less prone to fouling

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 33 >

Polymerized deposits

volute

diffuser

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 34 >

Fouling deposits

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 35 >

Consequences of polymerization
Consequences of polymerized deposits in the compressor for the operator with respect to the efficiency rating and availability
Production: At a given speed the discharge head / volume flow characteristic is lower. The efficiency curve tails off accordingly. Increasing the speed can counteract this, however the original volume is now achieved at a less favourable efficiency level and at a higher temperature. The speed of polymerization increases and the fouling process accelerates as a result.

head

constant discharge pressure

100% point
speed compensation

drop of efficiency

Clean compressor at normal speed

clean compressor at normal speed when fouling is present

when fouling is present 95C

temperatur increase

85C clean compressor at normal speed

actual suction flow

MAN Turbo AG Buchkremer 29.04.2010 < 36 >

Turbomachinery for Ethylene Plants

Washing system example 3

Water injection in the return channels is used currently.

To optimize - nozzle type - flow quantity - configuration a CFD engineering is put into execution.

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 37 >

Design Refrigeration Compressor TERNPROP - Cross Section

cast steel casing (low temperature) impeller inline arrangement internal side stream DGS in tandem arrangement

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 38 >

Sideloads
location upstream return channel allows for proper mixing of the two streams cast design allows for very large side stream with only small increase of bearing span

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 39 >

Experience in Ethylene Plants Capacity Increase

ESSO / EXXON MOSSMORRAN, GB Original Delivery 1981 CG Compressor Increase by 27 % (1988) Ethylene Compressors Increase by 26 % (1996) Propane Compressor Increase by 39 % (1996) BP CHEMICALS GRANGEMOUTH, GB Original Delivery 1991 CG Compressor Increase by 25 % (1997)

Example LP-Compressor of Cracked Gas Train BP Grangemouth Modified Parts: Shaft (Red) Impellers (Blue) Diaphragms (Yellow) Labyrinths (Green)
Turbomachinery for Ethylene Plants

SOW / BSL BOEHLEN, GER Original Delivery 1972 Refurbishment and Conversion to Dry Gas Seals Cracker Capacity Increase

(1994) by 35 % (1996)

MAN Turbo AG

Buchkremer

29.04.2010

< 40 >

References for Resulting Dimensions and Weights

Works assembly of a large moduls (500 tons) for a GTL plant

Turbomachinery for Ethylene Plants MAN Turbo AG Buchkremer 29.04.2010 < 41 >

References for Resulting Dimensions and Weights

Field installation of an 80 MW compressor train for a GTL plant

Turbomachinery for Ethylene Plants MAN Turbo AG Buchkremer 29.04.2010 < 42 >

Steam Turbines
Typically 110 bar, 530 C or 75 bar, 470 C

Turbine CGC

45 bar

Turbine PRC

Turbine ERC 18 bar

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 43 >

Ethylene Plants Large Steam Turbines

Steam Turbine package

Turbomachinery for Ethylene Plants MAN Turbo AG Buchkremer 29.04.2010 < 44 >

MAN Turbo Competence in Ethylene Plants - Conclusion

single source supply, compressors and steam turbines from same factory design generally acc. to API 617 / 612 MAN Turbo has experience with ethylene plants for various licensees MAN Turbo has as well recent references MAN Turbo has large train capability in factory and test bed Up-rating and service capability

Turbomachinery for Ethylene Plants

MAN Turbo AG

Buchkremer

29.04.2010

< 45 >