No abstract

Statistical software is a robust application that has proven reliable worldwide. However, it is not normally used in the actual large scale olefin plant as it relies on the simulation software by Olefin Licensor should any issue rises. The study was conducted in a newly commissioned large scale olefin plant to see the impact of various operating variables on the ethylene yield from Short Residence Time (SRT) VII Furnace. The analysis was conducted utilizing statistical analysis, Response Surface Methodology (RSM) in Minitab Software Version 18 to develop a reliable statistical model with a 95% confidence level. The historical data was taken from the Process Information Management System (PIMS) Software, PI Process Book Version 2015, and underwent both residuals and outliers removal prior to RSM analysis. 10 variables were shortlisted from the initial 15 identified variables in the studied SRT VII via Regression analysis due to RSM limitation to conduct the larger analysis in Minitab Software Version 18. The Response Optimizer tool showed that the ethylene yield from naphtha pyrolysis cracking in the studied plant could be maximized at 34.1% with control setting at 600.39 kg/ hr of Integral Burner Flow, 6.81% of Arch O2, 113.42 Barg of Steam Drum Pressure, 496.96°C of Super High Pressure (SHP) Temperature, 109.11 t/hr of SHP Boiler Feed Water (BFW) Flow, 92.78 t/hr of SHP Flow, 63.50 t/hr of Naphtha Feed Flow, and -13.38 mmHg of Draft Pressure.

Ethylene yield is significant in showing the performance of the steam cracker furnace in the olefin plant. This study was conducted in the actual large-scale olefin plant to see the impact of various variables towards the ethylene yield. The analysis was conducted utilizing Regression Analysis in Minitab Software Version 18 to develop a reliable ethylene yield model. The model concluded that ethylene yield in the studied plant was contributed by the factor of -0.000901, 0.02649, -0.282, 0.16, -0.0834, 0.1268, and 0.0057 of Hearth Burner Flow, Integral Burner Flow, Steam Drum Pressure, Super High-Pressure Steam (SHP) Boiler Feed Water Flow, SHP Flow, Naphtha Feed Flow, and Stack NOx Emission respectively. The Response Optimizer tool also showed that the ethylene yield from naphtha liquid feed utilizing pyrolysis cracking can be maximized at 32.55% with control setting at 9,476.41 kg/hr of Hearth Burner Flow, 608.56 kg/hr of Integral Burner Flow, 112.93 Barg of Steam Drum Pressure, 109.11 t/hr of SHP Boiler Feed Water Flow, 86.42 t/hr of SHP Flow, 63.49 t/hr of Naphtha Feed Flow and 126.23 mg/m3 of Stack NOx Emission.

Propylene yield is one of the key operating parameters that is monitored daily in the running olefin plant. This study was conducted in the actual world-scale olefin plant to measure the impact of identified controlled variables on the propylene yield. The Box-Cox data transformation was adopted in the Regression Analysis using Minitab Software Version 18 due to non-normal data were observed after normality and stability test were conducted using Box Plot, I-MR Chart, Run Chart, Graphical Summary, and Normality Plot tools. The model concluded that propylene yield in the studied plant was contributed by the factors of -0.000243 Hearth Burner Flow, 0.01332 Integral Burner Flow, and 0.08598 Naphtha Feed Flow. The Response Optimizer tool also suggested that the propylene yield from naphtha liquid feed can be maximized at 11.22% with the control setting at 10,993.86 kg/hr of Hearth Burner Flow, 604.61 kg/hr of Integral Burner Flow, and 63.50 t/hr of Naphtha Feed Flow.