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SRC

Super Radiant Coil


BD ENERGY SYSTEMS EXCLUSIVE LICENSEE

ETHYLENE FURNACES
STEAM CRACKING TECHNOLOGY EVOLUTION

Inventors : Dr. Maurizio Spoto - Dr. Benedetto Spoto


Author : Dr. Maurizio Spoto
maurizio.spoto@pycos.it

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The cracking furnaces is the core of
ethylene process
⚫ The reaction yield increases by reducing both the
gas residence time and the hydrocarbon partial
pressure.
⚫ Furnace designers are continuously modifying the
geometry of the radiant coil to improve the surface
to volume ratio.
⚫ The resulting higher heat flux and tube metal
temperature force the radiant coil to operate close
to its metallurgical limit.

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Short residence time requires small
diameter tubes which causes:

⚫ Higher Tube Metal Temperature (TMT)


⚫ Higher pressure drop
⚫ Higher coking rate
⚫ Higher carburization and creep rates
⚫ Selectivity loss during the Run Length (RL)
⚫ Tube plugging

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SRC Technology Objectives:
⚫ Short residence time with large bore tubes
⚫ Increasethe heat transfer area
⚫ Enhance the radiant heat transfer
⚫ Reduce the tube metal temperature
⚫ Reduce the coking rate
⚫ Avoid tube plugging
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SRC Technology Achievements:

⚫ High olefins selectivity


⚫ Low coking rate - Extended furnace run length
⚫ Lower Tube Metal Temperature
⚫ Extended coil life (low carburization rate)

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Typical commercial coils
Name
Geometry Run Length days Coil ID inches Residence time sec

UDC
> 60 4÷5 0.5÷0.8

Split Coil 45÷60 3÷4 0.3÷0.4

U-tube 30÷45 2÷2.5 0.2÷0.3

Millisecond 10÷20 1÷1.5 < 0.2

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Comparison
Standard Tube SRC Tube

SRC

Convection Heat Transfer Only Convection + Radiative Heat Transfer

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Heat transfer in cylindrical tube

qrb Firebox Radiative Heat Flow


qcb Firebox Convection Heat Flow
Two Tube Wall Outside Temperature
Twi Tube Wall Inside Temperature
Tf Cracking gas Temperature
Tbox Firebox Temperature
A Tube heat transfer surface
U Overall tube heat transfer coefficient
 Stefan Boltzmann constant
GS Overall exchange area

qb=qrb+qcb=GS**(Tbox4- Two4)+Ao*ho*(Tbox -Two) = U*A*(Twi-Tf )

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SUPER RADIANT COIL
Heat Transfer Mechanism

qrb Firebox Radiative Heat Flow


qcb Firebox Convection Heat Flow
qk Conduction heat flow
qc1 Convection heat flow 1
qC1
qC2 qc2 Convection heat flow 2
qC2
qr SRC Inner Radiative Heat Flow
qr SRC

Heat Balance:

qr= qrb + qcb = qC1+qC2


qr SRC =qC2

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SUPER RADIANT COIL – Heat Balance

Tf Fluid Temperature
Twi Tube Wall inside Temperature
TSRC SRC Temperature
Convection Heat Transfer :

SRC qC=qC1+qC2=
qC1
qC2 Awi *hC1 (Twi-Tf ) +ASRC*hSRC *(TSRC-Tf)

qC2 = qrSRC
qr SRC
hSRC > hc1
hc1 =Tube inner convection heat transfer coefficient

hSRC = SRC outer convection heat transfer coefficient

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Heat Transfer Over the Insert (SRC)

RADIANT HEAT TRANSFER INSIDE THE TUBE:

 *(T 4-T wi
4)*A
SRC SRC
qr SRC=
f(εSRC , εT , εg , FSRC,T)

SRC qC1 HEAT BALANCE OVER THE CYLINDRICAL INSERT(SRC):

qC2
qr SRC = qC2
qr SRC
TSRC Insert temperature
ASRC Insert surface

FSRC,T View factor

εSRC ,εT , εg Emissivity (SRC, tube and cracked gas)

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SUPER RADIANT COIL
Industrial Test Furnace
Polimeri Europa –Ethylene Plant- Gela (Italy)

Industrial test has been carried out by installing two SRC


devices in an industrial furnace @ Gela Ethylene plant
An identical couple of tubes in the same furnace and
operating under identical conditions have been kept
unchanged to act as reference tubes
Both couples of tubes receive the same heat flow from
the fire-box.
Tube wall temperatures have been collected by using a
laser pyrometer.
The tube wall temperature of the base coil has been on
an average 40 °C higher than the TMT of the SRC coils.

• Testing Period = 2 years

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Test furnace: Capacity = 12 ton/h

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13
SRC ADVANTAGES
• Reduced film thickness
• Lower Coke formation
• TMT decrease
• Lower tube carburization
• Less maintenance
• Extended tubes’ life

Achievement of unrivalled economic benefits

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SUPER RADIANT COIL
Material Cost
Technical data:
• OD = 48 mm
• L = 12000 mm
Cost:
• Tooling = 14k€ (fix cost: 1 ∞)
• SRC Tube ≈ 5k€

SRC cost ≈ 80% of Outer Radiant tube (OD =88.8 mm) cost

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SRC OPTIONS
• FURNACE MODIFICATIONS

1. PUT SRC INSERT IN EXISTING TUBES WHEN


APPLICABLE

2. REPLACEMENT OF EXISTING TUBES WITH


HIGHER ID TUBES WITH SRC INSERT REDUCES
BOTH PRESSURE DROP & CONTACT TIME

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SUPER RADIANT COIL: Applications
Ethane Main LPG/naphtha Main
Purpose Purpose

• Large Diameter Tubes • Large Diameter Tubes

• Low Tube Wall Temperature • Short Residence Time

• Low Coking Rate • Low Tube Wall Temperature

• No Tube Plugging • Low Coking Rate

• Increase Conversion • No Tube Plugging

• Increase Capacity • Long Operating Cycle

• Increase Selectivity • High Severity

• Low carburization • High Selectivity


• Low Pressure Drop • Low Pressure Drop

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SRC PERFORMANCE
• SUMMARY OF ADVANTAGES

1. HIGHER RUN LENGTH AT FIXED PRODUCTION


2. HIGHER RUN LENGTH AT HIGHER PRODUCTION
3. IMPROVED SELECTIVITY
4. POTENTIAL TO DECREASE SPECIFIC ENERGY
CONSUMPTION

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SUPER RADIANT COIL
Conclusions

Objectives: SRC achievements:


•Short residence time •Reduced cross sectional area
•Increase heat transfer rate •Higher film coefficient
•Enhance radiant heat transfer •Internal radiant heat transfer
•Reduce TMT •Increased Heat Transfer Area
•Reduce coking rate •Lower TMT
•Reduce tube plugging •Large diameter tube

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Pycos engineering proposition

The Super Radiant Coil Technology is


the best option to revamp existing
furnaces

PYCOS ENGINEERING & BDES PROVIDE FULL


SCOPE OF SERVICES:

• Feasibility Study
• Basic Design and EPC
• Startup & Acceptance Test
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SRC PROJECT SCOPE
1. Feasibility study 3 months
2. Detail Engineering 6 months
3. Material Supply ≈ 6 months
4. Installation 1 -2 months

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SUPER RADIANT COIL

PATENT GRANTED
IN EUROPE
USA & RUSSIA

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