Furnace Modernization: An Economical Way to Upgrade Your Existing Furnace to Improve Energy Performance and Reduce CO2 Emissions
- Type: Conference Presentation
AIChE Member Credits 0.5 AIChE Members $19.00 AIChE Fuels and Petrochemicals Division Members Free AIChE Graduate Student Members Free AIChE Undergraduate Student Members Free Non-Members $29.00
- Conference Type: AIChE Spring Meeting and Global Congress on Process Safety
- Presentation Date: April 21, 2021
- Duration: 25 minutes
- Skill Level: Intermediate
- PDHs: 0.50
Shell investigated several options to maintain security of the production capacity of its 16 cracking furnaces after 50 years of operation, at its Moerdijk petrochemicals complex in the Netherlands. Following the outcome of a study, the selected options to choose from were a one-to-one replacement of 16 existing furnaces or upgrading 8 of those furnaces by doubling their capacity.
After detailed evaluation it became clear that the modernization of 8 furnaces was the most optimum path forward. Key drivers for selecting this option were:
- Improve energy performance and emissions
- Reduce environmental footprint (about 10% CO2 reduction of Moerdijkâs annual total), an important step to the Shell energy transition targets of being net carbon neutral in 2050 or earlier in step with society.
- Further process safety improvements
- Fast implementation within 5 years, without impacting production
- Lower investment cost compared to green field investment
The main process design challenge on this project is doubling the furnace capacity and improving on overall efficiency while re-using the existing firebox and burners, and maintaining existing foundations. The main project execution challenge is implementing these revamps outside of a plant turnaround to minimize the impact on the Shell Moerdijk lower olefins production, without any concessions to safety in the running plant.
This paper describes the furnace revamp design and the revamp execution strategy that minimizes field labour on site and maximises a modular approach.
Shellâs technological know-how, project execution and operational experience combined with TechnipFMCâs Process Technology and EPC capabilities has led to the current furnace design, enabling a 100% capacity increase within the same firebox.
|AIChE Member Credits||0.5|
|AIChE Fuels and Petrochemicals Division Members||Free|
|AIChE Graduate Student Members||Free|
|AIChE Undergraduate Student Members||Free|