ETDE-DE—1117 DGMK Tagungsbericht 2001-4 Proceedings of the DGMK-Conference "Creating Value from Light Olefins - Production and Conversion" October 10-12, 2001, Hamburg, Germany DGMK German Society for Petroleum and Coal Science and Technology Petrochemistry Division Alle Rechte, auch die der Obersetzung, des auszugsweisen Nachdrucks, der Herstellung von Mikrofilmen und der fotomechanischen Wiedergabe, nur mit ausdrucklicher schriftlicher Genehmigung der DGMK. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of DGMK. Als Manuskript gedruckt. ISSN 1433-9013 ISBN 3-931850-84-6 Preis: EUR 75,- (DM146,69) zuzugl. ges. MwSt. Verbreitung und Verkauf nur durch: DGMK Deutsche Wissenschaftliche Geseilschaft ftir Erdol, Erdgas und Kohle e.V. Kapstadtring 2, 22297 Hamburg Postfach 60 05 49, 22205 Hamburg Telefon: (040) 63 90 04-11/33 Telefax: (040) 63 00 736 Bankverbindung: Dresdner Bank AG, Hamburg, Konto 9 085 166 00 (BLZ 200 800 00) Amtsgericht Hamburg 69 VR 6898 DISCLAIMER Portions of this document may be illegible in electronic image products. Images are produced from the best available original document. DGMK XX German Society for Petroleum and Coal Science and Technology Tagungsbericht 2001-4 Proceedings of the DGMK-Conference “Creating Value from Light Olefins - Production and Conversion" October 10-12, 2001, Hamburg, Germany (Authors' Manuscripts) edited by G. Emig, H.-J. Kramer & J. Weitkamp KS002755650 I: KS DE016792478 I CONTENTS Page Recent Advances in the Manufacture of Light Olefins by 7 Steamcracking St. J. Stanley Steamcracker Revamp Projects: Challenges and Technologies 9 R. Zeppenfeld, R. Walzl Optimizing Pyrolysis Gasoline Upgrading 21 V. Coupard, J. Cosyns, Q. Debuisschert, L. Quicke, P. Travers Maximizing Propylene Yields in Fluid Catalytic Cracking and 31 Related Technologies - Solutions for Increasing Propylene Production D. Greer, M. Houdek, R. Pittman, J. Woodcock Conversion of Problematic Petrochemical-Refinery Fractions to 45 High Value Steam Cracker Feed H. Bischof, W. Dohler, F. Fuder, J. Laege Preparation of a Synthetic Steamcracker Feedstock from Pyrolysis 49 Gasoline on Zeolite Catalysts A. Raichle, Y. Traa, J. Weitkamp Conversion of Naphthenes into a Valuable Steamcracker Feed 57 Using H-ZSM-5 Based Catalysts C. Ringelhan, V. Kurth, G. Burgfels, J. G. Neumayr, W. Seuffert, J. Klose ARINO™ (Aromatic RINg Opening) 65 Technology for Upgrading of Low Value Aromatics to High Value Steamcracker Feedstock H. Fritz, H. Bolt, U. Wenning Methanol to Olefins (MTO): State of the Art and Perspectives 73 S. Kvisle, H. Reier Nilsen, T. Fuglerud, A. Gr0nvold, B. V. Vora, P. R. Pujado, P. T. Barger, J. M. Andersen MTP, Methanol to Propylene - Lurgi's Way 85 M. Rothaemel, H.-D. Holtmann Selective Hydrogenation of 1,3-Butadiene over Supported Gold 97 Catalysts S. Schimpf, M. Lucas, P. Claus II Valuable Products from Butadiene, Carbon Dioxide and Hydrogen 103 V. A. Brehme, A. Behr Making Olefins from Light Paraffins by Catalytic Dehydrogenation 111 and Oxidative Dehydrogenation K. Harth The MTBE Issue from the Viewpoint of an Environmental 113 Protection Agency A. Friedrich Creating Value from Isobutene 115 St. Muller, A. Gammersbach, H.-J. Kramer, F. Kaledat C4 Fraction - A Raw Material for the Production of C10 Plasticizer 119 Alcohols J. Kolena, P. Moravek, J. Lederer New PO Processes 127 Th. Haas, W. Hofen, G. Thiele, P. Kampeis Oxidative Dehydrogenation (ODH) of Propane over Vanadia-Based 131 Catalysts: Probing Active Sites under Working Conditions A. Bruckner, P. Rybarczyk, J. Radnik, G.-U. Wolf, H. Kosslick, M. Baerns Oxidative Dehydrogenation of Ethane over Novel Mixed Oxides 139 A. Hartung, S. Gaab, J. Find, A. Lemonidou, J. A. Lercher Advances in the Selective Oxidation of C3 and C4 Hydrocarbons 147 R. K. Grasselli The Influence of the Gas Phase Composition on the Catalytic 159 Partial Oxidation of Propene I. GriBtede, M. Kohler, H.-G. Lintz, H.-C. Schwarzer Selective Oxidation of Propane on Basic Metal Oxide Catalysts 167 F. Klose, B. Ondruschka, P. Scholz, R. Bdining Pilot Plant Processing of n-Butane to Maleic Anhydride above the 175 Explosion Limit W. M. Brandstadter, B. Kraushaar-Czarnetzki POSTERSESSION Olefins Production in Catalytic Pyrolysis of Gas Condensate 183 and Straight-Run Gasoline A. L. Lapidus, F. G. Jagfarov, I. F. Krylov, N. A. Grigor'eva, A. Yu. Krylova The Mechanism of Olefin Formation from Light Paraffins over MFI 189 Zeolites Kh. M. Minachev, A. L. Lapidus, A. A. Dergachev Investigations of Mixed MCM-41/MFI Catalyst Systems for the 195 Manufacture of Light Olefins by Cracking of Hydrocarbons A. N. Bhave, A. Klemt, S. R. Patwardhan, W. Reschetilowski Non-Oxidative Propane Dehydrogenation over Supported Pt-Zn- 203 Catalysts T. Donauer, R. Glaser, J. Weitkamp Heterogeneous and Homogeneous Processes in Oxidative 211 Dehydrogenation of Propane in a Fixed Bed Catalytic Reactor O. Hein, A. Jess Selective Oxidative Catalytic Conversion of n-Butane into Olefins 219 C2-C3 at Moderate Temperatures S. B. Kogan, M. L. Kaliya, N. Froumin, M. Herskowitz Catalyst Development for the Oxidative Dehydrogenation of Ethane 227 and Propane to Olefins Applying an Evolutionary Approach M. Langpape, G. Grubert, D. Wolf, M. Baerns Optimizing Structural Configurations of Petrochemical 235 Manufacturing Sites J. Fabri Ethylene Oligomerization over Ni- and Pd-Zeolites 245 A. Lapidus, A. Krylova Selective Dimerisation of Light Olefins in Biphasic Mode Using 253 Ionic Liquid Solvents - Design and Application of a Continuous Loop Reactor P. Wasserscheid, A. Jess, M. Eichmann Ethylene as a C2-Building Block for Catalytic Synthesis of Fine 257 Chemicals M. Solinas, G. Francio, W. Leitner Supercritical Isomerisation of n-Butane over Sulfated Zirconia 263 B. Sander, M. Thelen, B. Kraushaar-Czarnetzki IV Effect of Sodium Promotion on the Performance of Fe x Oy/Si02 271 Catalysts in the Gas Phase Epoxidation of Propene V. Duma, R. Fodisch, D. Honicke Enhanced Aromatic Formation in the Methanol to Hydrocarbon 277 Reaction Using Composite Catalysts D. Freeman, R. P. K. Wells, G. J. Hutchings Development of a Process for the Production of Glycerol in Tertiary 285 Butyl Ether as Octane Booster on Isobutene Basis A. Behr, L. Obendorf, V. A. Brehme The Catalytic Wall Reactor as Tool for Kinetic Investigations in the 287 Selective Oxidation of Propene to Acrolein H. Redlingshofer, G. Emig Quantitative Analysis of Gasolines and Reformates by GC/TOFMS 289 R. Loscher, R. Hirsch, E. de Armas, R. Parry DGMK-Conference “Creating Value from Light Olefins - Production and Conversion", Hamburg, 2001 St. J. Stanley ABB Lummus Global Inc., Bloomfield, USA Recent Advances in the Manufacture of Light Olefins by Steamcracking Manuscript was not available by the time of printing DGMK-Tagungsbericht 2001-4, ISBN 3-931850-84-6 7 8 DGMK-Conference "Creating Value from Light Olefins - Production and Conversion*, Hamburg, 2001 R. Zeppenfeld, R. Walzl Linde AG, Hollriegelskreuth, Germany Steamcracker Revamp Projects: Challenges and Technologies Role of Steamcracker Revamping in Europe The growing use of synthetics in the consumer goods industry fuels an ever-increasing demand for ethylene and propylene, the major raw materials for industrial chemicals. To meet this demand, the petrochemical industry has to find economical ways of continuously expanding olefins production capacity. Capacity for ethylene production in Western Europe has grown by more than 100% during the last 20 years as shown in Fig. 1. Since 1993, no grass root cracker was commissioned but all new capacity in Europe (about 500 kt ethylene/year) results from revamping projects, of which Linde has carried out a remarkable portion. A new ethylene plant represents a very significant investment. In addition to the large capital cost, there are numerous associated expenses. To be profitable in international market, the annual capacity of a new ethylene plant must be at least 600 to 800 kta ethylene production per year to keep the fixed costs down to an acceptable proportion of the total and so remain competitive. Several reasons contributed to the apparent economic advantage of capacity revamping in Europe: • The moderate market growth (few percent per year) made it difficult, if not impossible, to justify an increase in capacity of that magnitude in one step. Revamping allows incremental new capacity with the economics of a grass-root cracker. • A lot of the European steamcrackers are now more than 25 years old, far older as their original design life. Corrosion is the most important cost factor arising from this situation. Corroded equipment and piping can be repaired or replaced very specifically as part of a capacity expansion project. • Higher efficiencies of modern equipment cannot justify its replacement alone. However, in combination with a capacity increase, better performance improves the revamp project's economics. • Due to major environmental legislative requirements (i.e. BAT) whole furnace sections may become candidates for complete replacements. Increasing of furnace capacity can be easily included in such a project with few extra cost. • The distributed plant ownership and distributed production sites resulted in a situation where no large single investment in ethylene production of more than 1 billion Euro and the related risks could be justified by any player. 9 DGMK-Tagungsbericht2001~4,