Document 7yJZR55E8gBDwjMVBYR54pE6
Cconoco)
Interoffice Communication
To From
G. L. Foshee, Lake Charles, Louisiana R. w. Churns, Ponca CiCy, Oklahoma
u.ita January 23, 19 79
Subioct Oxy Vent Gas Cleanup
received
jAN 3 0 Inn
CM M4**4
As part of the Louisiana Air Control Commission's State Implementation Plan, the VCM plant is expected to reduce the quantity of hydrocarbons in the oxy vent by a minimum of 65 percent. Present regulations call for compliance by October 1981. The following table lists capital costs and annual operating costs (both with and without capital charges for a 10 percent DCF) for the alternates considered:
Process
Solvent Absorption Oxygen-Based Oxy Carbon Adsorption Catalytic Oxidation
Capital Cost, $
2,600,000 2.870.000 3.170.000 3.420.000
ANNUAL OPERATING COST, $
(1) (2)
(108,000) 1,917,000
(28,000) 354,000
398,000 2,465,000
577,000 1,007,000
(1) Total operating cost ex depreciation. (2) Total operating cost including depreciation and capital
charges for a 10 percent DCF.
Solvent absorption has the lowest capital cost and the lowest operating cost. It is, therefore, the most attractive (or least unattractive) of the proposals and is recommended.
There are two additional considerations that would cause me to recommend oxygen-based oxy over solvent absorption in spite of the higher capital and operating costs and the fact that it is not commercially proven. Solvent absorption does not remove VCM from the vent stream. If a re quirement to reduce the VCM to 5 or 10 ppm were imposed at a later time, one of the other three alternates would have to be installed either in place of or along with solvent absorption. Oxygen-based oxy also has the advantage of increasing the capacity of the oxy section. I believe that at least 50 MM pounds per year of additional VCM could be produced with minor changes outside of the oxy section. If it is believed that either of the above considerations are true, I recommend proceeding with oxygen-based oxy at this time.
I am prepared to discuss these conclusions at anytime.
R. W. Churns Senior Process Engineer Chemicals Division Process Engineering Department
lkm EnC
SAU 000064996
G. L, Foshee Page 2 CC: JADe:HDC:JOG:DG:DAK:DJ R:GJH RJR:CMS:RJC:RJC:GJF:MEK File A-2 7.1
SAL 000064997
DISCUSSION
ECONOMIC EVALUATION
OXY VENT GAS CLEANUP
LAKE CHARLES VCM PLANT
As part of the Louisiana Air Control Commission's (LACC) State Implemen tation Plant (SIP) , the VCM plant is expected to reduce the quantity of hydrocarbons in the oxy vent by a minimum of 65 percent. The present regulations call for compliance by October 1981. Four possible solutions for achieving this reduction have been investigated:
1. Solvent absorption 2. Converting oxy to oxygen-based 3. Carbon adsorption 4. Catalytic oxidation
None of these solutions can be economically justified on EDC recovery or cost savings. As shown in Table I, solvent absorption has the lowest capital cost and the lowest operating cost. It is, therefore, the most attractive (or least unattractive) proposal and is recommended.
The present regulations make it advantageous to have a system which can operate at a 65 percent hydrocarbon reduction but can achieve a higher reduction with operating changes or minor design changes. Solvent ab sorption and carbon adsorption (with some difficulty) can do this. Oxygenbased oxy and catalytic oxidation, for all practical purposes, can only operate at 100 percent hydrocarbon reduction.
At this time, the VCM plant oxy section must, in addition to the hydro carbon reduction called for in the Louisiana SIP, comply with the EPA VCM standard of 0.0002 pound VCM per pound of 100 percent EDC product from oxy. We are presently in compliance with this regulation. It is not unreasonable to expect that EPA may at some future time impose the same restrictions (5 or 10 ppm VCM) on oxy reactors as on other parts of VCM plants. Oxygen-based oxy, carbon adsorption (possibly), and cata lytic oxidation systems can all reach this level. Solvent absorption will not remove more than a small part of the VCM.
Oxygen-based oxy enjoys an advantage not possessed by the other alternates in that it permits an increase in oxy section throughput. Because the ca pacity of the VCM plant is limited by the amount of HCl that can be consumed in oxy, this increase leads to an increase in VCM production. Subject to confirmation by more detailed calculations, I believe that an increase in VCM production of at least 50 MM pounds per year can be achieved with little or no capital investment outside of the oxy section. Table II shows the amount of incremental VCM that must be produced to justify the investment in oxygen-based oxy. This table includes calculations at different oxygen prices, capital investments, VCM netbacks, and returns on investment. An incremental VCM production of 63 MM pounds per year will bring a 15 percent DCF return on an investment of $4.3 MM at an oxygen price of $60 per ton and a VCM netback of $0.05 per pound. This potential capacity increase,
000^98
Dis cussion Page 2
*
coupled with the ability to eliminate VCM emissions, makes oxygen-based oxy an attractive alternate. If it is believed that more stringent VCM regulations will be in effect soon, I recommend, choosing the oxygen-based oxy alternate for oxy vent gas cleanup.
Solvent Absorption
Two variations of solvent absorption were considered. Each could be operated to remove either 65 percent or 90 percent of the oxy vent stream hydrocarbons. One scheme took the oxy vent gas from S-306 after it had been condensed against cooling water in H-305. This reduced the load on the propylene refrigeration system by eliminating the refrigerated after condenser, H-306, from the system. The other scheme used oxy vent gas from S-307 after it had been condensed against propylene refrigerant in H-306. The latter approach was selected because it had a lower capital cost and a lower operating cost (primarily steam to the EDC stripper reboiler) than the first one.
EDC is removed from the oxy vent gas by being absorbed in the solvent, a narrow-cut, aromatic distillate. The vent gas passes through a separator vessel (the spare S-307) to knock out entrained HC1. It enters EDC absorber C-350 below the bottom tray and passes through the column coutercurrent to the solvent. Rich solvent from the bottom of the absorber exchanges heat with lean solvent from the bottom of the EDC stripper, 0-351, in spiral solvent interchangers H-351A and B. Lean solvent is fed to the top tray of the EDC absorber. Rich solvent is fed below the center of the EDC stripper. Heat to the stripper is provided by 250 psig steam in a verti cal thermosyphon reboiler. The overhead vapors are partially condensed against cooling water. The liquid is returned to the column as reflux.
The vapor is recovered by compression with liquid ring compressors using cold EDC as the seal fluid and condensation against propylene refrigerant. The liquid product is sent through the existing washing and distillation sections where EDC is recovered as furnace feed and light ends (ethyl chloride) is recovered for sales or incinerator fuel.
This system has the advantage of being a proven process, as it is a part of the B. F. Goodrich and Ethyl VCM packages. This may lead to legal difficulties, as both of them have disclosed their processes to us and Toyo Soda hold a U.S. patent on this process. This system has no effect on VCM, ethylene, or carbon monoxide. It has the lowest capital and operating costs of any of the alternates.
Oxygen-Based Oxy
Tills proposal eliminates hydrocarbons in the oxy vent stream by replacing air as the oxidant with pure oxygen. This reduces the size of the vent so that it can be handled in the existing incinerators. This process is different from the others in that it changes the oxy system rather than treating the vent gas and leaving oxy as is.
SAL OOOO64999
Discussion Page 3
Oxygen-3as ad Oxy (Continued)
In the revised process, HC1, oxygen, fresh ethylene, and recycle ethylene are fed to the existing primary oxy reactors. Product EDC and water are condensed against cooling water and sent to the existing wash system. Noncondensables, including ethylene, which has replaced nitrogen as the diluent, are scrubbed with caustic and compressed. Host of this stream is recycled to the reactors. A purge stream is dried by condensing the water against propylene refrigerant and by dessicant. This stream is sent to the direct chlorination reactor where the ethylene reacts to form EDC. Tnerts, including CO and CO2, are vented from there to the existing incinerator system. This system is based on a proposal from Stauffer who have done pilot work on it. There is no operating prototype for this design, although Stauffer have told us that Shell have purchased equipment to convert their oxy to this type. PPG, Monsanto, Kellogg, and Mitsui Toatsu license and operate oxygen-based oxy processes.
The advantages of this proposal are that it allows an increase in VCM production, reduces oxy by-product formation, and reduces the size of the oxy vent gas stream, thus allowing it to be incinerated. At the time of Fluor's work on the VCM expansion, the plant capacity was limited by oxy, propylene refrigeration capacity, the EDC vaporizers, and the heavy ends column. Since then a new turbine has been purchased for the propylene compressor. New convection sections have bean installed in the cracking furnaces, thus unloading the EDC vaporizers. The EDC tar still overhead stream has been taken out of the caustic wash, thus im proving the heavy ends column feed quality. With the removal of oxy bottlenecks and subject to confirmation by more detailed calculations, I believe that an increase in VCM production of at least 50 MM pounds per year is possible. A reduction in oxy by-product formation results from eliminating the cleanup reactors. This replaces EDC produced in the low efficiency cleanup reactors with EDC produced in the direct chlorination reactor. EDC from the primary oxy reactors should also improve in quality by increasing the ethylene concentration and driving the reaction to EDC. This advantage was not considered in the economic calculations. The oxy vent gas stream goes to the direct chlorinator where the ethylene reacts to form EDC. Inerts present increase the size of the direct chlorinator vent stream but should not overload the inciner ators .
At the prices used, this project is economically attractive with an incre mental VCM production of 53 MM pounds per year. This is highly dependent on oxygen price. If $30 per ton 02 is used instead of $60 per ton, the incremental VCM production required falls to 22 MM pounds per year.
Carbon Adsorption
The carbon adsorption scheme is similar to those considered for PVC plants. Chlorinated hydrocarbons are adsorbed onto activated carbon sites as the oxy vent gas passes through the carbon beds. The hydrocarbons are desorbed by heating the bed through an internal steam coil and evacuating the vessel
SAL 000065000
Disc ; ion
Page ,
<
Carbon '.dsorption (Continued)
with vacuum pump. EDC and light ends are recovered by condensation against propylene refrigerant. The bed is then cooled to be put back in service.
Carbon adsorption can achieve either 65 or 95 percent reduction in the hydrocarbon content of the vent gas. It will reduce the VCM to acceptable levels but has little effect on CO or ethylene.
Cotalvtic Oxidation
Catalytic oxidation reduces the hydrocarbon content of the vent stream by converting the chlorinated and nonchlorinated hydrocarbons to HCl, C02, and H20. It is similar to conventional incineration except that the catalyst allows the oxidation to take place at a lower temperature, thus reducing the size and fuel requirements of the equipment. We evalu ated catalytic oxidation following the oxy system and also after solvent adsorption. The solvent adsorption step reduced the organic load and thus the size and operating cost of the reactor and HC1 recovery system. This alternate was selected.
In this process, air and the oxy vent gas are separately preheated in a Furnace. They are mixed and fed to a reactor containing the catalyst. Reactions to HCl, C02> and H2O take place in the reactor. The heat of reaction is removed by generating 250 psig steam. The reactor effluent goes to C-500 where the reaction is quenched and HCl is scrubbed out.
This approach has the highest capital cost and one of the highest operating costs. Solvent absorption and catalytic oxidation costs must be added to arrive at the total capital and operating costs. This approach eliminates all hydrocarbon air pollution from oxy.
KWC-lkm 1/23/79
SAL 000065001
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