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16 - CHM - Chemical and Process Engineering

CHM 120 - Advances in Ethylene Unit Pyrolysis Furnace Design and Optimization

Code Start Date Duration Venue
CHM 120 27 May 2024 5 Days Istanbul Registration Form Link
CHM 120 01 July 2024 5 Days Istanbul Registration Form Link
CHM 120 05 August 2024 5 Days Istanbul Registration Form Link
CHM 120 09 September 2024 5 Days Istanbul Registration Form Link
CHM 120 14 October 2024 5 Days Istanbul Registration Form Link
CHM 120 18 November 2024 5 Days Istanbul Registration Form Link
CHM 120 23 December 2024 5 Days Istanbul Registration Form Link
Please contact us for fees


Course Description

The heart of an ethylene plant is the cracking furnaces. They are complex equipment and represent the largest individual investment made in an ethylene plant.  The operation of the heaters greatly impacts the economic performance of the plant, so the incentive for maintaining cracking heaters in optimal operating and mechanical condition is significant.  They also require significant operator attention and maintenance. It is essential to have a well-running furnace section to ensure smooth and profitable operations at the plant and site. Frequently shutting down furnaces for decoking or maintenance costs money, disrupts downstream sections and prevents the plant from meeting its production targets. Operation of the ethylene cracking furnaces system is the main engineering direction to improve the economic performance, and to meet technical and environmental requirements. 

This 5 day course develops a multi objective operational paradigm for an industrial cracking furnace system that describes the operation of each furnace based on current feedstock allocations, and uses this model to optimize two important and conflicting objectives: maximization of key products yield and minimization of the fuel consumed per unit ethylene.  

Course Objectives

  • Developing key concepts and techniques for the optimization of Ethylene Unit 
  • Learning how to operate it to the fullest advantage of their plant.
  • Making operating decisions that can improve unit’s performance
  • Gaining comprehensive knowledge on Pyrolysis Process Technology 
  • Gaining Insights into the Overall Performance and Production Cost 
  • Realizing Key Equipment  and Furnaces Performance Parameters
  • Optimizing the Process Operation and Control 
  • Identifying Process Safety, loss prevention and Risk assessment. 
  • Achieving Reliable, Safe &  Trouble‐free Operation 
  • Identifying the main operating and constraints for an optimal, safe and reliable furnace operation, 
  • Identifying bad-quality combustion and implementing corrective steps 

Who Should Attend?

  • 1st Line Operations personnel,
  • Operation Supervisors,
  • 1st Line Maintenance personnel,
  • Maintenance Supervisors,
  • Senior Plant Supervisors,
  • Operations Engineers
  • Process Support Engineers,
  • Design Engineers,
  • Cost Engineers

Course Details/Schedule

Day 1

  • Overview of the chemical processing 
  • Industry review of process incidents
  • Types of hydrocarbon molecules 
  • Chemistry of combustion
  • Fired heater general types
  • Fire box, convection, stack and burners

Day 2

  • Fired heater engineering 
  • Pyrolysis furnace design guidelines
  • Improve the efficiency of fired heaters 
  • Fired heater process control optimization
  • Fired heater’s boiler control optimization

Day 3

  • Fired heater safety 
  • Revamping fired heaters
  • Upgrade convection section
  • Upgrade instrumentation and controls 
  • Maximizing furnace life
  • Designing for improved maintenance 
  • Reducing NOx emissions

Day 4

  • Ethane/Naphtha furnace technology 
  • Design constraints, residence time, partial pressure, and low pressure
  • Comparison of current designs, one pass, two pass U, W, hybrid coils
  • Design and normal run lengths of current designs, 
  • Factors affecting run lengths
  • Anti-Coking
  • Future opportunities

Day 5

  • Advanced process control and safety devices
  • Ethylene furnace troubleshooting 
  • Coils failure incidents and troubleshooting 
  • Failure of ethylene furnace outlet transfer line 
  • Overheating problems
  • Convection bowing
  • Insulation