Modelling and dynamic optimization of thermal cracking of propane for ethylene manufacturing

In tubular reactors inside a cracking furnace, heat transfer, thermal cracking reactions and coke buildup take place and closely interact with each other. It is important to understand the process and optimize its operation. A 1-dimensional (1D) pseudo-dynamic model was developed based on first principle and implemented in gPROMS®. Coke buildup inside the tube wall was also accounted for. The model was validated dynamically. The impact of process gas temperature profile, and constant tube outer wall temperature profile on product yields and coking rate are assessed. Finally, dynamic optimization was applied to the operation of this tubular reactor. The effects of coking on reduction of production time and the decoking cost have been considered. The tube outer wall temperature profile and steam to propane ratio in the feed were used as optimization variables. Dynamic optimization investigation indicates that it can improve operating profit by 13.1%.

► 1D pseudo-dynamic modelling of PFR for thermal cracking of propane in ethylene manufacturing.
► Dynamic model validation.
► Study of the impact of coke buildup inside tube wall.
► Steady state optimization for process operation.
► Dynamic optimization for process operation.