Evaluation of Jet Flooding in Distillation Column Olefins Plant on Naphtha to LPG Feed Substitution

The naphtha cracking process is the most commonly used technology for the production of ethylene, propylene, mixed C4s (including 1,3-butadiene and other C4 components), and pygas (pyrolysis gasoline, a mixture of benzene, toluene, and xylene), all of which are olefins. The cracking furnace and distillation columns are the primary operational units. The raw material is cracked and undergoes reactions in the cracking furnaces, while the distillation columns are responsible for separating the products. Raw material costs account for 80% of production costs. There is also the possibility of using LPG as a less expensive alternative to some of the naphtha. However, changing the raw material would affect the operability of the distillation columns and influence the yield on the cracking side. To determine the optimal naphtha substitution for LPG without causing hydraulic problems (such as jet flooding) in the distillation columns, analysis using simulation tools must be conducted. A reliability model is being developed to simulate the substitution of naphtha with other feed stocks by comparing simulation results with data from the actual plant. The LPG flow is a variable that is freely adjusted to substitute for naphtha. Simulation tools can be used to assess the effects of economically advantageous naphtha substitution for LPG without compromising plant operability. The optimum naphtha substitution rate is 21.14% from the base case, resulting in jet flooding occurring at Propylene Fractionator No. 2. By implementing this substitution, the benefits that can be obtained amount to USD 22,772.02 per hour.