Performance monitoring and optimization of steam crackers

A continuous performance monitoring system for steam crackers is presented that compares the real daily/monthly/yearly performance data to those theoretical maximum values that could be reached at optimum as well as at ideal circumstances.

Theoretically maximum production data are calculated on basis of a proven pyrolysis yield model, results of which are linearized and summarized according to certain mathematical formulas. Optimum circumstances
are considered when processing feeds with their real (measured) compositions at smooth operation. Ideal circumstances are counted when processing feeds with their best composition (available from the supplier) for thermal cracking.
Optimum feed-furnace structures are also calculated for both cases. Besides the production data specific feed and energy consumptions are also monitored daily. Variations are analyzed and causes are registered.
This monitoring system is applied for all three steam crackers of MOL Petrochemical Division. By means of a financial analysis performed in parallel, the optimum cracking severity can also be determined. On basis of
performance analysis bottlenecks of production capacity can also be discovered and development strategies can be built up as well.

Szabolcs Simon, Tivadar Gál Dr.