Kinetic modeling of industrial steam cracker

A comprehensive mathematical model is a very useful tool for the selection of feedstock, optimized cracker product mix, downstream production planning, and optimized plant performance. As a part of achieving this prime objective, a mathematical model has been developed for the simulation of the radiation section of a steam cracker unit. The model involves solving differential component, energy, and momentum balance equations numerically to generate temperature, concentration, and pressure profiles along the length of the reactor tube. The model has been developed in FORTRAN using the lSODE solver. The model considers 19 free radicals and 35 molecules connected over 433 reactions. The model was used to simulate the performance of propane and ethane cracking. The model predicted propane conversion is 95.55 against the plant data of 95% at a coil outlet temperature of 845 ​°C and the corresponding predicted ethylene and propylene yield is 34.49 and 11.53% respectively. The model has been validated for ethane cracking performance. The model predicted ethylene yield is in good agreement with that of plant values for ethane cracking. The model provides a basis for the optimization of process parameters for the given geometry. The model is useful to answer what-if questions and to investigate operational strategies.