The Nalco Champion PrimAct™ programs provide new technology to improve gasoline fractionator (a.k.a. primary fractionator) operations. Our integrated technology provides innovative monitoring and chemistry that not only mitigates fouling and viscosity control problems, but also provides a clear window into the tower operation, allowing ethylene producers to optimize their operations and realize significant energy and reliability credits.
Nalco Champion has dedicated significant research resources to primary fractionators in recent years. Our goal is to provide monitoring tools that not only tell an ethylene producer how the system is performing now, but predict future performance based on operational parameters.
Fouling in the Top Section of the Tower Fouling in the top section of the tower is generally attributed to polymerization of reactive species in the stream, primarily styrene, indene and other unsaturated hydrocarbons. Severe fouling problems threaten the desired throughput and run lengths, reduce ethylene yields, potentially downgrade pygas and other products, and increase maintenance cost for the plant. Nalco Champion uses a comprehensive mechanical, operational and chemical (MOC) approach to assess the situation. We then implement a treatment program with a successful track record in mitigating primary fractionator fouling issues. We provide:
Proven polymer inhibitors and dispersants
Rigorous program monitoring and periodic reviews
Fouling severity predictions
Fouling and Viscosity Control in the Bottom Section of the Tower High viscosity and fouling as a consequence of polynuclear aromatics (PNA) destabilization is a common issue for many ethylene producers. As plants crack lighter feedstock, the residence time of the quench oil increases, increasing the probability for fouling and viscosity issues. High viscosity and fouling directly impact the tower’s ability to recover energy, resulting in higher total cost of production. They can also lead to premature plant shutdown. To combat the problem, some producers bring in flux oil, diesel or other diluent to reduce quench oil viscosity, which further increases the cost of operation. We provide effective viscosity control technologies that:
Reduce/eliminate the need for flux oil injection
Allow customers to increase tower bottoms temperatures to improve heat recovery