(48b) Electrifying Compression: A Decade of Success with Critical, Non-Spared Electric Motors and VFDs on Ethylene Production.

In the ongoing global effort to reduce carbon intensity, heavy industries are actively seeking methods to cut greenhouse gas emissions. For ethylene producers, residual waste heat converted to steam has traditionally been used to run downstream rotating equipment. However, electrification of significant process areas presents a viable path to decarbonization. Converting steam driven compression to electric motors and variable frequency drives is a “low-hanging fruit” that enjoys technical readiness level (TRL) – 9 status. Reflecting on a decade of reliable operating experience, this paper describes the performance of two critical compressors in an ethylene facility since their installation in 2013.

The first half of the paper describes the rationale behind choosing electric versus using process steam, highlighting key electrical, mechanical, and project management considerations essential for achieving sustained reliability and availability. Topics include power delivery, motor and drive technology selection, impact on the grid, motor cooling strategies, compressor design and the overall approach to equipment selection and procurement.

The second half provides insights from operators’ field experiences, detailing the operational and maintenance aspects of the electrical and mechanical equipment. It discusses initial challenges and what operational and maintenance procedures have been followed to maintain maximum utilization of equipment.

The industry faces challenges in managing the steam balance and carbon intensity, it is good to know that the reliability and cost of electric motors and drives make this solution a viable option. The intent is that the reader will gain an understanding of how technical, operational, and schedule risk can be minimized so that such a project can be considered for capital investment decisions.