2025 Spring Meeting and 21st Global Congress on Process Safety
(48c) Comprehensive Turbomachinery Solutions for Reducing Carbon Intensity of Ethylene Plants
Author
Yuya Tanaka - Presenter, Mitsubishi Heavy Industries
In recent years, the momentum toward carbon neutrality has intensified, leading to a growing desire to reduce carbon emissions (decarbonization) in ethylene plants. Mitsubishi Heavy Industries Compressor Corporation (MCO) has extensive experience manufacturing compressors and associated steam turbine drivers used in ethylene plants, with operating capacities reaching up to 2,500 kTA. We have leveraged our experience to modernize numerous compressors and turbines that have been in operation for the last 30 to 40 years. This study presents compressor train solutions to reduce carbon intensity in both greenfield and brownfield modernization projects for ethylene plants.
Recently, MCO was awarded a contract to supply three main compressors, steam turbines and steam turbine generators for world’s first net-zero carbon emissions integrated ethylene cracker and derivatives complex, addressing scope 1 and 2 carbon dioxide emissions. MCO is contributing to the project's emissions goals by providing a high-power steam turbine, rated at 103MW, for CGC service, along with steam turbine generators that utilize a limited amount of steam extraction from the CGC steam turbine. The project is consists of multiple phases, with plant capacity expected to increase from 1,500 kTA to 2,500 kTA throughout these phases. Our compressors and steam turbines have also been designed to accommodate this wide production range without requiring any modifications as the capacity grows.
Petrochemical plants frequently internally revamp or replace turbomachinery in order to increase plant capacity or to improve efficiency (thus improving OPEX) by upgrading to the latest turbomachinery technology. When upgrading an existing plant, it is preferable to minimize the scope of modification to keep overall investment costs low. Drawing from our extensive experience in footprint replacement projects - having delivered more than 350 units and technologies - we are capable of proposing optimization solutions while minimizing the scope of modifications based on the existing plant conditions or specific customer requests.
Furthermore, from the perspective of a steam turbine manufacturer, MCO is well-equipped to provide advice on technical and commercial viability of replacing steam turbines with electric drivers to assist end-users in transitioning towards lower-carbon petrochemical plants.
In conclusion, there is a recent trend toward enhancing the productivity and reducing the carbon footprint of existing plants. We believe this study can serve as a valuable reference for all stakeholders involved in these projects, and we hope it will educate new stakeholders about the potential opportunities in the design of future plants.
Recently, MCO was awarded a contract to supply three main compressors, steam turbines and steam turbine generators for world’s first net-zero carbon emissions integrated ethylene cracker and derivatives complex, addressing scope 1 and 2 carbon dioxide emissions. MCO is contributing to the project's emissions goals by providing a high-power steam turbine, rated at 103MW, for CGC service, along with steam turbine generators that utilize a limited amount of steam extraction from the CGC steam turbine. The project is consists of multiple phases, with plant capacity expected to increase from 1,500 kTA to 2,500 kTA throughout these phases. Our compressors and steam turbines have also been designed to accommodate this wide production range without requiring any modifications as the capacity grows.
Petrochemical plants frequently internally revamp or replace turbomachinery in order to increase plant capacity or to improve efficiency (thus improving OPEX) by upgrading to the latest turbomachinery technology. When upgrading an existing plant, it is preferable to minimize the scope of modification to keep overall investment costs low. Drawing from our extensive experience in footprint replacement projects - having delivered more than 350 units and technologies - we are capable of proposing optimization solutions while minimizing the scope of modifications based on the existing plant conditions or specific customer requests.
Furthermore, from the perspective of a steam turbine manufacturer, MCO is well-equipped to provide advice on technical and commercial viability of replacing steam turbines with electric drivers to assist end-users in transitioning towards lower-carbon petrochemical plants.
In conclusion, there is a recent trend toward enhancing the productivity and reducing the carbon footprint of existing plants. We believe this study can serve as a valuable reference for all stakeholders involved in these projects, and we hope it will educate new stakeholders about the potential opportunities in the design of future plants.