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BASF and acetylene
How to make acetylene
Partial Oxidation
BASF Sachsse-Bartholom
BASF (D/USA) Ukraine, China
Montecatini process
Lonza (CH)
Calciumcarbide:
China, Japan, former USSR, Eastern
Europe
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BASF and acetylene
Partial oxidation of hydrocarbons
balanced
AOG
Acetylene
Partial oxidation (~ 60 % methane) Acetylene Formation
2CH4 + O2 2CO + 4H2 2CH4 1500C C2H2 + 3H2
residual methane 4%
2H2 + O2 2H2O
residence time a couple of 1/1000 sec
Flame, exothermal; Temp. ~ 1500C
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BASF and acetylene
Technology of premixed combustion
with reaction quenching
Reactands
O2 u = 25 m/s
T=600C
CH4
Mixing-
unit u > 150 m/s
avoid
flash back
O2
Recirculation
Burner-
block Main flame
Quench
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BASF and acetylene
Burner characteristics
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BASF and acetylene
Table of contents
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BASF and acetylene
Overview
AOG : CO+H2+CO2+...
Generation
CH4 CH4 + O2
C2H2 + CO + H2 + Separation C2H2
O2 CO2 + H2O + HA +
aromates + soot compression
H2O+soot+... HA+aromates+...
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BASF and acetylene
BASFs new closed water quench
3 burners
per cooling (These hydrocarbons
column end up in wastewater
and HA-gas)
No
deleted emissions
deleted
Soot separation
by wastewater
pre-treatment
unit
fuel
WWTP
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BASF and acetylene
Emmission: open water quench
g/t Ac
CO 667
Methane 141
Ethane 20
Ethylene 36
Acetylene 6,203
higher Acetylenes 1,056
Benzene 162
Naphthaline 14
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BASF and acetylene
Cracked gas separation
AOG (raw synthesis gas)
Main Acetylene
Stripper Vacuum
Scrubber Higher
Column
Acetylenes
(to power plant or flare or...)
HA-Gas
Prescrubber
Sec.
To wastewater
treatment plant
(WWTP)
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BASF and acetylene
Usage of acetylene off-gas (AOG)
Methanol
Methanol to chemicals
Methanol to olefins
Acetic acid
Vinyl acetate
Separation for production of H2 and CO
Any chemical, which requires H2 and/or CO
Ammonia / CO2
Urea
Fertilizers
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BASF and acetylene
Table of contents
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BASF and acetylene
e.g. safety aspect intrusion of air in vacuum sec.
Scenario
E.g. rupture of a 25 mm nozzle in the vacuum section at 200 mbar(abs.)
for example by a crane during maintenance work
Intrusion of 318 kg/h air (52 Nm/h O2)
Vacuum-Compressor feeds 3,000 Nm3/h acetylene
Oxygen content in acetylene is then 1.73 Vol.%
Limit is 1 Vol.%
at > 1 Vol.%
Sargent diagram no longer valid
Decomposition barriers no longer working
Instead of deflagration immediate detonation
may occur
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BASF and acetylene
Explosion regime acetylene/air
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BASF and acetylene
Autodecomposition of gas-mixtures
(acetylene and higher acetylenes)
Approach
Use of critical partial-pressures of pure components
Decomposition
Pressure [bar(a)]
Acetylene 1.4
Methylacetylene 1.8
Vinylacetylene 0.4
Diacetylene 0.2
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BASF and acetylene
Situation in acetylene recovery unit
11 bar
conti-O2 0,2 bar
120C
water,
vinylac.,
etc.
03.03.2003 18
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BASF and acetylene
Autodecomposition of gasmixtures
(Acetylene and higher acetylenes)
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BASF and acetylene
Acetylene plant in Geismar
50,000 t/a
8200 h/a
6 burner
2 burner trains
2 compressors
1 separation unit
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BASF and acetylene
Acetylene plant in Geismar
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BASF and acetylene
Conclusion
BASF closed water-quench process offers the only proven and clean
access to acetylene based on natural gas
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BASF and acetylene
Acknowlegement
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