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KBR SCORE Selective Cracking Optimum Recovery/Ethylene Technology Disclosure Number: IPCOM000217665D
Publication Date: 2012-May-10

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Selective Cracking Optimum Recovery

Ethylene Technology

Kellogg Brown & Root, Inc. Houston, Texas

January 2004

Paper No. 1822

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SCORETM Ethylene Technology


KBR was formed by the merger of the engineering and construction firms The M. W. Kellogg Company (Kellogg) and Brown & Root in 1998. In the same year, KBR signed a license agreement with ExxonMobil Chemical Company that resulted in the combining of experiences in technology, design and operations in steamcracking plants. The combination of, and improvements to, these three former separate technologies are the basis of KBR's SCORETM (Selective Cracking, Optimum REcovery) technology.

KBR's olefins experience dates back to the early days.of the olefins industry. Kellogg built the world's first naphtha cracker in 1951 for ICI in Wilton, England, and C. F. Braun (Braun), which was later incorporated into Brown and Root, built the world's first gas oil cracker in 1952 for Esso in Baton Rouge, Louisiana.

Development of the respective technologies continued into the 1960's, as Kellogg became the first designer to incorporate dephlegmators and plate-fin heat exchangers into the ethylene plant flowsheet in 1965. In 1967, Braun pioneered the development of the front-end acetylene converter and introduced the front-end deethanizer flowsheet for ethane cracking.

Kellogg continued fiowsheet development with the introduction of the front-end demethanizer flowsheet. Further refinements during the 1970's improved operational reliability, reduced plant costs, improved energy efficiency and increased plant size. These developments culminated in the construction of the world's two largest single- train ethylene plants at the time: one at Shell's facility in Deer Park, Texas and the other at Exxon's complex in Baytown, Texas, both of which are still in operation today.

In the 1980's, Braun introduced the LCET (Low Cost Ethylene Technology) design, which made extensive use of low pressure unit operations and process integration such

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Paper No. 1822

January 2004

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SCORETM Ethylene Technology

as heat pumped distillation. Further refinements of Braun's LCET design and of Kellogg's front-end demethanizer technology lead to major improvements in recovery section energy efficiency through the 1970's and 1980's.

As the energy price shocks subsided in the mid-1980's, focus again returned to reducing capital investment and overall project costs. Kellogg used their project execution capabilities to trim schedules. Green field ethylene projects were completed in as little as 29 months, from contract signing to ethylene product in the pipeline.

Kellogg was a pioneer in short contact time pyrolysis research in its R & D facilities, leading to the construction of the first Millisecond test furnace in Tokuyama, Japan in 1973. The first commercial scale Millisecond furnaces were built in Channelview, Texas in 1982, and in 1985, the first...