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requiring more heating, compression, pumping and separation. These effects will partly outweigh each other. Table 13 shows how energy consumption varies with feedstock (Stratton, 1983). Table 13. Breakdown of primary specific energy consumption (SEC) for ethylene production for different feedstocks. Feedstock energy is excluded. Source: Stratton (1983). Feedstock Ethane Naphtha GJ/t % GJ/t % GJ/t % GJ/t % Gas Oil U.S. Mix Heat of Reaction Compression 3.5 Heating and Separation 14.2 Losses SEC 19.4 6.2 20% 3.5 13% 17.7 66% 26.2 12.4 33% 4.1 11% 20.6 55% 31.9 6.0 23% 3.7 14% 16.8 63% 26.5 4.8 21% 16% 63% Note: The U.S. mix is assumed to be 60% ethane, 30% naphtha and 10% gas oil. Although the energy consumption data underlying the shares listed in Table 13 are relatively old, the efficiency level is comparable to the current U.S. situation. Calculating the weighted average, based on the U.S. feedstock mix and the total specific energy consumption figures listed in Table 13, leads to a SEC of 26.5 GJ/tonne ethylene, compared to our estimate of 26 GJ/tonne ethylene for the U.S. The ethane cracker described in Table 12 is slightly less efficient than the one included in Table 13. Table 13 shows only a limited breakdown In order to estimate energy savings potentials by individual measures a more detailed breakdown is needed, especially for the category of ‘heating, separation and losses’. For ethane we use the subdivision listed in Table 12. For other feedstocks a more detailed breakdown of energy consumption is given in Table 14, showing a naphtha cracker and a naphtha/ethane-propane-butane cracker (Di Cintio et al, 1993). Table 14. Detailed breakdown of energy consumption for a naphtha cracker and a flexible cracker. Source: Di Cintio et al (1992). Naphtha Cracker Flexible Cracker SEC (GJ/tonne) Feedstock Heating 20.7 Compression 4.8 Separation 6.3 Total 31.5 Share (%) 65% 15% 20% SEC (GJ/tonne) 13.1 3.6 7.2 23.9 Share (%) 55% 15% 30% Notes: The EEI of a naphtha cracker is about 150 (Phylipsen et al., 1998b) and of a high efficiency cracker, the EEI is approximately 120. In this calculation we assume a feedstock-mix of 70% naphtha, and 30% ethane/propane/butane (Di Cintio et al., 1993). According to Tables 12, 13 and 14 the energy consumption for separation varies between 6.3-7.3 GJ/tonne ethylene. Based on the U.S. feedstock mix and efficiency, we estimate separation energy consumption for the U.S. to be 7 GJ/tonne ethylene. The compression energy ranges from 3.5-5.2 GJ/tonne ethylene. Taking into account feedstock and efficiency, energy consumption for compression in the U.S. is estimated to be 4 GJ/tonne ethylene. With a total specific energy consumption of 26 GJ/tonne ethylene, cracker/feedstock heating energy consumption results in 15 GJ/tonne. Based on dilution steam rates listed by Di Cintio et al (1993) for various feedstocks and the U.S. feedstock mix, energy consumption for dilution steam can be estimated at 2 GJ/tonne 15 1PDF Image | Energy use and energy intensity
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