EXPERTS IN
ETHYLENE
SOLUTIONS
CUSTOMER PROCESS BROCHURE
HYDROCARBON PROCESSING
• Comprehensive gas • Latest technology • Safety maintained through
analysis solution covering breakthroughs deliver fast response technology
entire ethylene production cutting edge performance with high measurement
process
The precise and rapid analysis of
process gases within an ethylene
plant is vital to ensure safe and
efficient operation. A range of
process efficiencies can be achieved
by shortening the residence time in
the cracking furnace; rapidly adapting
to changing feed-stocks; improving
combustion control; optimizing
fractionation; and improving process
reliability. Safety is also improved as a
result of fast, reliable process analysis
technologies with high measurement
availabilities.
benefits
As the world expert in gas analysis,
Servomex has worked with ethylene
producers worldwide to create gas
analysis solutions that deliver optimum
process efficiency while maintaining
the highest levels of safety.
By offering operators the widest
available range of gas measurement
technologies, including breakthrough
measurements for light hydrocarbons,
Servomex delivers the precise correct
measurement for each point in the
process.
availability
The result is measurable performance
advantages, delivered with enhanced
safety as standard. Servomex
analyzers and systems are reliable and
economical, designed to deliver high
performance over a long performance
lifetime with lower cost-of-ownership.
Informed by our leading-edge expertise
in hydrocarbon gas analysis, and
supported by a global network of
Service and Support, Servomex brings
you control and confidence to every
point in the ethylene process.
ETHYLENE PROCESS
APPLICATION MAP
ETHYLENE CRACKING FURNACE
9 Fluegas 4900
O2, CO, NOX, SOX

FluegasExact 8
O2 & COe

Steam
SpectraScan
H2Scan
Fuel C1 to C5 H2
SpectraExact 2
ppm CO2
Feed Treating

SpectraScan
1
C1 C5
3
SpectraExact
SpectraScan
CO2 C1 to C5 Recycle Ethane

PROCESS DESCRIPTION
The SERVOTOUGH SpectraExact 2500 and SpectraScan
2400 (1) monitor the feed gas quality for high carbon
monoxide (CO) and to maintain a consistent feed to the
cracking unit, while the SpectraExact (2) monitors the
feed treating for carbon dioxide (CO2) removal. After the
recycled ethane has been blended with the treated feed, the
SpectraScan (3) maintains a consistent feed to the cracking
unit. The SpectraScan (4) and H2scan (5) maintain constant
fire and heating rates of the steam boiler and cracking unit,
with a real time, low maintenance BTU analysis, especially
when hydrogen (H2) and methane (CH4) rich tail gases are
recycled to the burners. Rapid, real time analysis of the feed
gas (3) and heating rate (5) is vital to prevent under- or
over-cracking, establish the conditions for maximum cracking
efficiency and the longest interval between de-coking cycles.
Optimized and safe combustion and reduced fuel consumption
is achieved by both detailed fuel analysis and rapid flue gas
analysis. The SERVOTOUGH FluegasExact 2700 (6) and (8)
offers analysis of both oxygen (O2) and combustibles (COe),
while the SERVOTOUGH LaserSP 2900 (7) offers an average
path analysis across the cracker unit. This delivers a fast and
KEY:
APPLICATION
TYPES:

10

12 Fluegas 4900 Fluegas 4900

O2 & NOX O2, CO, NOX, SOX

13

Laser SP Common
SCR
ppm & NH3 Stack

Fluegas 4900 11
O2 & NOX 14 15

SpectraScan SpectraExact
7 Laser SP H2Scan SpectraScan
CH4, O2 & CO C1 to C5 H2 H2Scan
6 FluegasExact CO2 C1 to C5 H2
O2 & COe
Prolysis
Probe

TLE

SpectraScan 5
H2Scan
C1 to C5 H2
Fuel

highly accurate analysis (<4s) of O2 and CO, as well as the On the outlet of the cracker unit a transfer line exchanger
added safety feature of measuring CH4 breakthrough. (TLE) rapidly cools the cracked gas to preserve the gas
composition: the SpectraScan and H2scan (14) monitor
Continuous Emissions Monitoring Systems (CEMS) utilizing
the gas quality after the cracking unit, ensuring the highest
the SERVOPRO 4900 (9)(10)(11)(12) and Servomex sample
possible ethylene yield and to prevent under- or over-
systems are used to measure the stack emissions for legislative
cracking. During the decoke cycle a SpectraScan (14) with
requirements of O2, CO, NOx and SOx. The 4900 can also be
added CO2 channel can also be utilised to monitor CO2 levels,
installed either side of a Selective Catalytic Reduction Unit to
as well as ensure the shortest decoking cycle with real time
monitor the SCR’s efficiency in reducing NOx emissions, while
analysis, or a separate SpectraExact (15) can be utilised for
the LaserSP (13) monitors the NH3 level, allowed to “slip”
this measurement.
through the catalysis during the NOx reduction reaction.
ETHYLENE PROCESS
APPLICATION MAP
QUENCHING, SCRUBBING, COMPRESSION AND DRYING

Gasoline/Fuel oil
Fractionation
Caustic &
water wash
Water
Quench Tower

Compression

SpectraExact
ppm CO2
1

Fuel Oil
Gasoline

QUENCHING COMPRESSIO

PROCESS DESCRIPTION
After the cracking is complete, the gas feed needs to be
cleaned and conditioned before fractionation. The gas is
further cooled to remove any heavy hydrocarbons, while
remaining CO 2 is also removed as this can freeze out in
the liquefaction stages later in the process. This process
is measured by the SERVOTOUGH SpectraExact 2500
(1), which measures <5ppm CO 2 for rapid analysis of
any CO 2 breakthrough.
The performance of the dryer / chiller stage is monitored
by the SERVOTOUGH SpectraScan 2400, SERVOTOUGH
SpectraExact 2500 and H2scan (2) (3) (4), to ensure
that only minimal levels of C1 & C2 are separated with the
hydrogen (H2). The H2 can be further purified by a Pressure
Swing Absorber (PSA), the output of which can be monitored
for impurities by the SpectraExact, LaserSP, SERVOPRO FID
and DF-370 (3), depending on individual requirements.
 KEY:
APPLICATION
TYPES:

High purity
PSA
hydrogen
3 LaserSP
CO, 0-5 ppm
SpectraExact
CO2, CH4, 0-10 ppm
Hydrogen rich
tail gas

2 SpectraExact
SpectraScan
H2Scan
Compression C1, C1 to C5, H2
Drying

To Demethaniser
SpectraExact 4
SpectraScan
H2Scan
ppm CO,
C1 to C5, H2
To Deethaniser

ON, CAUSTIC SCRUBBING & DRYING

ETHYLENE PROCESS
APPLICATION MAP
FRACTIONATION AND RE-HYDROGENATION
Methane rich tail gas
SpectraExact
3
SpectraScan
H2Scan
ppm CO, C1 to C2, H2
Hydrogen rich tail gas
SpectraExact 2
SpectraScan
H2Scan
ppm CO, C1 to C2, H2

Cold box H2

SpectraExact
1
SpectraScan
H2Scan 5
ppm CO, C1 to C2, H2
SpectraScan
Demethaniser C1 to C3

Gas from drying

Deethaniser
Acetylene
& chilling converter

Ethane
recycle
feed

SpectraScan
4 C1 to C5
10
SpectraScan
C2 to C5

PROCESS DESCRIPTION
The clean and dry cracked gas is now ready for fractionation
into its component parts. The demethaniser separates the
CH4 and remaining H2 from the cracked gas, the “tops”
of the column can be monitored by a SpectraExact,
SpectraScan and H2scan (1) to ensure valuable
hydrocarbons are not lost. A cold box or chiller is then
used to split any H2 from CH4, producing H2-rich and CH4-
rich tail gases which are monitored by the SpectraExact,
SpectaScan and H2scan (2) & (3) The “bottoms” of the
Demethaniser are monitored by a SpectraScan (4) to ensure
there are only low levels of CH4 present.
The SpectraScan’s unique light hydrocarbon analysis then
delivers multiple measurement points across the C1 to C3
 KEY:
APPLICATION
TYPES:

8 SpectraScan 9 DF-370
C1 to C3 ppm O2
SpectraExact SpectraScan Ethylene
ppm CO2 C2 to C5 liquidification
and storage
Ethylene
Compression
6
SpectraScan 13 SpectraScan
C1 to C3 C2 to C5
H2Scan Propylene
C2 Splitter

H2
H2
C3 Splitter

11

7 SpectraScan SpectraScan
C1 to C3 C2 to C5 12
SpectraScan Propane
C2 to C5 SpectraScan
C2 to C5 14
H2Scan
H2 Olefins
Depropaniser

Debutaniser

SpectraScan
C2 to C5 Gasoline

fractionation (5) (7) (8) (10) (11) (13) (14) (15); at each
of these measurement points the SpectraScan is used to
minimize hydrocarbon losses from the “tops” or “bottoms”
of the fractionation columns, and due to the fast analysis
of the SpectraScan real time optimization of the columns
is possible for the first time. The SpectraScan and H2scan
(6) (12) are used to optimise the hydrogenation units,
these convert acetylene (C2H2) and C3H4 to ethylene (C2H4)
and propylene (C3H6) by the addition of H2. Too much H2
is inefficient, risking over-conversion or the H2 becoming a
contaminant in the ethylene andp propylene products. Before
the ethylene is stored, trace O2 as a contaminant can be
measured using the DF-370 (9).
 ETHYLENE ANALYSIS SOLUTIONS
FluegasExact 2700 FID
SERVOTOUGH

SERVOPRO
THE WORLD’S
TRACE
MOST ADVANCED
HYDROCARBON
FLUEGAS
ANALYZER
ANALYZER

LaserSP 2900 4900

SERVOTOUGH

SERVOPRO
HIGH- MULTIGAS
SENSITIVITY CONTINUOUS
CROSS-STACK EMISSIONS
TDL ANALYZER ANALYZER

SpectraScan 2400 H2Scan CHIP ON A FLEX

SERVOTOUGH

TECHNOLOGY
REAL-TIME LIGHT PROVIDING A
HYDROCARBON ROBUST AND
GAS ANALYZER RELIABLE DIRECT
MEASUREMENT

SpectraExact 2500 DF-370

SERVOTOUGH

HIGH
DF RANGE

PHOTOMETRIC SENSITIVITY
MULTIGAS DIGITAL TRACE
ANALYZER O2 ANALYZER

CP/HP2 Rev. 1 03/16

RANGE

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