Since receiving its first contract award in 1966 to build a 200,000 ton/year ethylene plant in Japan, TOYO has maintained a technical alliance with Lummus on ethylene process technology and has been involved in 45 grassroots plants as well as 45 plant retrofit or revamping projects that include technology licensing and/or EPC. The largest ethylene plant ever designed by TOYO has a capacity of 1,200,000 ton/year of ethylene, licensed to Formosa Petrochemical Corp. of Taiwan in 2003.
The features of the Lummus ethylene process are the use of an SRT furnace (Short Residence Time furnace) with an excellent selectivity, feedstock flexibility, operational reliability and safety. It is also easy to start up and uses energy efficient technology incorporating a highly efficient steam cracker and downstream fractionation units. The recent innovation of Lummus's olefin technology is listed below as new technology.
The new technology including the integration of a steam cracker unit with OCT (Olefins Conversion Technology) provided by Lummus, delivers improved plant performance as presented below.
The world's leading track record in ethylene plant construction
Since the execution of collaboration agreement with Lummus in 1962, TOYO has constructed ethylene plants in 45 projects around the world. Our work ranges from basic design based on the license of Lummus to detailed design, procurement, construction and commissioning. Of the total 159 ethylene plants constructed since 1986 worldwide, 43% adopted the Lummus technology and TOYO has constructed 17%. As can be seen, the combination of Lummus and TOYO boast the leading shares in licensed technologies and construction experience.
Share of ethylene plant award since 1986 (as of 2022)
Features of the process with new technologies / OCT
- High capacity SRT-X with ethylene production capacity of up to 300 KTA and high selectivity SRT-VII pyrolysis module
- Low-pressure chilling train
- Binary/Tertiary Refrigeration
- CDHydro® - Catalytic distillation hydrogenation
- Olefins Conversion via Metathesis (OCT)
- Environmental improvement, GHG & NOx Reduction
Features of energy efficiency and environmental impact side
- Energy consumption: 12% reduction
- Greenhouse gas emissions: 12% reduction
- ISBL equipment count: 23% reduction
- Compressor power: 14% overall reduction
- Operating margins: up to 30% improvement
Solution for CO2 Reduction in Ethylene Plant
Gas Turbine Integration to existing furnace(GTI）
・GTI process use gas turbine to produce power while simultaneously utilizing the hot oxygen rich exhaust gas as combustion air in the furnace.
・It can be seamlessly integrated into existing plant
・High thermal efficiency of 90% or more can be achieved by combining with Ethylene plant as well as energy supply.
・Reductio energy for entire plant by 13% and CO2 reduction by 21%.
・Construction experience : 6 in domestic and 7 in overseas
GTI Cracking furnace
GTI System Flow scheme