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Shale Gas to Ethylene (G2) - Revision history
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MichelleS: /* Economic Analysis */
2015-03-14T02:08:42Z
<p><span dir="auto"><span class="autocomment">Economic Analysis</span></span></p>
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<td style="background-color: #f8f9fa; color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #eaecf0; vertical-align: top; white-space: pre-wrap;"><div>Figure 2 displays the breakdown of energy usage, including heat exchangers, condensers, pumps, and other equipment. The areas with the highest energy usage are the cracking reactor with the quencher (34%), the fractionation train (32%) and ethylene splitter (26%). The high cracking reactor energy usage is as to be expected because it requires very high temperatures. The fractionation train and ethylene splitter require a lot of energy because both of these systems contains cryogenic separation.</div></td>
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MichelleS
https://processdesign.mccormick.northwestern.edu/index.php?title=Shale_Gas_to_Ethylene_(G2)&diff=3386&oldid=prev
Tammywong2015: /* References */
2015-03-14T02:07:38Z
<p><span dir="auto"><span class="autocomment">References</span></span></p>
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Tammywong2015
https://processdesign.mccormick.northwestern.edu/index.php?title=Shale_Gas_to_Ethylene_(G2)&diff=3385&oldid=prev
Tammywong2015: /* References */
2015-03-14T02:06:38Z
<p><span dir="auto"><span class="autocomment">References</span></span></p>
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<td colspan="2" style="background-color: #fff; color: #202122; text-align: center;">Revision as of 21:06, 13 March 2015</td>
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<td style="color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #a3d3ff; vertical-align: top; white-space: pre-wrap;"><div>Platts Global Petrochemical Index. Platts Global Ethylene Price Index, 2014. Available at: http://www.platts.com/news-feature/2014/petrochemicals/pgpi/ethylene</div></td>
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<td style="color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #ffe49c; vertical-align: top; white-space: pre-wrap;"><div><del style="font-weight: bold; text-decoration: none;">#</del>Praxair. Buying Ethylene, MSDS and Spec Sheet. Available at: http://www.praxair.com/gases/buy-ethylene</div></td>
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<td style="color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #a3d3ff; vertical-align: top; white-space: pre-wrap;"><div>Praxair. Buying Ethylene, MSDS and Spec Sheet. Available at: http://www.praxair.com/gases/buy-ethylene</div></td>
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<td style="color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #ffe49c; vertical-align: top; white-space: pre-wrap;"><div><del style="font-weight: bold; text-decoration: none;">#</del>Shanbhag N.G., America H. Compressed Air Best Practices. Calculating the Water Costs of Water-Cooled Air Compressors - Part 1 (n.d.) Available at:http://www.airbestpractices.com/technology/air-compressors/calculating-water-costs-water-cooled-air-compressors-part-1</div></td>
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<td style="color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #a3d3ff; vertical-align: top; white-space: pre-wrap;"><div>Shanbhag N.G., America H. Compressed Air Best Practices. Calculating the Water Costs of Water-Cooled Air Compressors - Part 1 (n.d.) Available at:http://www.airbestpractices.com/technology/air-compressors/calculating-water-costs-water-cooled-air-compressors-part-1</div></td>
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<td style="color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #ffe49c; vertical-align: top; white-space: pre-wrap;"><div><del style="font-weight: bold; text-decoration: none;">#</del>Shell Global Solutions. Sulfinol-M. Shell Website. Published 2012. Available at:http://s02.static-shell.com/content/dam/shell/static/globalsolutions/downloads/services/sulfino-m.pdf. </div></td>
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<td style="color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #a3d3ff; vertical-align: top; white-space: pre-wrap;"><div>Shell Global Solutions. Sulfinol-M. Shell Website. Published 2012. Available at:http://s02.static-shell.com/content/dam/shell/static/globalsolutions/downloads/services/sulfino-m.pdf. </div></td>
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<td style="color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #ffe49c; vertical-align: top; white-space: pre-wrap;"><div><del style="font-weight: bold; text-decoration: none;">#</del>Sims DW. Pre-fractionating the feedstock to separate into an ethane rich stream and a propane rich stream, steam cracking each stream to form ethylene. 1999, US5990370 A. http://www.google.com/patents/US5990370</div></td>
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<td style="color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #a3d3ff; vertical-align: top; white-space: pre-wrap;"><div>Sims DW. Pre-fractionating the feedstock to separate into an ethane rich stream and a propane rich stream, steam cracking each stream to form ethylene. 1999, US5990370 A. http://www.google.com/patents/US5990370</div></td>
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<td style="color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #ffe49c; vertical-align: top; white-space: pre-wrap;"><div><del style="font-weight: bold; text-decoration: none;">#</del>Sundaram, KM, Froment, KF. “Modeling of thermal cracking kinetics—I: Thermal cracking of ethane, propane and their mixtures.” Chemical Engineering Science. 1997; 32 (6): 601-608. doi:10.1016/0009-2509(77)80225-X.</div></td>
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<td style="color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #a3d3ff; vertical-align: top; white-space: pre-wrap;"><div>Sundaram, KM, Froment, KF. “Modeling of thermal cracking kinetics—I: Thermal cracking of ethane, propane and their mixtures.” Chemical Engineering Science. 1997; 32 (6): 601-608. doi:10.1016/0009-2509(77)80225-X.</div></td>
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<td style="color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #ffe49c; vertical-align: top; white-space: pre-wrap;"><div><del style="font-weight: bold; text-decoration: none;">#</del>Towler G, Sinnott R. Chemical Engineering Design: Principles, Practice and Economics of Plant and Process Design. 2nd ed. Boston: Elsevier; 2013.</div></td>
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<td style="color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #a3d3ff; vertical-align: top; white-space: pre-wrap;"><div>Towler G, Sinnott R. Chemical Engineering Design: Principles, Practice and Economics of Plant and Process Design. 2nd ed. Boston: Elsevier; 2013.</div></td>
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<td style="color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #ffe49c; vertical-align: top; white-space: pre-wrap;"><div><del style="font-weight: bold; text-decoration: none;">#</del>Transform Software and Services. “A Comparative Study of North America's Largest Shale Gas Reservoirs.” Available at: https://www2.transformsw.com/joomla/index.php?option=com_content&view=article&id=67&Itemid=82</div></td>
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<td style="color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #a3d3ff; vertical-align: top; white-space: pre-wrap;"><div>Transform Software and Services. “A Comparative Study of North America's Largest Shale Gas Reservoirs.” Available at: https://www2.transformsw.com/joomla/index.php?option=com_content&view=article&id=67&Itemid=82</div></td>
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<td style="color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #ffe49c; vertical-align: top; white-space: pre-wrap;"><div><del style="font-weight: bold; text-decoration: none;">#</del>U.S. Energy Information Administration (EIA). Natural Gas Futures Prices (NYMEX), Feb. 25 2012. Available at: http://www.eia.gov/dnav/ng/ng_pri_fut_s1_m.htm</div></td>
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<td style="color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #a3d3ff; vertical-align: top; white-space: pre-wrap;"><div>U.S. Energy Information Administration (EIA). Natural Gas Futures Prices (NYMEX), Feb. 25 2012. Available at: http://www.eia.gov/dnav/ng/ng_pri_fut_s1_m.htm</div></td>
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<td style="color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #ffe49c; vertical-align: top; white-space: pre-wrap;"><div><del style="font-weight: bold; text-decoration: none;">#</del>U.S. Energy Information Administration (EIA). Natural Gas Weekly Update, Feb 26, 2015. Available at: http://www.eia.gov/naturalgas/weekly/</div></td>
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<td style="color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #ffe49c; vertical-align: top; white-space: pre-wrap;"><div><del style="font-weight: bold; text-decoration: none;">#</del>Woebcke, HN. Process for pyrolysis of hydrocarbons. 1993, US5271827 A. Available at: https://courses.northwestern.edu/webapps/portal/frameset.jsp?tab_tab_group_id=_2_1&url=%2Fwebapps%2Fblackboard%2Fexecute%2Flauncher%3Ftype%3DCourse%26id%3D_429745_1%26url%3D</div></td>
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<td style="color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #a3d3ff; vertical-align: top; white-space: pre-wrap;"><div>Woebcke, HN. Process for pyrolysis of hydrocarbons. 1993, US5271827 A. Available at: https://courses.northwestern.edu/webapps/portal/frameset.jsp?tab_tab_group_id=_2_1&url=%2Fwebapps%2Fblackboard%2Fexecute%2Flauncher%3Ftype%3DCourse%26id%3D_429745_1%26url%3D</div></td>
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<td style="background-color: #f8f9fa; color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #eaecf0; vertical-align: top; white-space: pre-wrap;"><br /></td>
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<td style="background-color: #f8f9fa; color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #eaecf0; vertical-align: top; white-space: pre-wrap;"><div>=Appendices=</div></td>
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Tammywong2015
https://processdesign.mccormick.northwestern.edu/index.php?title=Shale_Gas_to_Ethylene_(G2)&diff=3379&oldid=prev
Tammywong2015: /* References */
2015-03-14T02:03:06Z
<p><span dir="auto"><span class="autocomment">References</span></span></p>
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<td colspan="2" style="background-color: #fff; color: #202122; text-align: center;">Revision as of 21:03, 13 March 2015</td>
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<td style="background-color: #f8f9fa; color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #eaecf0; vertical-align: top; white-space: pre-wrap;"><div>#Shell Global Solutions. Sulfinol-M. Shell Website. Published 2012. Available at:http://s02.static-shell.com/content/dam/shell/static/globalsolutions/downloads/services/sulfino-m.pdf. </div></td>
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<td style="background-color: #f8f9fa; color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #eaecf0; vertical-align: top; white-space: pre-wrap;"><div>#Sims DW. Pre-fractionating the feedstock to separate into an ethane rich stream and a propane rich stream, steam cracking each stream to form ethylene. 1999, US5990370 A. http://www.google.com/patents/US5990370</div></td>
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<td style="background-color: #f8f9fa; color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #eaecf0; vertical-align: top; white-space: pre-wrap;"><div>#Sims DW. Pre-fractionating the feedstock to separate into an ethane rich stream and a propane rich stream, steam cracking each stream to form ethylene. 1999, US5990370 A. http://www.google.com/patents/US5990370</div></td>
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<td style="color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #ffe49c; vertical-align: top; white-space: pre-wrap;"><div>Sundaram, KM, Froment, KF. “Modeling of thermal cracking kinetics—I: Thermal cracking of ethane, propane and their mixtures.” Chemical Engineering Science. 1997; 32 (6): 601-608. doi:10.1016/0009-2509(77)80225-X.</div></td>
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<td style="color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #a3d3ff; vertical-align: top; white-space: pre-wrap;"><div><ins style="font-weight: bold; text-decoration: none;">#</ins>Sundaram, KM, Froment, KF. “Modeling of thermal cracking kinetics—I: Thermal cracking of ethane, propane and their mixtures.” Chemical Engineering Science. 1997; 32 (6): 601-608. doi:10.1016/0009-2509(77)80225-X.</div></td>
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<td style="background-color: #f8f9fa; color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #eaecf0; vertical-align: top; white-space: pre-wrap;"><div>#Towler G, Sinnott R. Chemical Engineering Design: Principles, Practice and Economics of Plant and Process Design. 2nd ed. Boston: Elsevier; 2013.</div></td>
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<td style="background-color: #f8f9fa; color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #eaecf0; vertical-align: top; white-space: pre-wrap;"><div>#Towler G, Sinnott R. Chemical Engineering Design: Principles, Practice and Economics of Plant and Process Design. 2nd ed. Boston: Elsevier; 2013.</div></td>
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<td style="background-color: #f8f9fa; color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #eaecf0; vertical-align: top; white-space: pre-wrap;"><div>#Transform Software and Services. “A Comparative Study of North America's Largest Shale Gas Reservoirs.” Available at: https://www2.transformsw.com/joomla/index.php?option=com_content&view=article&id=67&Itemid=82</div></td>
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<td style="background-color: #f8f9fa; color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #eaecf0; vertical-align: top; white-space: pre-wrap;"><div>#Transform Software and Services. “A Comparative Study of North America's Largest Shale Gas Reservoirs.” Available at: https://www2.transformsw.com/joomla/index.php?option=com_content&view=article&id=67&Itemid=82</div></td>
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Tammywong2015
https://processdesign.mccormick.northwestern.edu/index.php?title=Shale_Gas_to_Ethylene_(G2)&diff=3378&oldid=prev
Tammywong2015: /* References */
2015-03-14T02:02:09Z
<p><span dir="auto"><span class="autocomment">References</span></span></p>
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<td colspan="2" style="background-color: #fff; color: #202122; text-align: center;">Revision as of 21:02, 13 March 2015</td>
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Tammywong2015
https://processdesign.mccormick.northwestern.edu/index.php?title=Shale_Gas_to_Ethylene_(G2)&diff=3376&oldid=prev
Tammywong2015: /* References */
2015-03-14T02:01:53Z
<p><span dir="auto"><span class="autocomment">References</span></span></p>
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Tammywong2015
https://processdesign.mccormick.northwestern.edu/index.php?title=Shale_Gas_to_Ethylene_(G2)&diff=3371&oldid=prev
Tammywong2015: /* References */
2015-03-14T01:59:23Z
<p><span dir="auto"><span class="autocomment">References</span></span></p>
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Tammywong2015
https://processdesign.mccormick.northwestern.edu/index.php?title=Shale_Gas_to_Ethylene_(G2)&diff=3361&oldid=prev
Tammywong2015: /* References */
2015-03-14T01:45:32Z
<p><span dir="auto"><span class="autocomment">References</span></span></p>
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<td style="color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #ffe49c; vertical-align: top; white-space: pre-wrap;"><div><ref>American Petroleum Institute,[http://www.whitehouse.gov/sites/default/files/omb/assets/oira_2060/2060_03222012-2.pdf. "VOC Content Threshold for Reduced Emissions Completions"], March 2, 2011 </ref></div></td>
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Tammywong2015
https://processdesign.mccormick.northwestern.edu/index.php?title=Shale_Gas_to_Ethylene_(G2)&diff=3360&oldid=prev
Tammywong2015: /* References */
2015-03-14T01:44:46Z
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<td class="diff-marker"><a class="mw-diff-movedpara-right" title="Paragraph was moved. Click to jump to old location." href="#movedpara_5_0_lhs">⚫</a></td>
<td style="color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #a3d3ff; vertical-align: top; white-space: pre-wrap;"><div><a name="movedpara_3_0_rhs"></a><ins style="font-weight: bold; text-decoration: none;"><ref>American Petroleum Institute,[</ins>http://www.whitehouse.gov/sites/default/files/omb/assets/oira_2060/2060_03222012-2.pdf. <ins style="font-weight: bold; text-decoration: none;">"VOC Content Threshold for Reduced Emissions Completions"], March 2, 2011 </ref></ins></div></td>
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<td style="color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #ffe49c; vertical-align: top; white-space: pre-wrap;"><div><a name="movedpara_5_0_lhs"></a><del style="font-weight: bold; text-decoration: none;">|url=</del>http://www.whitehouse.gov/sites/default/files/omb/assets/oira_2060/2060_03222012-2.pdf. </div></td>
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Tammywong2015
https://processdesign.mccormick.northwestern.edu/index.php?title=Shale_Gas_to_Ethylene_(G2)&diff=3356&oldid=prev
MichelleS at 01:41, 14 March 2015
2015-03-14T01:41:55Z
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<td style="background-color: #f8f9fa; color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #eaecf0; vertical-align: top; white-space: pre-wrap;"><br /></td>
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<td style="background-color: #f8f9fa; color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #eaecf0; vertical-align: top; white-space: pre-wrap;"><div>This discussed design results in the following product streams: 26,600 kg/hr of >98% purity ethylene , 6,300 kg/hr of 94% pure hydrogen, 68,600 kg/hr of 96% pure methane, 30,600 kg/hr of 97% pure propane, and 38,200 kg/hr of NGLs, which is 72% butane and 26% pentane. The total profits from the sale of these products surmounts to about $328 million annually. The annual cost of this design includes the cost of purchasing feeds, offsite organic waste treatment, utilities (determined from Aspen Energy Analyzer), labor, and other miscellaneous costs. This annual cost is $250 million. Additionally, the total capital cost, determined from estimated equipment sizes as well as added contingency for piping and other fixtures, sums to $120 million. From these costs, the design has a 10 year NPV of $547 million, a payback period of 3 years and an internal rate of return (IRR) of 72%. These calculations indicate a profitable design that should be pursued. However, this design and the resulting calculations should be refined with additional researching and alternatives beyond what is presented in this report. </div></td>
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<td style="background-color: #f8f9fa; color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #eaecf0; vertical-align: top; white-space: pre-wrap;"><div>This discussed design results in the following product streams: 26,600 kg/hr of >98% purity ethylene , 6,300 kg/hr of 94% pure hydrogen, 68,600 kg/hr of 96% pure methane, 30,600 kg/hr of 97% pure propane, and 38,200 kg/hr of NGLs, which is 72% butane and 26% pentane. The total profits from the sale of these products surmounts to about $328 million annually. The annual cost of this design includes the cost of purchasing feeds, offsite organic waste treatment, utilities (determined from Aspen Energy Analyzer), labor, and other miscellaneous costs. This annual cost is $250 million. Additionally, the total capital cost, determined from estimated equipment sizes as well as added contingency for piping and other fixtures, sums to $120 million. From these costs, the design has a 10 year NPV of $547 million, a payback period of 3 years and an internal rate of return (IRR) of 72%. These calculations indicate a profitable design that should be pursued. However, this design and the resulting calculations should be refined with additional researching and alternatives beyond what is presented in this report. </div></td>
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<td style="background-color: #f8f9fa; color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #eaecf0; vertical-align: top; white-space: pre-wrap;"><div>=Introduction=</div></td>
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<td style="background-color: #f8f9fa; color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #eaecf0; vertical-align: top; white-space: pre-wrap;"><div>This report summarizes a project to design a process to produce ethylene and NGLs from shale gas. The production of ethylene is desirable because ethylene is a valuable product in the production of polymers, chemicals and other consumer products. In this final report, the design and simulation in HYSYS are discussed in detail. In addition, the rationale behind the selection of the specific technology chosen for the design is provided. The objectives when choosing specific technology were to maximize efficiency and conversion while minimizing capital and operating costs of the facility. Finally, an economic analysis was conducted, including capital costs, variable costs and fixed costs analyses with an overall NPV calculation. Additionally, a sensitivity analysis was conducted to determine the effect of certain design tradeoffs and changes in market pricing.</div></td>
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<td style="background-color: #f8f9fa; color: #202122; font-size: 88%; border-style: solid; border-width: 1px 1px 1px 4px; border-radius: 0.33em; border-color: #eaecf0; vertical-align: top; white-space: pre-wrap;"><div>This report summarizes a project to design a process to produce ethylene and NGLs from shale gas. The production of ethylene is desirable because ethylene is a valuable product in the production of polymers, chemicals and other consumer products. In this final report, the design and simulation in HYSYS are discussed in detail. In addition, the rationale behind the selection of the specific technology chosen for the design is provided. The objectives when choosing specific technology were to maximize efficiency and conversion while minimizing capital and operating costs of the facility. Finally, an economic analysis was conducted, including capital costs, variable costs and fixed costs analyses with an overall NPV calculation. Additionally, a sensitivity analysis was conducted to determine the effect of certain design tradeoffs and changes in market pricing.</div></td>
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MichelleS