{
  "authors": [],
  "basis": {
    "capacity": "6250 kg/h acetylene (50 kt/a at 8000 h), ASSUMED; 36.2 t/h synthesis gas co-product",
    "location": "generic (not chosen)",
    "operating_hours_per_year": 8000
  },
  "benchmarks": [],
  "chemistry": {
    "inputs": [
      {
        "chemical": "methane",
        "grade": null,
        "note": "feed:NG: pipeline natural gas to the partial oxidation, taken as methane, 4.73 kg/kg acetylene (unallocated)",
        "role": "feedstock"
      },
      {
        "chemical": "methane",
        "grade": null,
        "note": "feed:FUELNG: natural-gas support fuel of the fired preheater, taken as methane",
        "role": "feedstock"
      },
      {
        "chemical": "n-methyl-2-pyrrolidone",
        "grade": null,
        "note": "feed:NMP: NMP solvent make-up, 2.0 g/kg",
        "role": "feedstock"
      },
      {
        "chemical": "oxygen",
        "grade": null,
        "inventory_key": "feed:OXY",
        "note": "99.5 mol% O2 by pipeline from an air separation unit (e.g. asu-1), 5.58 kg/kg acetylene (unallocated)",
        "role": "feedstock"
      },
      {
        "chemical": "air",
        "grade": null,
        "inventory_key": "feed:AIR",
        "note": "Combustion air of the fired preheater, 5.32 kg/kg acetylene",
        "role": "feedstock"
      }
    ],
    "outputs": [
      {
        "chemical": "acetylene",
        "grade": null,
        "inventory_key": "product:ACETYLENE",
        "note": "Acetylene gas (99.55 mol%, 1.2 bar(a)) to the consumers",
        "role": "main-product"
      },
      {
        "chemical": "synthesis-gas",
        "grade": null,
        "inventory_key": "product:SYNGAS",
        "note": "Synthesis gas (H2/CO) to the consumers, 5.76 kg/kg acetylene",
        "role": "co-product"
      },
      {
        "chemical": "carbon-dioxide",
        "grade": null,
        "inventory_key": "emission:CO2",
        "note": "1.19 kg/kg acetylene (unallocated), fossil, from burning the plant's off-gas and support fuel in the fired preheater",
        "role": "emission"
      },
      {
        "chemical": "wastewater",
        "grade": null,
        "inventory_key": "product:WW",
        "note": "Quench-water purge, 2.70 kg/kg acetylene, after vacuum degassing; the soot sludge (product:SLUDGE, 0.46 kg/kg, 10 wt% carbon) and the NMP residue (product:RESIDUE) go to incineration",
        "role": "waste"
      }
    ],
    "utilities": [
      {
        "chemical": "electricity",
        "grade": null,
        "inventory_key": "feed:POWER",
        "note": "1.52 kWh/kg acetylene (unallocated): cracked-gas compressor 8.8 MW, pumps, ESP, vacuum pump, air fan",
        "role": "utility"
      },
      {
        "chemical": "steam",
        "grade": null,
        "inventory_key": "feed:STEAM",
        "note": "MP steam 12 bar(a), 1.10 kWh/kg acetylene: acetylene stripper and hot-stripper reboiler",
        "role": "utility"
      },
      {
        "chemical": "cooling-water",
        "grade": null,
        "inventory_key": "product:CW",
        "note": "17.7 kWh/kg acetylene, 82 % of it the quench heat removed from the circulating water (25/35 C, ASSUMED)",
        "role": "utility"
      }
    ]
  },
  "description": "Natural gas (98 % methane) and 99.5 % oxygen are preheated separately to 873 K in a fired\nheater, premixed and burnt in a BASF (Sachsse-Bartholome) burner at an O2/natural-gas ratio\nof 0.60 (vol); the flame reaches about 1970 K and is quenched with water to 353 K. A cooling\ncolumn and a wet electrostatic precipitator remove the soot; the quench water runs in a closed\ncircuit with vacuum degassing (the dissolved hydrocarbons go to the fired heater), soot\nseparation and a purge. The cracked gas (7.5 % acetylene) is compressed to 11 bar(a) and\nwashed with NMP; a degasser recycles the co-absorbed gases to the compressor, the acetylene\nstripper delivers the product and a hot stripper removes the higher acetylenes and water,\nwhich are burnt in the fired heater. The unabsorbed gas is synthesis gas (H2/CO 2.15).\n\nThe burner is a sourced outlet-composition model (the typical cracked gas of US8975460B2 and\nthe soot ratio of US5824834A), not kinetics; the O2/natural-gas ratio and the 1970 K flame\nfollow from the element and energy balances and agree with the patents. Separators, the\nNMP section and the duties come from an independent script (scripts/balance.py) because no\nproperty package of core covers soot, the quench water or NMP. See DESIGN.md for every\nassumption and gated step.\n",
  "design_basis": {
    "assumptions": [
      "ASSUMED natural gas and oxygen preheated separately to 873 K (600 C), the value of the examples of US5824834A and of US8975460B2 and US11459281B2 (D-004).",
      "Burner as a sourced outlet-composition model (D-005): dry cracked gas of US8975460B2 (H2 56, CH4 5, C2H2 7.5, CO 26, CO2 3.5, higher hydrocarbons 1 vol%), acetylene/soot 22 kg/kg (US5824834A comparative example 2), residual O2 0.1 vol% ASSUMED; O2/NG 0.602 and the adiabatic 1970 K follow.",
      "ASSUMED water quench to 353 K (80-90 C per US11459281B2 claim 1), cooling column to 308 K, ESP; closed water circuit degassed at 400 mbar(a) (99.31 % of the dissolved hydrocarbons, US11459281B2) and cooled to 303 K with cooling water (D-006).",
      "ASSUMED three-stage compression to 11 bar(a), isentropic efficiency 0.78 (D-007).",
      "ASSUMED NMP recovery splits and solvent loading 20 Nm3 C2H2/m3 (inside the 15-35 cited in US10059640B2); 98.0 % of the acetylene formed reaches the product to product (D-009).",
      "All flows, temperatures and duties are concept estimates (scripts/balance.py); accuracy +/-30 % not demonstrated."
    ],
    "source": "process/design-basis.yaml"
  },
  "engineering": {
    "description": "Acetylene (6.25 t/h) by BASF-type partial oxidation of natural gas with oxygen, water quench, soot removal and NMP recovery, with synthesis gas as co-product. Concept stage: balanced PFD and preliminary gate-to-gate LCI (issue ChemE-as-Code/process-library#184).",
    "name": "Acetylene (natural-gas partial oxidation)",
    "requires": "cheme-as-code>=0.8",
    "stage": "concept",
    "stages": [
      {
        "id": "concept",
        "title": "Concept and feasibility"
      },
      {
        "id": "basic",
        "title": "Basic engineering"
      },
      {
        "id": "detail",
        "title": "Detail engineering"
      }
    ],
    "tool": "plantcode"
  },
  "facets": {
    "feedstock_basis": [
      "fossil",
      "atmospheric",
      "electricity"
    ],
    "product_classes": [
      "chemicals",
      "industrial-gases"
    ],
    "region": "generic",
    "unit_operations": [
      "reaction",
      "quench",
      "compression",
      "absorption",
      "stripping"
    ]
  },
  "families": [
    "olefins",
    "syngas"
  ],
  "gap_count": 4,
  "gates": null,
  "id": "acetylene-1",
  "issues": {
    "closed_count": 0,
    "list_url": "https://github.com/ChemE-as-Code/process-library/issues?q=is%3Aissue%20label%3A%22process%3Aacetylene-1%22",
    "new": {
      "action": "https://github.com/ChemE-as-Code/process-library/issues/new?template=1-action-item.yml&labels=process%3Aacetylene-1&process=acetylene-1",
      "change": "https://github.com/ChemE-as-Code/process-library/issues/new?template=4-design-change.yml&labels=process%3Aacetylene-1&process=acetylene-1",
      "hold": "https://github.com/ChemE-as-Code/process-library/issues/new?template=2-engineering-hold.yml&labels=process%3Aacetylene-1&process=acetylene-1",
      "process": "https://github.com/ChemE-as-Code/process-library/issues/new?template=6-process-development.yml&labels=process%3Aacetylene-1&process=acetylene-1",
      "tq": "https://github.com/ChemE-as-Code/process-library/issues/new?template=3-technical-query.yml&labels=process%3Aacetylene-1&process=acetylene-1",
      "tracker": "https://github.com/ChemE-as-Code/process-library/issues/new?template=7-process-tracker.yml&labels=process%3Aacetylene-1&process=acetylene-1"
    },
    "open": [],
    "open_by_gate": {},
    "open_count": 0,
    "private": false,
    "repository": "ChemE-as-Code/process-library"
  },
  "keywords": [
    "acetylene",
    "ethyne",
    "partial oxidation",
    "Sachsse-Bartholome",
    "BASF process",
    "natural gas",
    "oxygen",
    "quench",
    "soot",
    "carbon black",
    "N-methylpyrrolidone",
    "NMP",
    "absorption",
    "synthesis gas",
    "diacetylene"
  ],
  "lca": {
    "allocation": "energy",
    "backend": "factors",
    "boundary": "cradle-to-gate",
    "categories": [
      {
        "id": "climate-change",
        "method": "GWP100",
        "title": "Climate change",
        "unit": "kg CO2-eq"
      }
    ],
    "data_sources": [],
    "factors_status": "published",
    "functional_unit": {
      "amount": 1,
      "chemical": "acetylene",
      "grade": null,
      "label": "1 kg acetylene",
      "product": "ACETYLENE",
      "product_name": "Acetylene",
      "product_title": "Acetylene to the consumers (1.2 bar(a))",
      "unit": "kg"
    },
    "goal": "Preliminary gate-to-gate life cycle inventory of acetylene made by partial oxidation of natural gas with oxygen (BASF type) with NMP recovery and a synthesis-gas co-product, at the concept stage: which raw materials, utilities, wastes and emissions the plant exchanges per kg of acetylene, as the foreground for a later cradle-to-gate study. No impact results: the backgrounds are not mapped yet (D-013).",
    "inventory": [
      {
        "direction": "input",
        "key": "feed:NG",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 1.27822,
        "title": "Natural gas (pipeline)",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:OXY",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 1.506,
        "title": "Oxygen 99.5 mol% (air separation unit, e.g. asu-1)",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:FUELNG",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.00872558,
        "title": "Natural-gas support fuel",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:AIR",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 1.43543,
        "title": "Combustion air",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:NMP",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.00053712,
        "title": "NMP make-up",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:POWER",
        "kind": "energy",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.410424,
        "title": "Electric power",
        "unit": "kWh"
      },
      {
        "direction": "input",
        "key": "feed:STEAM",
        "kind": "energy",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.297255,
        "title": "MP steam 1200 kPa(a)",
        "unit": "kWh"
      },
      {
        "direction": "output",
        "key": "product:ACETYLENE",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 1.0,
        "title": "Acetylene to the consumers (1.2 bar(a))",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "product:SYNGAS",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 5.7572,
        "title": "Synthesis gas (H2/CO) to the consumers",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "product:WW",
        "kind": "material",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 0.730341,
        "title": "Quench-water purge to wastewater treatment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "product:SLUDGE",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.124552,
        "title": "Soot sludge to incineration",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "product:RESIDUE",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.000483408,
        "title": "Solvent regeneration residue to incineration",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "product:STACK",
        "kind": "material",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 1.54859,
        "title": "Fired-heater flue gas to stack",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "product:CW",
        "kind": "energy",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 4.78756,
        "title": "Cooling water return",
        "unit": "kWh"
      },
      {
        "direction": "output",
        "key": "emission:AR",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 0.0184144,
        "title": "AR to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:C2H2",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 2.08649e-06,
        "title": "C2H2 to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:C4H2",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 2.45848e-05,
        "title": "C4H2 to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:C6H6",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 1.64409e-05,
        "title": "C6H6 to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:CH4",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 4.21368e-06,
        "title": "CH4 to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:CO",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 1.05217e-07,
        "title": "CO to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:CO2",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 0.322391,
        "title": "CO2 to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:H2O",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 0.0794222,
        "title": "H2O to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:N2",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 1.08481,
        "title": "N2 to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:NMP",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 1.34281e-08,
        "title": "NMP to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:O2",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 0.0435054,
        "title": "O2 to the environment",
        "unit": "kg"
      }
    ],
    "not_computed": [],
    "publishable": false,
    "result": {
      "classification": "partial",
      "gaps": 10,
      "label": "partial screening carbon footprint",
      "publication": "public"
    },
    "sources": [
      "lca/README.md",
      "lca/dataset.yaml",
      "lca/factors.yaml",
      "lca/gaps.csv",
      "lca/inventory.csv",
      "lca/lca.yaml",
      "lca/mappings.yaml",
      "lca/results.csv",
      "lca/results.md"
    ],
    "values_withheld": "stale-run-manifest",
    "withheld_reason": "stale-run-manifest"
  },
  "lci_gaps": [
    {
      "dataset": "acetylene-by-partial-oxidation-of-natural-gas-with-nmp-recovery-6.25-t-h-acetylene-synthesis-gas-co-product",
      "key": "feed:NMP",
      "link": "technosphere",
      "type": "input"
    },
    {
      "dataset": "acetylene-by-partial-oxidation-of-natural-gas-with-nmp-recovery-6.25-t-h-acetylene-synthesis-gas-co-product",
      "key": "product:SLUDGE",
      "link": "technosphere",
      "type": "output"
    },
    {
      "dataset": "acetylene-by-partial-oxidation-of-natural-gas-with-nmp-recovery-6.25-t-h-acetylene-synthesis-gas-co-product",
      "key": "product:RESIDUE",
      "link": "technosphere",
      "type": "output"
    },
    {
      "dataset": "acetylene-by-partial-oxidation-of-natural-gas-with-nmp-recovery-6.25-t-h-acetylene-synthesis-gas-co-product",
      "key": "emission:C4H2",
      "link": "biosphere",
      "type": "emission"
    }
  ],
  "maintainers": [
    {
      "name": "Artur Schweidtmann"
    }
  ],
  "maturity": "concept",
  "preliminary": true,
  "provenance": {
    "library_commit": "c3ab3488c602bc797fdc98feffd4578375150dd0",
    "previews": {
      "sheets": [
        "BFD",
        "PFD"
      ],
      "source_commit": "c3ab3488c602bc797fdc98feffd4578375150dd0",
      "tool": "cheme 1.6.0 (pyDEXPI 2.1.0)"
    },
    "previews_stale": false,
    "source_commit": "c3ab3488c602bc797fdc98feffd4578375150dd0"
  },
  "publication": {
    "license": "CC-BY-4.0",
    "status": "public"
  },
  "references": [
    {
      "title": "BASF AG (1998) US5824834A: Process for the production of acetylene and synthesis gas (examples: feed ratios, acetylene, soot, process water)",
      "url": "https://patents.google.com/patent/US5824834A/en"
    },
    {
      "title": "BASF SE (2015) US8975460B2: Process for preparing acetylene by the Sachsse-Bartholome process (description: typical cracked-gas composition, flame and preheat temperatures)",
      "url": "https://patents.google.com/patent/US8975460B2/en"
    },
    {
      "title": "BASF SE (2022) US11459281B2: Method for producing acetylene and syngas (quench temperature, dissolved emissions, vacuum degassing of the quench water)",
      "url": "https://patents.google.com/patent/US11459281B2/en"
    },
    {
      "title": "BASF SE (2018) US10059640B2: Apparatus and process for the preparation of acetylene and synthesis gas (NMP pre-wash, main wash, degassing and stripping conditions)",
      "url": "https://patents.google.com/patent/US10059640B2/en"
    },
    {
      "doi": "10.1002/14356007.a01_097.pub4",
      "title": "Pässler, P. et al. Acetylene. Ullmann's Encyclopedia of Industrial Chemistry (route reference; not read in full)"
    }
  ],
  "repository": {
    "access": "public",
    "path": "processes/acetylene-1",
    "url": "https://github.com/ChemE-as-Code/process-library"
  },
  "representations": [
    {
      "bytes": 46552,
      "id": "BFD",
      "kind": "bfd",
      "preview": "artifacts/acetylene-1/BFD.svg",
      "source": "process/BFD.xml",
      "status": "preview",
      "title": "Block flow diagram"
    },
    {
      "bytes": 282449,
      "id": "PFD",
      "kind": "pfd",
      "preview": "artifacts/acetylene-1/PFD.svg",
      "source": "process/PFD.xml",
      "status": "preview",
      "title": "Process flow diagram"
    },
    {
      "id": "process-model",
      "kind": "process-model",
      "source": "process/flowsheet.yaml",
      "status": "viewer",
      "title": "Flowsheet and stream table"
    },
    {
      "id": "simulation",
      "kind": "simulation",
      "source": "process/simulation.yaml",
      "status": "viewer",
      "title": "Process simulation"
    },
    {
      "id": "equipment-list",
      "kind": "equipment-list",
      "source": "equipment/equipment-list.yaml",
      "status": "viewer",
      "title": "Equipment list"
    },
    {
      "id": "lca",
      "kind": "lca",
      "source": "lca/lca.yaml",
      "status": "viewer",
      "title": "Life cycle assessment"
    }
  ],
  "summary": "Natural gas and oxygen, preheated to 600 C, react in a BASF-type burner; the cracked gas is water-quenched, freed of soot, compressed and washed with N-methylpyrrolidone, which yields 99.5 % acetylene and leaves a hydrogen-rich synthesis gas as co-product. Concept stage, assumed basis, preliminary gate-to-gate LCI.",
  "title": "Acetylene by partial oxidation of natural gas with NMP recovery (6.25 t/h, synthesis-gas co-product)",
  "validation": {
    "notes": "Concept PFD with closed mass, component and element balances (cheme validate, cheme process streams: every block and step ok). The burner R101 and the fired heater F101 are calculated by cheme (conversion model); the burner's conversions are fixed by a published cracked-gas composition and soot ratio, and the resulting O2/natural-gas ratio (0.602) and adiabatic flame temperature (1970 K, from scripts/balance.py) agree with US5824834A (0.58-0.75) and US8975460B2 (about 1700 C). The quench-water purge (2.72 kg/kg acetylene) matches the process water of US5824834A comparative example 2 (2.67 m3/t). Core cannot evaluate the burner energy balance (no data for soot; C4H2/C6H6 fitted to 1000 K only) nor the quench, the circuit water or the NMP section; their values are specified from scripts/balance.py. Core's fired-heater duty (25.8 MW to a 433 K stack) is consistent with the 23.0 MW used plus 10 % casing loss. Capacity, natural-gas and oxygen purity, NMP splits and loss, compression pressure and utility allowances are assumed. Preliminary gate-to-gate LCI with every background unmapped (gaps). Not reviewed. Main products and feeds are listed under chemistry with their chemicals registry entries (issue #251).",
    "status": "unreviewed"
  },
  "viewer": {
    "commit": "c3ab3488c602bc797fdc98feffd4578375150dd0",
    "dirty": false,
    "sheets": [
      "process/BFD.xml",
      "process/PFD.xml"
    ],
    "skipped": [],
    "snapshot": "snapshots/acetylene-1/",
    "stale": false,
    "tool": "cheme-as-code 1.6.0",
    "views": [
      "checks",
      "streams"
    ]
  }
}