{
  "authors": [],
  "basis": {
    "capacity": "1000 kt/a polymer-grade ethylene (ASSUMED)",
    "location": "generic (not chosen)",
    "operating_hours_per_year": 8000
  },
  "benchmarks": [],
  "chemistry": {
    "inputs": [
      {
        "chemical": "ethane",
        "grade": null,
        "note": "feed:ETHANE: purity ethane by pipeline, 1.27 kg/kg ethylene (unallocated)",
        "role": "feedstock"
      },
      {
        "chemical": "methane",
        "grade": null,
        "note": "feed:NATGAS: natural gas make-up to the fuel header, taken as methane",
        "role": "feedstock"
      },
      {
        "chemical": "sodium-hydroxide",
        "grade": null,
        "note": "feed:CAUSTIC: fresh caustic soda solution 10 wt%, counted by mass of the solution",
        "role": "feedstock"
      },
      {
        "chemical": "air",
        "grade": null,
        "inventory_key": "feed:AIR",
        "note": "Combustion air of the cracking furnaces",
        "role": "feedstock"
      },
      {
        "chemical": "water",
        "grade": null,
        "inventory_key": "feed:BFW",
        "note": "Boiler feed water make-up to the dilution steam system",
        "role": "feedstock"
      }
    ],
    "outputs": [
      {
        "chemical": "ethylene",
        "grade": null,
        "inventory_key": "product:ETHYLENE",
        "note": "Polymer-grade ethylene",
        "role": "main-product"
      },
      {
        "chemical": "propylene",
        "grade": null,
        "inventory_key": "product:PROPYLENE",
        "note": "Polymer-grade propylene",
        "role": "co-product"
      },
      {
        "chemical": "crude-c4",
        "grade": null,
        "inventory_key": "product:CRUDEC4",
        "note": "Crude C4 cut",
        "role": "co-product"
      },
      {
        "chemical": "pyrolysis-gasoline",
        "grade": null,
        "inventory_key": "product:PYGAS",
        "note": "Pyrolysis gasoline (C5/C6 cut)",
        "role": "co-product"
      },
      {
        "chemical": "carbon-dioxide",
        "grade": null,
        "inventory_key": "emission:CO2",
        "note": "Fossil CO2 of the furnace flue gas: 0.472 kg/kg ethylene unallocated (59.1 t/h over 125 t/h ethylene), 0.433 kg/kg ethylene with mass allocation (ethylene share 91.6 %). Both are gross: they include the fuel that preheats and superheats the exported SHP steam (product:HPS, about a third of the fired duty), which carries no burden (D-015, D-016)",
        "role": "emission"
      },
      {
        "chemical": "wastewater",
        "grade": null,
        "inventory_key": "product:BLOWDOWN",
        "note": "Process water blowdown; the spent caustic (product:SPENTCAUSTIC) is a second wastewater",
        "role": "waste"
      },
      {
        "chemical": "steam",
        "grade": null,
        "inventory_key": "product:HPS",
        "note": "SHP steam 11500 kPa(a), 520 C, raised in the TLEs and convection sections (ASSUMED export, D-015); outside the mass allocation and without a burden, so the fuel and CO2 that raise it stay with the hydrocarbon products",
        "role": "co-product"
      }
    ],
    "utilities": [
      {
        "chemical": "electricity",
        "grade": null,
        "inventory_key": "feed:POWER",
        "note": "Cracked gas and refrigeration compressor drives (ASSUMED electric, D-015)",
        "role": "utility"
      },
      {
        "chemical": "steam",
        "grade": null,
        "inventory_key": "feed:MPS",
        "note": "MP steam 1800 kPa(a) to the dilution steam generator",
        "role": "utility"
      },
      {
        "chemical": "steam",
        "grade": null,
        "inventory_key": "feed:LPS",
        "note": "LP steam 450 kPa(a) to the column reboilers",
        "role": "utility"
      },
      {
        "chemical": "cooling-water",
        "grade": null,
        "inventory_key": "product:CW",
        "note": "25/35 C (ASSUMED)",
        "role": "utility"
      }
    ]
  },
  "description": "Purity ethane and the recycled ethane are cracked with dilution steam at a coil outlet of\n840 C; the recycled propane has its own coil. The furnace is a conversion model that\nreproduces the once-through ethane and propane yields of the EU BREF on large volume organic\nchemicals (2017, Table 3.3): a sourced yield model, not kinetics. The cracked gas raises SHP\nsteam in the transfer line exchangers, is quenched with water (the condensate becomes dilution\nsteam again), compressed in five stages with a caustic wash, dried and separated at low\ntemperature: demethaniser (tail gas and hydrogen to the furnace fuel), deethaniser, acetylene\nconverter, C2 splitter, depropaniser, MAPD converter, C3 splitter and debutaniser. The tail\ngas and a natural-gas make-up fire the furnaces.\n\nThe separations are specified splits from an independent balance script, and the energy\nfigures rest on ideal-gas enthalpies: core has no qualified property package for C2+\nhydrocarbon mixtures yet. See DESIGN.md for every assumption and gated step.\n",
  "design_basis": {
    "assumptions": [
      "Furnace: once-through yields of BREF LVOC 2017 Table 3.3 (ethane: 70 % conversion; propane column for the C3 recycle coil) as a conversion model, coil outlet 840 C, 200 kPa(a), 0.30 kg steam/kg hydrocarbon (D-004, D-005). Sourced yields, not kinetics.",
      "Separations are specified splits (recoveries, purities) in scripts/balance.py, not rigorous columns (D-006, D-010).",
      "Firebox: complete combustion, 15 % excess air, stack 120 C, casing loss 1.5 % of the LHV (D-013).",
      "Compressor isentropic efficiency 0.78; refrigeration COP 60 % of Carnot (D-008, D-014).",
      "All values are concept estimates; accuracy not stated."
    ],
    "source": "process/design-basis.yaml"
  },
  "engineering": {
    "description": "",
    "name": "Ethylene and propylene by steam cracking",
    "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"
    ],
    "product_classes": [
      "chemicals"
    ],
    "region": "generic",
    "unit_operations": [
      "reaction",
      "compression",
      "cryogenic-distillation",
      "distillation",
      "absorption",
      "adsorption",
      "heat-exchange"
    ]
  },
  "families": [
    "olefins"
  ],
  "gap_count": 4,
  "gates": null,
  "id": "ethylene-1",
  "issues": {
    "closed_count": 0,
    "list_url": "https://github.com/ChemE-as-Code/process-library/issues?q=is%3Aissue%20label%3A%22process%3Aethylene-1%22",
    "new": {
      "action": "https://github.com/ChemE-as-Code/process-library/issues/new?template=1-action-item.yml&labels=process%3Aethylene-1&process=ethylene-1",
      "change": "https://github.com/ChemE-as-Code/process-library/issues/new?template=4-design-change.yml&labels=process%3Aethylene-1&process=ethylene-1",
      "hold": "https://github.com/ChemE-as-Code/process-library/issues/new?template=2-engineering-hold.yml&labels=process%3Aethylene-1&process=ethylene-1",
      "process": "https://github.com/ChemE-as-Code/process-library/issues/new?template=6-process-development.yml&labels=process%3Aethylene-1&process=ethylene-1",
      "tq": "https://github.com/ChemE-as-Code/process-library/issues/new?template=3-technical-query.yml&labels=process%3Aethylene-1&process=ethylene-1",
      "tracker": "https://github.com/ChemE-as-Code/process-library/issues/new?template=7-process-tracker.yml&labels=process%3Aethylene-1&process=ethylene-1"
    },
    "open": [],
    "open_by_gate": {},
    "open_count": 0,
    "private": false,
    "repository": "ChemE-as-Code/process-library"
  },
  "keywords": [
    "ethylene",
    "propylene",
    "steam cracking",
    "ethane",
    "olefins",
    "cracked gas compression",
    "demethaniser",
    "C2 splitter",
    "acetylene hydrogenation",
    "pyrolysis gasoline"
  ],
  "lca": {
    "allocation": null,
    "backend": "factors",
    "boundary": "gate-to-gate",
    "categories": [
      {
        "id": "climate-change",
        "method": "GWP100",
        "title": "Climate change",
        "unit": "kg CO2-eq"
      }
    ],
    "contributions": [
      {
        "basis": "ipcc2021-gwp100 (124-38-9, air, fossil)",
        "category": "climate-change",
        "impact": 0.432561,
        "key": "emission:CO2",
        "phase": "operation",
        "share": 0.9979,
        "status": "PUBLISHED"
      },
      {
        "basis": "ipcc2021-gwp100 (74-82-8, air, fossil)",
        "category": "climate-change",
        "impact": 0.000480044,
        "key": "emission:CH4",
        "phase": "operation",
        "share": 0.0011,
        "status": "PUBLISHED"
      },
      {
        "basis": "ipcc2021-gwp100 (10024-97-2, air, fossil)",
        "category": "climate-change",
        "impact": 0.000439771,
        "key": "emission:N2O",
        "phase": "operation",
        "share": 0.001,
        "status": "PUBLISHED"
      }
    ],
    "data_sources": [],
    "factors_status": "published",
    "functional_unit": {
      "amount": 1,
      "chemical": "ethylene",
      "grade": null,
      "label": "1 kg ethylene",
      "product": "ETHYLENE",
      "product_name": "Ethylene",
      "product_title": "Polymer-grade ethylene",
      "unit": "kg"
    },
    "goal": "Preliminary gate-to-gate life cycle inventory of polymer-grade ethylene from ethane steam cracking at concept stage: every foreground exchange per kg ethylene from the balanced flowsheet, to be linked to background datasets later (DESIGN.md D-016).",
    "inventory": [
      {
        "direction": "input",
        "key": "feed:ETHANE",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 1.16133,
        "title": "Purity ethane feed (pipeline)",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:NATGAS",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.0705096,
        "title": "Natural gas make-up to the fuel header",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:AIR",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 5.77531,
        "title": "Combustion air",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:BFW",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.0153302,
        "title": "Boiler feed water make-up to the dilution steam system",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:CAUSTIC",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.0917456,
        "title": "Fresh caustic soda solution 10 wt%",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:POWER",
        "kind": "energy",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.870965,
        "title": "Electric power (machine drives, D-015)",
        "unit": "kWh"
      },
      {
        "direction": "input",
        "key": "feed:MPS",
        "kind": "energy",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.338901,
        "title": "MP steam 1800 kPa(a) to the dilution steam generator",
        "unit": "kWh"
      },
      {
        "direction": "input",
        "key": "feed:LPS",
        "kind": "energy",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.336098,
        "title": "LP steam 450 kPa(a) to the column reboilers",
        "unit": "kWh"
      },
      {
        "direction": "output",
        "key": "product:ETHYLENE",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 1.0,
        "title": "Polymer-grade ethylene",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "product:PROPYLENE",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.0261504,
        "title": "Polymer-grade propylene",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "product:CRUDEC4",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.0347736,
        "title": "Crude C4 cut",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "product:PYGAS",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.031296,
        "title": "Pyrolysis gasoline (C5/C6 cut)",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "product:FLUE",
        "kind": "material",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 6.0038,
        "title": "Cracking furnace flue gas to atmosphere",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "product:BLOWDOWN",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.0153302,
        "title": "Process water blowdown to wastewater treatment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "product:SPENTCAUSTIC",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.0951105,
        "title": "Spent caustic to treatment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "product:HPS",
        "kind": "energy",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 2.47011,
        "title": "SHP steam raised in the TLEs and convection sections (11500 kPa(a), 520 C)",
        "unit": "kWh"
      },
      {
        "direction": "output",
        "key": "product:CW",
        "kind": "energy",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 2.72984,
        "title": "Cooling water return",
        "unit": "kWh"
      },
      {
        "direction": "output",
        "key": "emission:C2H4",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 0.0,
        "title": "C2H4 to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:C2H6",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 0.0,
        "title": "C2H6 to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:CH4",
        "kind": "emission",
        "phase": "operation",
        "provenance": "estimated",
        "quantity": 1.61088e-05,
        "title": "CH4 to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:CO2",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 0.432561,
        "title": "CO2 to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:H2",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 0.0,
        "title": "H2 to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:H2O",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 0.964464,
        "title": "H2O to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:N2",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 4.43132,
        "title": "N2 to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:O2",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 0.175459,
        "title": "O2 to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:NOx",
        "kind": "emission",
        "phase": "operation",
        "provenance": "estimated",
        "quantity": 0.000385485,
        "title": "NOx to the environment (estimated)",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:CO",
        "kind": "emission",
        "phase": "operation",
        "provenance": "estimated",
        "quantity": 0.000192662,
        "title": "CO to the environment (estimated)",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:PM",
        "kind": "emission",
        "phase": "operation",
        "provenance": "estimated",
        "quantity": 2.7385e-05,
        "title": "PM to the environment (estimated)",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:N2O",
        "kind": "emission",
        "phase": "operation",
        "provenance": "estimated",
        "quantity": 1.61088e-06,
        "title": "N2O to the environment (estimated)",
        "unit": "kg"
      }
    ],
    "no_total": {},
    "not_computed": [],
    "pcf": [],
    "publishable": true,
    "result": {
      "classification": "partial",
      "gaps": 12,
      "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"
    ],
    "totals": {
      "baseline": {
        "climate-change": 0.433481
      }
    },
    "withheld_reason": null
  },
  "lci_gaps": [
    {
      "dataset": "ethylene-and-propylene-by-ethane-steam-cracking-1000-kt-a-ethylene",
      "key": "feed:ETHANE",
      "link": "technosphere",
      "type": "input"
    },
    {
      "dataset": "ethylene-and-propylene-by-ethane-steam-cracking-1000-kt-a-ethylene",
      "key": "feed:CAUSTIC",
      "link": "technosphere",
      "type": "input"
    },
    {
      "dataset": "ethylene-and-propylene-by-ethane-steam-cracking-1000-kt-a-ethylene",
      "key": "product:SPENTCAUSTIC",
      "link": "technosphere",
      "type": "output"
    },
    {
      "dataset": "ethylene-and-propylene-by-ethane-steam-cracking-1000-kt-a-ethylene",
      "key": "emission:PM",
      "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": [
    {
      "doi": "10.2760/77304",
      "title": "Falcke, H. et al. (2017) Best Available Techniques (BAT) Reference Document for the Production of Large Volume Organic Chemicals. JRC Science for Policy Report EUR 28882 EN (JRC109279), chapter 3 Lower olefins"
    },
    {
      "doi": "10.1002/14356007.a10_045.pub2",
      "title": "Zimmermann, H.; Walzl, R. Ethylene. Ullmann's Encyclopedia of Industrial Chemistry (lead from issue #176; not audited in this run)"
    },
    {
      "title": "IPCC (2006) 2006 IPCC Guidelines for National Greenhouse Gas Inventories, Vol. 2 Energy, Ch. 2 Stationary Combustion"
    }
  ],
  "repository": {
    "access": "public",
    "path": "processes/ethylene-1",
    "url": "https://github.com/ChemE-as-Code/process-library"
  },
  "representations": [
    {
      "bytes": 62819,
      "id": "BFD",
      "kind": "bfd",
      "preview": "artifacts/ethylene-1/BFD.svg",
      "source": "process/BFD.xml",
      "status": "preview",
      "title": "Block flow diagram"
    },
    {
      "bytes": 318309,
      "id": "PFD",
      "kind": "pfd",
      "preview": "artifacts/ethylene-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": "Ethane steam cracking with ethane and propane recycle, quench, cracked-gas compression with caustic wash and drying, front-end demethaniser, tail-end acetylene hydrogenation and C2/C3 splitters to polymer-grade ethylene and propylene, crude C4 and pyrolysis gasoline. Concept stage, assumed basis, preliminary gate-to-gate LCI with unmapped backgrounds.",
  "title": "Ethylene and propylene by ethane steam cracking (1000 kt/a ethylene, concept)",
  "validation": {
    "notes": "Concept PFD with closed mass, component and element balances (cheme validate: 0 errors, 0 warnings). Furnace, hydrogenation reactors and firebox outlets are calculated by cheme (conversion reactors; furnace conversions derived from the BREF LVOC 2017 Table 3.3 yields). Capacity, feed composition, splits, purities, efficiencies and utility levels are ASSUMED; separations and duties come from scripts/balance.py on ideal-gas enthalpies (no qualified property package for the C2+ hydrocarbons), so the energy balance is not evaluable in core beyond the reactor duties, which cheme process reactors reproduces. The preliminary gate-to-gate LCI closes in mass, elements and carbon by origin, with every background unmapped (gaps). Not reviewed. Main products and feeds are listed under chemistry with their chemicals registry entries (issue #251). cheme maturity: calculation maturity none (sourced boundary fails: capacity and feed are ASSUMED; balanced model basis fails: the splits and conversions of H102, T201, D210, T310, D320, V402, R501 and R601 are unsourced). concept is claimed as the lowest level of the manifest; the warning cheme.maturity-claim-exceeds is acknowledged. The refrigeration power is a conservative upper estimate (D-014).",
    "status": "unreviewed"
  },
  "viewer": {
    "commit": "c3ab3488c602bc797fdc98feffd4578375150dd0",
    "dirty": false,
    "sheets": [
      "process/BFD.xml",
      "process/PFD.xml"
    ],
    "skipped": [],
    "snapshot": "snapshots/ethylene-1/",
    "stale": false,
    "tool": "cheme-as-code 1.6.0",
    "views": [
      "checks",
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}