Product Description
Fabricated in our dedicated heavy equipment workshops in Jingjiang, our Ethylene Cracker is a world-class, high-severity thermal cracking fired heater engineered to pyrolyze hydrocarbon feedstocks-ranging from ethane and propane to light naphtha and heavy atmospheric gas oil-into polymer-grade ethylene, propylene, and valuable petrochemical co-products. Utilizing our 26-year manufacturing heritage and advanced metallurgical processing certified under ASME "U" and "S" standards, we engineer each Ethylene Cracker with precision radiant coil geometries and high-heat-flux burner zoning to maintain ultra-short residence times and high olefin selectivity while suppressing internal coke formation. Designed to integrate directly with high-pressure transfer line exchangers (TLE), this industrial-grade Ethylene Cracker maximizes overall plant thermal efficiency and run-length cycles, providing petrochemical producers and global EPC contractors with an ultra-reliable, high-capacity cracking furnace built for the most punishing operational regimes.
Applications
World-Scale Olefin Production Complexes: Primary thermal cracking of naphtha, natural gas liquids (NGL), and liquefied petroleum gas (LPG) for polymer-grade ethylene and propylene.
Ethane/Propane Gas Cracking Facilities: Dedicated short-residence-time gaseous hydrocarbon cracking for optimized ethylene yield.
Refinery-Petrochemical Integrated Units: Processing raffinate, gas condensates, and hydrocracker bottoms into chemical feedstocks.
Revamp & Capacity Expansion Projects: Replacing legacy cracker radiant sections to boost single-furnace throughput, improve cracking selectivity, and extend decoking intervals.
Technical Specifications
|
Design & Fabrication Codes |
API 560, ASME Section VIII Div. 1, ASME B31.3, ISO 13705, Class A Boiler / Pressure Vessel Standard |
|
Furnace Geometry |
Twin-radiant box with single convection section or large single-cell bottom/sidewall fired rectangular cabin |
|
Single-Furnace Production Capacity |
50,000 to 200,000 tons/year ethylene output per furnace |
|
Coil Configuration |
Short residence time (0.1–0.25 seconds), single-pass, two-pass, or split-pass (U-coil / W-coil) high-selectivity radiant coils |
|
Radiant Coil Material |
Micro-alloyed high-nickel centrifugally cast alloy steel (35Cr45NiNb, 25Cr35NiNb) with internal micro-fin or swirl profile options |
|
Cracking Temperature Range |
Coil outlet temperature (COT) from 800°C to 880°C; Tube metal design temperature up to 1,150°C |
|
Operating Pressure |
Coil inlet pressure up to 0.45 MPa; Coil outlet pressure approximately 0.15–0.22 MPa |
|
Thermal Efficiency |
92% – 95% (Fully integrated with high-pressure steam generation and feed preheating convection banks) |
Customization Capabilities
High-Selectivity Coil Array Tailoring: Custom coil arrangements, including 2-1 split coils, small-diameter vertical multi-pass tubes, and optimized return bend configurations to minimize pressure drop and maximize ethylene yield.
Optimized Burner Layout Engineering: Flexible combustion configurations combining floor-mounted radiant hearth burners with targeted sidewall matrix burners, reducing burner counts while eliminating localized flame impingement.
Matched Transfer Line Exchanger (TLE) Integration: Full mechanical matching and custom spool fabrication for high-pressure transfer line exchangers and ultra-fast quench systems.
Full Casing Prefabrication: High-precision manufacturing of modular casing panels, insulated with multi-layer ceramic fiber modules and lightweight refractory castable lining.
Flexible Order Quantities: Supporting single-cell custom cracker replacements during plant maintenance turnaround or full multi-cell unit deliveries for grassroots complexes with zero MOQ.
Quality Control
Certified Factory Accreditations: Fully certified under ASME "U" and "S" stamps, ISO 3834-2 International Welding Quality System, and ISO 9001:2015.
Dynamic QR Code Tracking System: Every centrifugally cast cracking tube, precision-machined Y-piece, return bend, and tube hanger is individually serialized with an encrypted QR code traceable to melting heats and testing logs.
Comprehensive Weld & Alloy Verification: 100% Radiographic Testing (RT) and Liquid Penetrant Testing (PT) on all high-alloy welds, together with 100% Positive Material Identification (PMI) on all coil components.
Third-Party Inspection Coordination: Full support for mandatory third-party hold-point inspections conducted by BV, DNV, SGS, or client-nominated auditing teams.
Protective Export Packing: Custom heavy-gauge structural steel shipping skids with internal polyurethane cushioning, moisture-barrier wrapping, and rust-inhibitive nitrogen purging for alloy coils during ocean transit.
FAQ
Q: How do you achieve short delivery cycles for large custom cracking furnaces?
A: For full custom ethylene cracker packages, our production cycle is 4 to 6 months. By utilizing standardized modular panel assembly and keeping certified high-alloy casting materials in our pipeline, we can deliver repeat replacement coil sets within 3 months.
Q: How do you control dimensional tolerances on multi-tube cracking coils during shop prefabrication?
A: We utilize dedicated heavy assembly jigs and laser alignment tools in our Jingjiang workshops. Each harp or coil section undergoes trial assembly and 3D coordinate verification prior to dispatch to ensure zero field rework.
Q: What after-sales and installation support do you provide overseas?
A: We provide complete technical supervision, welding procedure specification (WPS) documentation, and dispatch-ready field advisory engineers for site installation, testing, and commissioning, backed by an 18-month/12-month standard warranty.
Q: What payment terms are accepted for overseas EPC contracts?
A: We accept EXW and FOB trade terms. Our standard payment schedule is 30% advance deposit upon contract signing, 40% milestone payment linked to shop fabrication/NDT milestones, and 30% balance prior to ocean shipment. Accepted currencies include USD, EUR, and RMB.
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