Furnace Modernization: An Economical Way to Upgrade Your Existing Furnace to Improve Energy Performance and Reduce CO2 Emissions

Shell investigated several options to maintain security of the production capacity of its 16 cracking furnaces after 50 years of operation, at its Moerdijk petrochemicals complex in the Netherlands. Following the outcome of a study, the selected options to choose from were a one-to-one replacement of 16 existing furnaces or upgrading 8 of those furnaces by doubling their capacity.

After detailed evaluation it became clear that the modernization of 8 furnaces was the most optimum path forward. Key drivers for selecting this option were:

• Improve energy performance and emissions
• Reduce environmental footprint (about 10% CO₂ reduction of Moerdijk’s annual total), an important step to the Shell energy transition targets of being net carbon neutral in 2050 or earlier in step with society.
• Further process safety improvements
• Fast implementation within 5 years, without impacting production
• Lower investment cost compared to green field investment

The main process design challenge on this project is doubling the furnace capacity and improving on overall efficiency while re-using the existing firebox and burners, and maintaining existing foundations. The main project execution challenge is implementing these revamps outside of a plant turnaround to minimize the impact on the Shell Moerdijk lower olefins production, without any concessions to safety in the running plant.

This paper describes the furnace revamp design and the revamp execution strategy that minimizes field labour on site and maximises a modular approach.

Shell’s technological know-how, project execution and operational experience combined with TechnipFMC’s Process Technology and EPC capabilities has led to the current furnace design, enabling a 100% capacity increase within the same firebox.