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<p>This paper presents a comparative thermodynamic analysis of refrigerants used in ethylene boil-off gas (BOG) re-liquefaction systems within petrochemical plants, aimed at enhancing operational efficiency and environmental sustainability. The study evaluates refrigerants including R-290, R-744, R-125, R-170, and R-1270 alongside cascade refrigeration systems combining R-744 with R-717 and R-290, using Aspen HYSYS simulations to assess performance metrics such as Coefficient of Performance (COP), compressor power consumption, refrigerant mass flow rates, and total pressure ratios under varying operating conditions. Results quantify that R-1270 achieves the lowest power consumption rate of approximately 60.11&#xa0;kW per unit BOG mass flow, slightly outperforming R-290, while also requiring significantly lower refrigerant mass flow. Conversely, R-125 exhibits the highest energy demand and refrigerant usage. Cascade cycles demonstrate competitive performance with reduced total pressure ratios and power requirements. These findings elucidate the thermodynamic advantages of selecting specific refrigerants for ethylene BOG reliquefaction, highlighting R-1270's potential for reducing energy consumption and environmental impact. The study's insights provide practical guidance for optimizing refrigeration cycle designs in petrochemical applications, supporting improvements in system performance and sustainability.</p>

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Enhancing efficiency and sustainability: a comparative analysis of refrigerants in ethylene BOG re-liquefaction processes

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年10月5日

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  • Ahmed T. Abd El-Hamid,
  • Ahmed A. Hanafy,
  • Sameh Tawfik,
  • Wael M. El-Maghlany

摘要

This paper presents a comparative thermodynamic analysis of refrigerants used in ethylene boil-off gas (BOG) re-liquefaction systems within petrochemical plants, aimed at enhancing operational efficiency and environmental sustainability. The study evaluates refrigerants including R-290, R-744, R-125, R-170, and R-1270 alongside cascade refrigeration systems combining R-744 with R-717 and R-290, using Aspen HYSYS simulations to assess performance metrics such as Coefficient of Performance (COP), compressor power consumption, refrigerant mass flow rates, and total pressure ratios under varying operating conditions. Results quantify that R-1270 achieves the lowest power consumption rate of approximately 60.11 kW per unit BOG mass flow, slightly outperforming R-290, while also requiring significantly lower refrigerant mass flow. Conversely, R-125 exhibits the highest energy demand and refrigerant usage. Cascade cycles demonstrate competitive performance with reduced total pressure ratios and power requirements. These findings elucidate the thermodynamic advantages of selecting specific refrigerants for ethylene BOG reliquefaction, highlighting R-1270's potential for reducing energy consumption and environmental impact. The study's insights provide practical guidance for optimizing refrigeration cycle designs in petrochemical applications, supporting improvements in system performance and sustainability.