Barcelona refining summit 2014
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Transcript of Barcelona refining summit 2014
FACS - 31/3/2014Global Refining Summit 2014
Dynamic Heat Exchange SolutionsSignificant cost saving for refineries by innovative process
equipment
Femke Schaëfer
Barcelona – March 31st , 2014
Global Refining Summit 2014 FACS - 31/3/2014
Topics:
• Short introduction to Bronswerk Heat Transfer®
• Improvement areas in refinery
• Three case studies
• Bonus
Global Refining Summit 2014 FACS - 31/3/2014
Introduction
Global Refining Summit 2014 FACS - 31/3/2014
Global Refining Summit 2014 FACS - 31/3/2014
Our markets:
Sustainability Service & Maintenance
Power
Oil
Gas
Chemical
Air Handling
Food Processing
Global Refining Summit 2014 FACS - 31/3/2014
Global Refining Summit 2014 FACS - 31/3/2014
Global Refining Summit 2014 FACS - 31/3/2014
What we do:
• Thermal designs:
based on:
Aspen/HTFS
HTRI
HEI
Computational Fluid Dynamics
Hysys
Global Refining Summit 2014 FACS - 31/3/2014
What we do:
• Mechanical designs:
- ASME
- EN13445
- AD2000
- RTOD
- PD5500
- CODAP
- GOST
FEM analysis
Global Refining Summit 2014 FACS - 31/3/2014
What we do :
• Process design:
Process optimization
Global Refining Summit 2014 FACS - 31/3/2014
What we do :
• Equipment:
Heat exchangers
Air cooled coolers
And other process
equipment
Global Refining Summit 2014 FACS - 31/3/2014
What we do :
• Materials:
Titanium
(Super)Duplex
Nickel-Alloy
Inconel
Other exotics
Global Refining Summit 2014 FACS - 31/3/2014
What we do :
• Systems:
Incl. controls
Global Refining Summit 2014 FACS - 31/3/2014
What we do :
• Site work: Erection Assembly Start up Commissioning Service
Global Refining Summit 2014 FACS - 31/3/2014
What we do :
• Service & Maintenance: Upgrading Debottlenecking Inspection Specialist
maintenance for machines operating hazardous materials
Global Refining Summit 2014 FACS - 31/3/2014
Our focus on innovation:
• Product development
• System solutions
• New technology
Compact Header®
Radiax®
Whizz-Wheel® fans
Global Refining Summit 2014 FACS - 31/3/2014
Global Refining Summit 2014 FACS - 31/3/2014
Global Refining Summit 2014 FACS - 31/3/2014
Global Refining Summit 2014 FACS - 31/3/2014
Global Refining Summit 2014 FACS - 31/3/2014
Area’s for improvement
Global Refining Summit 2014 FACS - 31/3/2014
One: Newbuilds or Upgrading
Start at the source: size reduction of process equipment during design
Size of S&T heat exchangers
Nr of S&T heat exchangers
Size of air cooled coolers
Global Refining Summit 2014 FACS - 31/3/2014
Two: Improvement of installation
During operation; more efficient power consumption
25-30% of worlds energy
consumption is used for
ventilation
Increasing output
Global Refining Summit 2014 FACS - 31/3/2014
Three: Less downtime
Maintenance; limitation of production losses by fouling reduction in
Heat Exchangers
Crude oil quality is dropping
Decreasing production output
Higher energy use and CO2
emission
Maintenance is costly
Global Refining Summit 2014FACS - 31/3/2014
The solutions
Global Refining Summit 2014 FACS - 31/3/2014
Current situation:
•Huge plot space requirement
•High power consumption for air coolers
•Big influence on CAPEX & OPEX
Case study 1 – High efficiency cooling
Global Refining Summit 2014 FACS - 31/3/2014
Case study 1 – High efficiency cooling
•New fan design based on
aerospace technology
•Intensified heat transfer
through higher air
pressure and velocity
•Over 30% plot space
reduction
OR
•Over 50% reduction in
power consumption
Global Refining Summit 2014 FACS - 31/3/2014
Original design based on standard air coolers;
• Absorbed electrical power: 1143 kW
• Plot space used: 4224 m²
• Noise power emission: 101 dB(A)
Case study 1 – High efficiency cooling
Global Refining Summit 2014 FACS - 31/3/2014
Improved design based on high efficiency air coolers (with Whizz-Wheel® fans);
Old New
• Absorbed electrical power: 1143 kW 528 kW
• Plot space used: 4224m² 2974 m²
• Noise power emission: 101 dB(A) 94 dB(A)
Case study 1 – High efficieny cooling
Global Refining Summit 2014 FACS - 31/3/2014
Benefits;
• Noise reduction: 7 dB(A)
• Size reduction: 1250 m² = 29%
• Power consump. red.: 615 kW = 53%
• Opex savings: € 492.000,- / yr Figure 3: comparative
Figure 2: high efficiency designFigure 1: standard design
Case study 1 – High efficiency cooling
Global Refining Summit 2014 FACS - 31/3/2014
Global Refining Summit 2014 FACS - 31/3/2014
VS
Increasing output
• 50% less kW
• 35% more cooling air
• 10-15% more production
• € 700 million gas production
• € 70 million additional
• Debottlenecking investment: € 0,5 million
Global Refining Summit 2014 FACS - 31/3/2014
Increasing output
Restrictions:
• Maximum noise level
• Production capacity
down to 60%
Results:
• Elimination of all
noise issues
• Production up to
100%
Bonus:
• 56% savings in
energy consumption
Global Refining Summit 2014 FACS - 31/3/2014
Increasing output
Restrictions:
• Lower noise level or
plant shut down!
Results:
• 20 fans installed
• Elimination of all
noise issues
Bonus:
• 56% savings in
energy consumption
Global Refining Summit 2014 FACS - 31/3/2014
High pressure compact cooling & maintenance
Global Refining Summit 2014 FACS - 31/3/2014
Case study 2 – High pressure compact cooling
Situation: Conventional high pressure S&T HEX at a refinery
Global Refining Summit 2014 FACS - 31/3/2014
Original design based on conventional D-type high pressure shell & tube heat
exchangers;
Global Refining Summit 2014 FACS - 31/3/2014
• Design pressure 450 bar
tubeside
• Design pressure 350 bar
shell side
Case study 2 – High pressure compact cooling
New design based on compact header® high pressure shell & tube heat
exchangers;
Global Refining Summit 2014 FACS - 31/3/2014
• Design pressure 450 bar
tubeside
• Design pressure 350 bar
shell side
Case study 2 – High pressure compact cooling
• Up to 60% weight reduction
• Reduced plot space
• Much higher allowable
temperature gradients
• High pressure is no issue up to
1000 bar
• Easy maintenance
Global Refining Summit 2014 FACS - 31/3/2014
Case study 2 – High pressure compact cooling
Global Refining Summit 2014 FACS - 31/3/2014
Plugs
Maintenance
Global Refining Summit 2014 FACS - 31/3/2014
Global Refining Summit 2014 FACS - 31/3/2014
Fouling prevention
Global Refining Summit 2014 FACS - 31/3/2014
Case study 3 – Fouling prevention
Situation: Fouling inside thermosyphon reboiler tubes in crude stabilization unit in
Abqaiq
Source: http://www.ortloff.com/sulfur-recovery/modified-claus-process-with-tailgas-cleanup/
Global Refining Summit 2014 FACS - 31/3/2014
Original design based on thermosyphon reboiler;
Case study 3 – Fouling prevention
Shell side: steam
• Inlet temp: 157°C
• Outlet temp: 87°C
Tube side: Crude oil (Arabian light)
•Inlet temp: 70°C
•Outlet temp: 85°C
Heat transfer surface: 6000m2
Maintenance:
•Cleaning of tubes: 1-2 months
•Retubing: 2 years
Source: http://upload.wikimedia.org/wikipedia/commons/5/57/Thermosyphon_Reboiler.png
Global Refining Summit 2014 FACS - 31/3/2014
Case study 3 – Fouling prevention
Alternative design based on Klarex® shell & tube heat exchangers;
Global Refining Summit 2014 FACS - 31/3/2014
Original Alternative
Shell side fluid: steam
• Inlet temp: 157°C
• Outlet temp: 87°C
Tube side: Crude oil (Arabian light)
•Inlet temp: 70°C
•Outlet temp: 85°C
Heat transfer surface: 6000m2 4600m2
Maintenance:
•Cleaning of tubes: 1-2 months 2-3 years
•Retubing: 2 years 2 years
• Fluidized (vertically entrained)
cleaning particles inside the tubes
• This prevents deposition of wall-
fouling compounds (turbulence)
• Heat transfer enhancement due to
change from laminar flow pattern
into turbulent flow
• Smaller heat transfer surface
required
• Continuous operation
Case study 3 – Fouling prevention
Case study 3 – Fouling prevention
Global Refining Summit 2014
Benefits:
• Heat transfer surface reduction: 1.400 m2 = 34%
• Saving in Opex:
• Maintenance = € 84.000,- x 40 (reboiler) = € 3.4 million/yr
• Capex: For new plant - 1 klarex instead of 2 reboilers
• 1 reboiler € 850.000,- x 40 reboilers = € 34 million
• 1 klarex € 950.000,- x 20 klarex heat exchangers = € 19 million
15 million less Capex and 3.4 million less Opex every year.
FACS - 31/3/2014
Situation: Shell side fouling conventional naphta exchanger in the recovery
process in Abqaiq
Global Refining Summit 2014 FACS - 31/3/2014
Case study 3 – Fouling prevention
Case study 3 – Fouling prevention
Original design based on conventional naphta exchanger;
Parameters naphta exchanger:
• Tube side: lean oil
• Shell side: rich oil
Maintenance:
•Cleaning: every 2-3 months
•Retubing: every year
•Costs: € 30.000,-
•Total costs in 1 years: € 165.000,-
Global Refining Summit 2014 FACS - 31/3/2014
Case study 3 – Fouling prevention
Alternative design based on Twist-Flex-Baffle ® exchanger;
Parameters Twist-Flex-Baffle® exchanger:
• Tube side: lean oil
• Shell side: rich oil
Maintenance:
•Cleaning: every 2 years
•Retubing: every year
Benefits:
•Improved heat transfer: > 10%
•Reduced pressure loss: > 10%
Global Refining Summit 2014 FACS - 31/3/2014
Flare gas recoveryFlare gas compression with smart-compact Radiax ®compressor:
• Several hundreds of millions m3 of flare gas wasted
• Gas at atmospheric pressure
• Compress to 20-80 Bar
Global Refining Summit 2014 FACS - 31/3/2014
Flare gas recoveryFlare gas compression with smart-compact Radiax ®compressor:
Global Refining Summit 2014 FACS - 31/3/2014
Global Refining Summit 2014 FACS - 31/3/2014
Global Refining Summit 2014 FACS - 31/3/2014
Flare gas recoveryFlare gas compression with smart-compact Radiax ®compressor:
• Several hundreds of millions of flare gas wasted
• Gas at atmospheric pressure
• Compress to 20-80 Bar
Global Refining Summit 2014 FACS - 31/3/2014
Summary
Yes, Bronswerk Heat Transfer can help your refinery become more sustainable and profitable at the same time:
1. Start at the source: size reduction of process equipment during design
Global Refining Summit 2014 FACS - 31/3/2014
Klarex® 34% in heat transfer surface
Twist-Flex-Baffle® 10% improved heat transfer
High efficiency air coolers with
Whizz-Wheels®
up to 30% in plot space area
Flexplate® additional 25-30% in plot space
Radiax® Compressor/Turbine up to 95% in space requirement
Summary
2. During operation; reduction of power consumption
Global Refining Summit 2014 FACS - 31/3/2014
High efficiency air coolers with
Whizz-wheels®
Power consumption reduction up
to 50%
Radiax® Compressor/Turbine Energy recovery: € 7,5 mill a year
Without additional investment
Summary
3. Maintenance; limitation of production losses by fouling reduction in Heat Exchangers
Global Refining Summit 2014 FACS - 31/3/2014
Klarex® OPEX savings of € 3,4 million a year
Twist-Flex-Baffle® OPEX savings of € 165.000,-
a year
Compact Header® HEX Easy one-man-maintenance
Thank you for your attention.Questions please
Global Refining Summit 2014 FACS - 31/3/2014
How to contact us:
www.bronswerk.com
facebook.com/bronswerk
Linkedin.com/company/bronswerk-heat-transfer
twitter.com/bronswerk
Global Refining Summit 2014 FACS - 31/3/2014
And come visit our booth in the central hall