Selecting and Enabling Effective Cost Savings Through ...

Selecting and Enabling Effective

Cost Savings Through Innovative

Heat Transfer Enhancement

Technology

Presented by :

Martin Gough,

CALGAVIN Ltd

hiTRANTM Thermal Systems Working Principles of CALGAVIN Technology

Direction of Flow

How Does hiTRAN™ Technology Work?

• Removes the laminar boundary layer

• Mixes fluid with bulk flow

• Improves heat and mass transfer- changing the mode of heat transfer at the tube wall from conduction to convection – a higher rate of heat transfer

Analytical Engineering – Lube oil air Cooler

Analytical Engineering – Heavy gas oil Cooler

Case Study 1:Graphite Vent Gas Condenser

Improved Product Quality

Condition Before Installation

-50

-40

-30

-20

-10

0

10

0.96

0.97

0.98

0.99

1

0 500 1000 1500 2000 2500 3000

bu

lk t

em

pe

ratu

re [

C]

Vap

or

we

igh

t fr

acti

on

[-]

Tube length [mm]

VaporWeightFraction

BulkTemperature

shell temperature

• Tube side Reynolds number

~ 18000

• Wet wall shear controlled

flow regime

Results After Revamp

0.96

0.97

0.98

0.99

1

0 500 1000 1500 2000 2500 3000

Vap

or

weig

ht

fracti

on

[-]

Tube length [mm]

plain empty hiTRAN

-50

-40

-30

-20

-10

0

10

0 500 1000 1500 2000 2500 3000

Bu

lk t

em

pe

ratu

re [

C°]

Tube length [mm]

plain empty hiTRAN shell temperature

hiTRAN™ inserts performed

as predicted

• ~5 °C lower outlet

temperature

• Minor increase in

pressure drop (5mbar)

• Increased condensate

mass flow more than

10000 kg/year product

recovery

• Avoiding additional

empty tube unit to meet

demand, CAPEX saving

$258634 (reference

Exchanger Optimizer)

Results After Revamp

Case Study 2:Paraxylene Feed/Effluent

Increased Throughput

Feed/Effluent Exchanger Revamp

From operating data client recognised the opportunity for heat recovery in order to increase production

Ruhr OEL, Gelsenkirchen, Germany

Shell Tube

Fluid Paraxylene Effluent Feed

Flow 85940kg/hr 85940kg/hr

Vapour fraction 1 / 0.57 0.32 / 1

Temp. (In/Out) 403°C / 138°C 94°C / 327°C

HTC 975W/m2K 591W/m2K

Duty 19.7 MW

Reynolds (In/Out) 2130 / 68000

TEMA Type AES

Tube dims. 1734 tubes, 20x2x12000mm, 1 pass

Design Data

Heat Transfer Analysis

0

500

1000

1500

2000

2500

0 2000 4000 6000 8000 10000 12000

tube length [mm]

Heat

Tra

nsfe

r [W

/m2K

]

0

0.2

0.4

0.6

0.8

1

1.2

Va

po

ur

Qu

ali

ty [

-]

SS HTC

TS HTC

TS

Vapour Fraction

hiTRAN™ Thermal System Solution

Benefits after hiTRAN™ Installation

• No requirement for larger fired heater

• No changes to pipework

• No additional civil engineering costs

• Heat Transfer in superheated region increased by 48%

• Reduction of the duty for the fired heater saved around 0.8MW

• Saved 1700t/y CO2 calculated

• ROI paid within 18 months

• Achieved 17.5% increased throughput

• Empty tube equivalent capital cost $1042900

(reference Exchanger Optimizer)

CALGAVIN Global References

Indian ReferencesP.NO. COMPANY APPLICATION DESC. CUSTOMER BENEFIT END USER INSTALL COUNTRY TUBESIDE FLUID

Company Type: End User

7223 GEI Industrial Systems Ltd Residue Cooler Reduced Size Indian Oil India Residue

8396 BGR Energy Systems Ltd (Air

Fin Cooler Division)

Oil cooler Reduced Size Oil & Natural Gas Corporation

(ONGC)

India ISO VG46



Oil cooler Reduced Size Cairn Energy India ISO VG46



Air fin cooler Improved Duty Chennai Petroleum Corporation

Ltd

India

10481 BGR Energy Systems Limited Lube oil cooler Reduced Size ONGC India Lube oil

10644 BGR Energy Systems Limited Lube oil cooler Reduced Size ONGC India ISO VG 46



10989 BGR Energy Systems Limited Oil cooler Reduced Size SAVAIR Energy Systems Ltd,

Mumbai

India oil

11153 Jord International Lube oil coolers Reduced Size Enpro India India ISO VG 46



Product Fractionator Bottoms

Cooler - Multiple bidders

Reduced Size Indian Oil Corporation Limited India Frac bottoms

12487 Nuovo Pignone S.r.l. Oil cooler Reduced Size India Lube oil



12516 Industrial Manufacturers Twisted Tape - Reliance Improved Duty Reliance Jamnagar Refinery India

12516 Industrial Manufacturers Twisted Tape - Reliance Improved Duty Reliance Jamnagar Refinery India

12558 Robox Heat Technology b.v. Duraclear U tube cooler Improved Duty India Duraclear

P.NO. COMPANY APPLICATION DESC. CUSTOMER BENEFIT END USER INSTALL COUNTRY TUBESIDE FLUID

Company Type: End User

6738 Daurala Organics Limited Falling Film Evaporator

trial

Improved Duty Daurala India Mandelic acid

8492 Shell Research Ltd Crude oil fouling tests Reduced Fouling SHELL India crude oil



10822 Hindustan Petroleum

Corporation Limited

New bundle CDU II - see

project folder

Reduced Fouling Hindustan Petroleum

Corporation Limited

India Crude

10822 Hindustan Petroleum

Corporation Limited

New bundle CDU II - see

project folder

Reduced Fouling Hindustan Petroleum

Corporation Limited

India Crude

11816 Linde Engineering India Pvt

Ltd

Twisted Tape Improved Duty Linde India India HC

6627 Kelvion France Oil coolers Reduced Size Essar oil India Crude Oil






7016 GEA Batignolles Thermal

Technologies(Changshu)Co.L

Lube oil coolers Reduced Size GAIL India Lube oil

Thank you for listening

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