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


Introduction


Our markets:

Sustainability Service & Maintenance

Power

Oil

Gas

Chemical

Air Handling

Food Processing


What we do:

• Thermal designs:

based on:

Aspen/HTFS

HTRI

HEI

Computational Fluid Dynamics

Hysys


What we do:

• Mechanical designs:

- ASME

- EN13445

- AD2000

- RTOD

- PD5500

- CODAP

- GOST

FEM analysis


What we do :

• Process design:

Process optimization


What we do :

• Equipment:

Heat exchangers

Air cooled coolers

And other process

equipment


What we do :

• Materials:

Titanium

(Super)Duplex

Nickel-Alloy

Inconel

Other exotics


What we do :

• Systems:

Incl. controls


What we do :

• Site work: Erection Assembly Start up Commissioning Service


What we do :

• Service & Maintenance: Upgrading Debottlenecking Inspection Specialist

maintenance for machines operating hazardous materials


Our focus on innovation:

• Product development

• System solutions

• New technology

Compact Header®

Radiax®

Whizz-Wheel® fans


Area’s for improvement


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


Two: Improvement of installation

During operation; more efficient power consumption

25-30% of worlds energy

consumption is used for

ventilation

Increasing output


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


Current situation:

•Huge plot space requirement

•High power consumption for air coolers

•Big influence on CAPEX & OPEX

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


Original design based on standard air coolers;

• Absorbed electrical power: 1143 kW

• Plot space used: 4224 m²

• Noise power emission: 101 dB(A)



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


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




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


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


http://kennisbank.bronswerk.nl/kennisbank/images/5/56/Whizzwheel00084.jpg

http://kennisbank.bronswerk.nl/kennisbank/images/5/56/Whizzwheel00084.jpg

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


High pressure compact cooling & maintenance


Case study 2 – High pressure compact cooling

Situation: Conventional high pressure S&T HEX at a refinery


Original design based on conventional D-type high pressure shell & tube heat

exchangers;


• Design pressure 450 bar

tubeside


shell side


New design based on compact header® high pressure shell & tube heat

exchangers;



tubeside


shell side


• Up to 60% weight reduction

• Reduced plot space

• Much higher allowable

temperature gradients

• High pressure is no issue up to

1000 bar

• Easy maintenance




Plugs

Maintenance

Fouling prevention


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/


Original design based on thermosyphon reboiler;


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



Alternative design based on Klarex® shell & tube heat exchangers;


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



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




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,-



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%


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



• Several hundreds of millions of flare gas wasted

• Gas at atmospheric pressure

• Compress to 20-80 Bar


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


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


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


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


How to contact us:

www.bronswerk.com

facebook.com/bronswerk

Linkedin.com/company/bronswerk-heat-transfer

twitter.com/bronswerk


And come visit our booth in the central hall

http://www.linkedin.com/company/2233102




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