Dynamic ACC Solutions
Debottlenecking Air Cooled Coolers
Hans van Essen
Bahrain – October, 2014
Index
• Introduction Bronswerk
• Whizz-wheel®
• Case 1: Debottlenecking –Litoral-A offshore platform.
• Case 2: Debottlenecking – Bayernoil
• Additional solutions
History:
1940
1988 – Privately owned
2014
What we do:
• Process design
• Thermal design
• Mechanical design
• Manufacturing
• Supply
• Installation & Commissioning
• After market
Heat to atmoshpere (Air Cooled Cooling):
• “closed” systems, called Air Cooled Coolers (ACC)
• “open” systems, called Cooling towers
This presentation covers the bottlenecks and other lack
of duty in ACC, and particularly how to overcome this
lack.
Reasons for lack of duty:
• Original design was (too) small
• Fouling of the cooler
• Influence of wind
• Higher cooling air temperature, because:
– Global warming
– Local warming
– Hot air recirculation
Whizz-wheel®
:
Develop ultra low noise fans to meet the stricter client
requirements.
Conventional :
Whizz-wheel®
:
Main features
•Rim
•Small hub
•Blades are fully curved
Whizz-wheel®
:
Developed for low noise: 6 – 20 dB lower noise
Benefits:
• 45 - 60% lower absorbed power
• Up to 40% more cooling air flow with same absorbed power
• Or a combination
• Minimal vibrations
• Rigid construction
• Less sensitive to wind
CASE 1: Debottlenecking
2 new gas compression modules – Mexico
Litoral-A
Case description :
Plant
• Existing platform
• Two new gas compression trains (modules)
Challenges:
1. Plot space
2. Maximal absorbed power
3. Maximum noise level
Solutions :
Conventional Whizz-wheel®
Plot space area 582m2 412m2
Installed motor power 390 kW 308 kW
Sound pressure level 90 dB(a) @ 1m <85 dB(a) @ 1m
Total height 7,6m 7m
Total weight of units 141 ton 126 ton
Results:
• 40% reduced plot space
• 24% lower absorbed power
• 8% reduced height
• 12% less weight
• No noise issues
Quote PM: “without the whizz-wheel we could not have
executed this project.”
CASE 2: Debottlenecking
BAYERNOIL– Germany
Case description:
Plant
• 120.000 barrels/day
• Located in a populated area
• More then 60 fans
• Different services
Challenge:
• Reduce high noise
emissions
Solutions :
Option 1: Standard low noise fans
• Noise level of 72 dB(a)
• 12,6 kW absorbed power
Option 2: Whizz-wheel ® system
• noise level of 66 dB(a)
• 5,6 kW absorbed power
Results:
• 20 dB(A) proven lower noise
• 56% lower absorbed power
• 5% more airflow
• Installation during operation
Air side Fouling
• Prevention (screens)
• High pressure water cleaning
• Dry cleaning
Hot Air Recirculation & Wind
• Wind screens
Fogging
• Decrease ambient air temperature
Site Survey
What is your specific challenge?
• Intensification of your plant
• Increased ambient air temperature
• Wind
• Hot Air Recirculation
• Air side fouling
• Vibrations
• damaged fans
• ..
With a Site Survey the problem can be identified and a
solution is within reach!
Thank you for your attention.
Questions?
How to contact us:
Hans van Essen
+31-33-24-72-562
www.bronswerk.com