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TRANSCRIPT
© Alfa Laval Slide 2
www.alfalaval.com
Optimize Energy Recovery in Refineries
Copyright : Evae AnderssonThe material in this presentation may not be reproduced or transmitted
in any form without the permission of the copyright holder.
Optimize EnergyRecovery in Refineries
Using Compact Plate Heat Exchangers
Eva Andersson
© Alfa Laval Slide 4
www.alfalaval.com
CPHEs in Refinery industry• With the Kyoto protocol and EU regulations, refineries for the
future has to start looking into lowering emissions throughreducing energy consumption
• Cutting down on energy consumption i refineries means
– Changing from residue fuel to NG
– Upgrade process equipment
• Compact plate heat exchangers (CPHEs) such as the Compabloc and Packinox heat exchangers have proven to be indispensable tools in the quest for high performance process equipment meeting this challenge
• > 1000 CPHE references in refineries world-wide: 350 Packinox, 600 Compabloc
© Alfa Laval Slide 5
www.alfalaval.com
Heat RecoveryAnnual Savings
30 00030SOx and NOxemissions
50 0002 500CO2 emissions
300 000970Heater fuel
$/year and MWTon/year and MWSavings
Annual savings for 1 MW of increased heat recovery, resultingin a 1 MW reduction in net energy needs in the heater
Based on fuel cost of $40/bbl and heater efficiency of 65%, CO2 credit cost of $20/ton and SOx and NOx content in the fuel of 0,6% and 0,25% respectively, to a value of $1000 /ton
© Alfa Laval Slide 6
www.alfalaval.com
Typical CPHEProduct description
• Plate heat exchanger
• Gasket-free
• Globally counter-current flow
• Complete accessibility
© Alfa Laval Slide 7
www.alfalaval.com
Typical CPHEOperation
Click on picture for animationClick on picture for animation
OutOutHot mediumHot mediumCold mediumCold medium
InInHot mediumHot mediumCold mediumCold medium
© Alfa Laval Slide 8
www.alfalaval.com
Corrugated plate design promotes:
High turbulence
• Efficient heat transfer– 3-5 times higher in liquid/liquid applications– 2-3 times higher in 2-phase applications
• Minimised fouling– 5-10 times higherwall shear stress
Typical CPHEEfficiency
© Alfa Laval Slide 9
www.alfalaval.com
Designed for:
Temperature-cross and close temperature approach
• High efficiency in Heat recovery
Typical CPHE Heat Recovery
Out
In
Out
In
T1
T2T1
T2
Closetemperature approach:down to 3°C Temperature
cross
© Alfa Laval Slide 10
www.alfalaval.com
• Fewer units
• Less heat transfer surface
• Thinner plate material
� Cost-efficient in corrosion-free material
Yearly inspections not required
Corrosion problems eliminated
Fouling due to corrosionproducts eliminated
HTA: Σ 1000 m2
HTA: 170 m2
Typical CPHE Corrosion resistance
© Alfa Laval Slide 11
www.alfalaval.com
Typical CPHE – S&T comparison
30 – 401Hold-up volume
N/A3 – 5°CTemperature pinch
1,5 – 21Installation cost
2 – 51Weight full
1,5 – 41Weight empty
4 – 101Service area
5 – 101Footprint
11 – 1,5Pressure drop
3 – 51Heat transfer area
13 – 5Heat transfer efficiency
15 – 8Wall shear stress
Shell & TubeCompabloc
© Alfa Laval Slide 12
www.alfalaval.com
Energy consuming refineryprocesses• Crude preheating
• Fluid Catalytic Cracking
• Catalytic Reforming
© Alfa Laval Slide 13
www.alfalaval.com
Atmospheric distillationPetroleum Gas & Light Naphtha
Heavy Naphtha
Kerosene
Light Gas Oil (LGO)
Heavy Gas Oil (HGO)
Atmospheric residue
Preheated Crude oil
Distillationtower
Firedheater
Click on the highlighted products to get more information!
Crude oilfeed
~40°C
~25-175°C
~150-260°C
~235-360°C
~330-380°C
~250-280°C
~350-370°C
© Alfa Laval Slide 14
www.alfalaval.com
Economical studyCrude preheaters – S&T HEN
© Alfa Laval Slide 15
www.alfalaval.com
Economical studyCrude preheaters – PHE HEN
© Alfa Laval Slide 16
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Economical StudiesCrude preheating – USA
4.5X2XExchanger Cost, Installed
0$1.411Emissions Savings/ Million USD / Year
0$2.41Heater Fuel Savings / Year, Million USD @ $7/MMBTU
3XXExchanger Flooded Weight, tons
14+7Number of Shells
1.5XXExchanger Cost
238299Heater Charge Temperature (°C)
S&TCompabloc75,000 bbl/day Crude Train
Installed cost = 3,6 MUSD -> less than one year pay-back time
© Alfa Laval Slide 17
www.alfalaval.com
Economical StudiesCrude preheating – USA
Duty:
HVGO 298 � 271 °CCrude oil 263 � 239 °C
Q = 7.0 MW
Crude = mix of Mexican Mayan and Canadian Heavy
In operation since 2004
Installed cost for 2 CPs $ Check with AL Annual savings in fuel cost $2.2 million/yearAnnual savings in emissions $0.5 million/yearTotal annual savings $2.7 million /yearPay back ~ less than 12 months
© Alfa Laval Slide 18
www.alfalaval.com
Fluid Catalytic Cracking, FCC
Reactor
Main fractionator
Regenarator
Flue gas
Reactor effluent
FCC feed
O’heads condenser
Distillate coolersand PAs
Clarified slurry oil cooler
FCC bottoms cooler
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Spent
Catalyst
RegeneratedCatalyst
Steam
Condenser
FCC mix
C4 and lighter
Gasoline
Gas Oil
Heavy Gas Oil
© Alfa Laval Slide 19
www.alfalaval.com
Economical StudiesBFW preheating, Canada
1st Stage – Heat recovery:Overhead vapour 141 � 87°C BFW 128 � 43°C
2nd Stage – Cooling:Overhead vapour 87 � 29°CCooling water 45 � 24°C
Total recovered heat: 14 MW
In operation since 2002
Installed cost for 8 CPs in HC $ check with ALAnnual savings in fuel cost $4.3 million/year Annual savings in emissions: $1.1 million/yearTotal annual savings $5.4 million /yearPay back ~ less than 15 months
© Alfa Laval Slide 20
www.alfalaval.com
Catalytic Reforming
Click on the highlighted products to get more information!
Firedheater
HP separator
Recycle gascompressor
Feed/effluentheat exchanger
ReactorStabilizer
Reformate overheads
Reboiler
Reformatecooler
����� � �� � � � � �� � � � �
Firedheater
Firedheater
ReactorReactor
Reactor
Feed/bottoms
Condenser
Cooler
© Alfa Laval Slide 21
www.alfalaval.com
Economical StudyFeed/Effluent heat exchanging – CRU
• Increased heat recovery in Feed/effluent Packinox heat exchanger
Hot Approach Temperature – S&T option 44°C, 123 MW
Hot Approach Temperature – PKX option 28°C, 130 MW
� Heater duty lowered with 7 MW, annual energy savings of 3,1MUSD, additional annual savings in emission of 560 kUSD
� Cooler and heater savings 500 kUSD
• Reduced number and weight
Number & Weight S&T option: 4 S&Ts, 275 tons
Number & Weight PKX option: 1 PKX, 150 tons
� Reduced installed cost savings HX (4,5 MUSD vs 5 MUSD)
* Based on a CCR capacity of 50 000 bbl/day with a crude oil price of 40 USD/bbl, CO2 cost of 20 USD/ton, NOx and SOx cost of 1100 USD/ton
© Alfa Laval Slide 22
www.alfalaval.com
Summary - CPHEs
Possible to reduce energy consumption and emissions due to
• Increased heat transfer efficiency
• Maximized energy recovery
With a Typical Investment Pay Back period of around a year
© Alfa Laval Slide 23
www.alfalaval.com
French Contact
Johannes DOUCET
Key account manager / Business development
Responsable marché raffinage France
Tel 01 30 81 82 41
Fax 01 30 81 81 11
Mob 06 16 24 37 49
Mail : [email protected]