Optimizing plant efficiency

Heat recovery and saving energy

Hans van Essen

Den Haag – April 22 2015

Content

• Introduction Bronswerk

•Radiax®

– Case 1: Mechanical vapour recompression

• Whizz-wheel®

– Case 2: Debottlenecking – ACHE offshore

– Case 3: Debottlenecking – ACHE refinery

• Site survey

History:

1940

1988 – Privately owned

2015

What we do:

• Process design

• Thermal design

• Mechanical design

• Manufacturing

• Supply

• Installation & Commissioning

• After market

Radiax®

:

Developing the Radiax® started from the beginning, a fully

new principle compressor / turbine / pump was designed.

Radiax®

:

Key features:

• Compact (up to factor 10)

• Fully integrated drive and seal system

• Oil free system behavior

• Flexible in extended ranges

• No surge and No stall

• Flat pressure vs flow curves (no specific work point)

• High pressure ratio

• High efficiencies over extended ranges

Radiax®

:

Applicatoins

- Wet compression & wet expansion

- Well gas conditioning for gas turbines

- Waste Heat Recovery (ORC & RC)

- Vapour recompression

CASE 1: Steam Recompression

Case description :

Stripper

flash drum

Steam ejector

4 bara

7000 kg/h

144°C / 4 bara

Water: 312352 kg/h

HP steam

2500 kg/h

3,29 bara

4500 kg/h

3,29 bara

Operating cost: €537.000,- / year

Solution :

Stripper

Flash drum

4 bara

7000 kg/h

144°C / 4 bara

Water: 312352 kg/h

2,85 bara

7000 kg/h

Radiax

2,85 bara

E-power: 200kW

Operating cost: €137.600,- / year

• OPEX reduction:

€400.000,-/year

• ROI: <2 year

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

Whizz-wheel®

:

Trends:

• Upgrading existing facilities

• Decreasing OPEX

– absorbed motor power

– Maintenance

• More strict noise requirements

CASE 2: 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 3: Debottlenecking

Air Cooled Coolers – 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

Site Survey

What is your specific challenge? Or where can you safe

energy

With a Site Survey the problem can be identified and a

solution is within reach!

Thank you for your attention.

Questions?

Let’s talk more in our booth (No. 12)

How to contact us:

Hans van Essen

essen@bronswerk.com

+31-33-24-72-562

www.bronswerk.com