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Technology and engineering advanced services

Technology and engineering advanced services

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  • 1. engineering and technology partnerC A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 2. TA B L E O F C O N T E N TS your engineering and technology partner COMPANY BUSINESS CONCEPT R&D PHILOSOPHY CAPABILITIES AND SERVICES PROCESS ENGINEERING Process Simulation Upset Analysis Sensitive Analysis PROCESS EQUIPMENT Thermal-Hydraulic and FEA CHT - Conjugated heat transfer Equipment Design CASE STUDIES PROCESS ENGINEERING Process Simulation Upset Analysis Sensitive Analysis PROCESS EQUIPMENT Thermal-Hydraulic and FEA CHT - Conjugated heat transfer Equipment DesignC A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 3. C A D E s o l u c i o n e s P E T RO C H E M I S T R Y d e i n g e n i e r i a - - R E F I N E R Y E S P A Ñ A - S P A I N - O I L & G A S - R E N E WA B L E SC O M P A N Yadding value to our partnersCADE is an expert provider of advanced and specialized engineering,technology and R&D services focused on process and mechanicalengineering, serving as a technology partner to its cliens. -Since the beginning of its activities in 2003, CADEs philosophy has beenfocused on developing close collaborative relationships with its clients. G E N E R A T I O NThis objective is achieved by becoming an extension of our clientsengineering and R&D staff, working together to face any challenge.In order to meet all of the clients requests, CADE takes on each andevery project guided by the companys three main principles:SPECIALIZATION, FLEXIBILITY AND EXCELLENCE P OW E R
  • 4. BUSINESS CONCEPTadvanced engineering and technolgy develompentNowadays, it is essential to face any complex problems CADE combines advanced capabilities in process andassociated with the development, operation and upgrade of mechanical engineering working collectively with its clientsexisting or new technologies and the related equipment by to achieve these objectives.applying multiple engineering and technolgy approaches. CADE supports its client by providing custom-made advancedWith the goal of obtaining the best solution available and engineering solutions adjusted to suit the nature of themaximizing effectiveness and efficiency, it is necessary to clients projects and technical capabilities.understand the implicit problems of these technologies andthe related equipment during all stages. A full range of advanced engineering capabilities are applied for reaching your goals.This task can only be achieved by applying all the engineeringdisciplines involved in the design, fabrication, start-up andoperation phases together with a comprehensive knowledgeand vast experience in different industrial fields. Focus: advanced mechanical and process engineering industries served customers and parnters - POWER GENERATION (CONVENTIONAL, NON CONVENTIONAL) - PLANT OWNERS AND OPERATORS - RENEWABLE ENERGY - TECHNOLOGY LICENSORS - REFINERY PLANTS - EPC CONTRACTORS - PETROCHEMICAL INDUSTRY - PACKAGE UNIT SUPPLIERS - WASTE TREATMENT - MANUFACTURING COMPANIES - WASTE TO ENERGY - ENGINEERING COMPANIES - CHEMISTRY AND PHARMACY - FOOD INDUSTRY C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 5. developing technology and applications R & DDue to specialized nature of CADEs activities, new applications, P H I L O S O P H Ypotential upgrades and transfers of technology from onesector to another are commonly required in order to takeon our clients most challenging projects.CADE actively integrates internal R&D activities within itsbusiness structure in order to face these challenges andgenerate knowledge that allow us to develop new technologies,applications and products.CADE takes advantage of being integrated in the ALBACETESCIENTIFIC AND TECHNOLOGICAL PARK in order to count onthe most significant institution in technology and R&D forsupport and collaborative work.R &D approach and methodologyWithin the scope developed by CADE for its internal R&Dprojects as well as those developed jointly with itsclients/partners, the following R&D methodology is regularlyapplied:- Technology needs assesment/design basis- State of the art research- Potential technological solution/upgrade- Pilot Plant / Prototype design/construction- Experiments design- Process simulation and optimization- Definition of scaling models- Feasibility research- Industrial scaled design C A D Es t rategic R &D fields s o l u c i o n e s- SOLAR - CSP Technologies (process & equipment)- CSP plants - Energy Storage- Supercritical fluids tecnologies - Extracting applications - Reacting medium - Thermodynamic cycles- Waste Treatment and Enviromental Technologies- Biomass / Biogas- Waste Heat Recovery- Refrigeration and cooling d e- Steam generation- Drying technologies- Biodiesel i n g e n i e r i a- Mixing equipment and processesongoing internal R &D projects- Design and development of innovative SPRAY DRYER- Design and development of hydrogen production technologyfrom humid biomass waste based on supercritial fluid technology -- HTF System optimization of CSP plants- Thermal Energy Storage based on concrete E S P A Ñ A - S P A I N
  • 6. CAPABILITIES AND SERVICES advanced mechanical engineering1 - Process Engineering advanced energy, thermal and process engineering 1.1 - Process Simulation 1.2 - Upset Analysis 1.3 - Sensitive Analysis2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design key points - Complex systems (streams, variables, etc.) - Transient State - Multi-component systems - Multi-phase flow - Reacting medium - Optimization Needs CADEs approach PROCESS SIMULATION PROCESS OPTIMIZATION Steady State - Design State Transient State - Operational State SCOPE PFDs Vs. Operational Conditions Hydraulic Operational Variables Optimization Thermal Feasibility analysis (technical - economical) Thermodynamics Improvement and upgrades proposal Separation Process Inputs for HAZOP Reacting Medium ASPEN HYSYS software tools MATHCAD HTFS (ASPEN) ANSYS C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 7. CAPABILITIES AND SERVICES advanced mechanical engineering1 - Process Engineering advanced energy, thermal and process engineering 1.1 - Process Simulation 1.2 - Upset Analysis 1.3 - Sensitive Analysis2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design key points - High pressure and temperature (equipment) - High influence of operational parameters of performance - High sensibility processes - Complex control systems - Low control grade - Unstable processes approach P R O C E S S VA L I D A T I O N / R E - D E S I G N Pressure Relief Systems PROCESS SIMUL ATION Re-Design (operational condtitions, materials, etc.) UNDER UPSET CONDITIONS By Pass Systems Control Loops Transient State SIL Levels Process Instrumentation Inputs for HAZOP MECHANICAL ANALYSIS M E C H A N I C A L VA L I D A T I O N / R E - D E S I G N UNDER UPSET CONDITIONS FEA Thermal - Structural FEM analysis Fatigue analysis Static / Transient State Temperature/stress distribution over solid model (metal) Pressure parts reinforcement (tubesheets, nozzles, etc.) Internal refractory lining ASPEN HYSYS MATHCAD software tools HTFS (ASPEN) ANSYS C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 8. CAPABILITIES AND SERVICES advanced mechanical engineering1 - Process Engineering advanced energy, thermal and process engineering 1.1 - Process Simulation 1.2 - Upset Analysis 1.3 - Sensitive Analysis2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design key points - Unestable equilibrium state - High sensibility processes - High Dependance between variables - High Performance assurance CADEs approach P R O C E S S VA L I D A T I O N / R E V I E W Change of Operational Parameters SENSITIVE STUDY Phase Diagrams Control Strategies Definition of Control Loops Transient State Re-Tuning of Control Loops Relationships between variables "What If" Studies Inputs for HAZOP software tools ASPEN MATHCAD C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 9. CAPABILITIES AND SERVICES advanced mechanical engineering1 - Process Engineering advanced energy, thermal and process engineering 1.1 - Process Simulation 1.2 - Upset Analysis 1.3 - Sensitive Analysis2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design - High pressure and temperature key points - Dynamic processes - Thermal and Mechanical Performance importance - High Stress requirements - Cycle operation (Start Up, Shut Down). Fatigue phenomena - Heat Bridges, Heat Losses, Internal Lining - Flow Effect: Vibrations, noise, pressure drop, turbulence - Fitness for Service Assessment API 579 - Compressibility effects (gases) CADEs approach P R O C E S S VA L I D A T I O N / R E - D E S I G N THERMO - HYDRAULIC ANALYSIS Flow Distribution CFD SIMUL ATION Heat Transfer Profiles Steady State Temperature Profiles Transient State Pressure Profiles Velocity Profiles MECHANICAL ANALYSIS M E C H A N I C A L D E S I G N / VA L I D A T I O N FEA Thermal - Structural FEM analysis Fatigue analysis Steady State Short and long term cycle perfomance Transient State Temperature/stress distribution over solid model (metal) Full dynamic response, spectrum, harmonic, modal analysis Fitness for Service Assessment API 579 CFD (Computational Fluid Dynamics) FLUENT, CFX, OPENFOAM software tools MATHCAD ANSYS C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 10. CAPABILITIES AND SERVICES advanced mechanical engineering1 - Process Engineering advanced energy, thermal and process engineering 1.1 - Process Simulation 1.2 - Upset Analysis 1.3 - Sensitive Analysis2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design - Transient heating of solid / fluid key points - Tridimensional Heat Transfer inside solid / fluid - Heat Transfer controlled by Heat Capacity of solid - Phase change of solid / fluid - Large thickness equipment under cycle operation - Liquid/Gas circulation inside solid - High mass ratio solid/fluid systems - Heat transfer inside solid assumed as not negligible CADEs approach P R O C E S S D E S I G N / CFD VA L I D A T I O N CONJUGATED HEAT TRANSFER Heat Transfer between fluid and solid CFD Temperature Profiles (solid and fluid) Exchanged Power Profiles Vs Time Transient State Local Effects (extended surfaces) Heating demand by solid (heating applications) Heat recovered (heat recovery applications) MECHANICAL ANALYSIS FEA M E C H A N I C A L D E S I G N / VA L I D A T I O N Thermal-Structural FEM analysis Steady / Transient State Short and long term cycle perfomance Fatigue analysis Full dynamic response, spectrum, harmonic, modal analysis Fitness for Service Assessment API 579 CFD (Computational Fluid Dynamics) FLUENT, CFX, OPENFOAM software tools ANSYS C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 11. CAPABILITIES AND SERVICES advanced mechanical engineering 1 - Process Engineering advanced energy, thermal and process engineering 1.1 - Process Simulation 1.2 - Upset Analysis 1.3 - Sensitive Analysis 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design key points - Heat Transfer - Air Cooler - TEMA Heat Exchanger - Hydraulic regimen influence - HRSG / Waste Heat Boiler - Mass Transfer - Steam Drum - Gas-Liquid Systems - Steam Dryer - Solid-Fluid Systems - Deaerator - Heat Recovery - Separation Equipment - Reacting medium - Reactor - Dynamic Mixer CADEs approach P RO C E S S D E S I G N REFERENCE CASE Main Dimensions Internals Design Case Reference P&ID Rating Case Reference PFD (design and rating cases) Process Data Sheet (design and rating cases)S P A I N MECHANICAL DESIGN M E C H A N I C A L D E S I G N / VA L I D A T I O N Mechanical design Piping stress analysis- Design according to codes Static / Dynamic FEA Thermal - Structural analysisE S P A Ñ A Steady / Transient State FEA Short and long term cycle perfomance Fatigue analysis Full dynamic response, spectrum, harmonic, modal analysis-i n g e n i e r i a THERMO-HYDRAULC CFD SIMULATION + F E M A N A LY S I S CFD + FEA as per point 2.1 Fitness for Service Assessment API 579 Steady / Transient Stated es o l u c i o n e s Mathcad ASPEN ASME Hysys AD2000 software tools HTFS (ASPEN) design codes EN PVELITE CODAP CAESAR II CFD - FLUENT, CFX, OPENFOAM BS ANSYSC A D E
  • 12. 1 - Process Engineering 1.1 - Process Simulation CASE STUDY 1.2 - Upset Analysis 1.3 - Sensitive Analysis advanced mechanical engineering advanced energy, thermal and process engineering 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design flare gas recovery systemobjectiveThermal and Hydraulic simulation of exhaust gas pipe network (including relief valves behaviour) and flare stack.Mechanical validation of pipes, KO Drum and flare stack.Following issues were carried out:- Simulation of relief valves- Heat transfer simulation between gas and external ambient (hot case, cold case, rain, etc.)- Friction pressure losses and vacuum simulation of pipe network- CFD simulation for obtaining temperature and pressure profiles inside the flare stack in transient conditions.- Mechanical validation of pipes and KO Drum under vacuum conditions.- Mechanical validation of flare shaft considering temperature profile along the shaft for hot and cold cases.- Upgrading mechanical proposal for KO Drum and Flare according to current corrosion status.approach- Thermal and Hydraulic simulation- Mechanical pipe network validation under vacuum according to ASME B31.3- FEA validation of KO Drum and shaft flare including temperature influence on guyed stackresults and conclusions- Pressure and temperature profiles along pipe network- Pressure and temperature profiles along flare shaft- Upgrading mechanical proposal for vessels (KO Drum) and shaft flare C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 13. 1 - Process Engineering 1.1 - Process Simulation CASE STUDY 1.2 - Upset Analysis 1.3 - Sensitive Analysis advanced mechanical engineering advanced energy, thermal and process engineering 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Designsteam generator train in CSP (concentrated solar power) plantsobjectiveThermal design of a Steam Generator Train for a CSP Power Plant(Solar Parabolic Trough) unde steady state operational conditionsand transient simulation during Steam Turbine Start Up.Following issues were carried out:Transient Performance of Steam Generator Train (Steamtemperature, pressure and mass flow Vs time)Solar field simulation Vs time (HTF temperatures and flow curvesVs time)Thermal design under steady state conditionsRedesign of Heat Exchanger Train to meet Steam Requirementsduring turbine start upapproach - Thermal steady state design - Simulation of HTF System (Solar field, steam generation train and steam turbine) - Optimization of steam generator train to meet steam turbine start up ramp (design) results and conclusions - Optimized geometry of Steam Generation Train - Performance curves C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 14. 1 - Process Engineering 1.1 - Process Simulation CASE STUDY 1.2 - Upset Analysis 1.3 - Sensitive Analysis advanced mechanical engineering advanced energy, thermal and process engineering 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design HTF system sizing optimization in CSP plantsobjectiveSize optimization of HTF pipe network in Solar Parabolic Trough Power Plant according to real solar irradiation (DNI) on plant location.Following issues were carried out.- Simulation of solar irradiation- Simulation of solar collectors performance within solar field- Calculation of HTF temperature and mass flow curves withing solar field- Hydraulic simulation of pipe network in order to determinate friction losses.- Thermal simulation of pipe network in order to determinate heat losses.- Size optimization of individual parts of pipe network from aneconomical and energetic point of view.approach- Simulation of solar field- Thermal and Hydraulic simulation of HTF pipe network- Optimization algorithmresults and conclusions- Optimum size of individual parts of HTF pipe network C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 15. 1 - Process Engineering 1.1 - Process Simulation CASE STUDY 1.2 - Upset Analysis 1.3 - Sensitive Analysis advanced mechanical engineering advanced energy, thermal and process engineering 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Designdownstream treatment and combustion of a compressed SyngasobjectiveSimulation of Downstream treatment and Combustion in a Gas Turbine of a compressed Syngas stream.Following issues were carried out.- Simulation of Downstream treatment (cooling, depressurization, solubility and gas-liquid separation)- Gas turbine simulation- Optimization of process variables in order to maximize electric power from turbine- Hydraulic simulation of pipe network in order to determinate friction losses.- Integration useful thermal energy of exhaust hot gases from turbine in actual process plant- Feasibilityapproach- Simulation of Downstream Process- Simulation of Gas Turbine- Optimization algorithmresults and conclusions- PFD- P&ID- Optimized Downstream Treatment variables- Technical-Economical feasibility study C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 16. 1 - Process Engineering 1.1 - Process Simulation CASE STUDY 1.2 - Upset Analysis advanced mechanical engineering 1.3 - Sensitive Analysis advanced energy, thermal and process engineering 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design advanced gasification processes (reacting medium)objectiveOptimization of Pressure and Temperature for a biomass gasification process in order to maximize Low Heating Value (LHV) of Syngas.Following issues were carried out.- Simulation of kinetic of Gasification Process- Study of influence of Pressure and Temperature in kinetic and composition of Syngas- Performance curves Vs pressure and temperature- Optimization of process variables to maximize LHV of Syngas- Proposal of gasification reactor dimensions- Economical study for optimization case.approach- Simulation of process- Optimization algorithm- Feasibility studyresults and conclusions- Optimized process variables- Performance of reactor for optimized variables- Technical-Economical feasibility study for optimized cases- Proposal of gasification reactor main dimensions C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 17. 1 - Process Engineering 1.1 - Process Simulation CASE STUDY 1.2 - Upset Analysis advanced mechanical engineering 1.3 - Sensitive Analysis advanced energy, thermal and process engineering 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design heat recovery steam generator (HRSG) objectiveInfluence evaluation of two upset conditions from a process and mechanical point of viewon HRSG (fired tube type).Conditions to be evaluated: by-pass system failure and steam line depressurization.Following issues were carried out:- Thermal and Hydraulic simulation under upset conditions (tube side and shell side)- Refractory lining performance (channels, tubesheet, and tubes)- Temperature distribution of pressure parts by performing transient FEA- Stress distribution of pressure parts by performing transient FEA- Proposal to minimize effects of upset conditions under consideration approach- Thermal-Hydraulic simulation- Transient Thermal and Mechanical FEA results and conclusions- Temperature and pressure distribution of cold and hot fluids- Temperature and stress distribution of pressure parts- Remediation and prevention process measures C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 18. 1 - Process Engineering 1.1 - Process Simulation CASE STUDY 1.2 - Upset Analysis advanced mechanical engineering 1.3 - Sensitive Analysis advanced energy, thermal and process engineering 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Designwater knock-out drum with internal tube heat exchangerobjectiveSimulation of Water Knock-Out (3-phase configuration) under failure of temperature control valve of steamsupply line for internal coil.Following issues were carried out:- Maximum steam flow through control valve- Temperature and evaporation rate of water under maximum steam flow- Turbulence inside vessel- Performance of separator (composition of each phase)- Performance of demister under upset conditions (flow temperature, pressure and gas composition)approach- Heat transfer simulation between internal tube exchanger and fluid)- Hydrodynamic simulation of liquids under evaporation conditions- Thermodynamic equilibrium of phasesresults and conclusions- Separation Efficiency for each phase- Composition of each phase- Maximum temperature of each phase C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 19. 1 - Process Engineering 1.1 - Process Simulation CASE STUDY 1.2 - Upset Analysis advanced mechanical engineering 1.3 - Sensitive Analysis advanced energy, thermal and process engineering 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design biogas lineobjectiveSimulation of influence of failure in Methane composition Control Loop on biogas lineequipment (H 2 S removal, gas turbine, flare and related equipment )Following issues were carried out:- Calculation of maximum flow and composition of biogas under uncontrolled captation.- Simulation of effect over hydraulic seals of biogas line (biogas leak to atmosphere)- Response simulation of H2S removal system under biogas peak flow (peak of H2Scontent in outlet stream)- Composition of combustion gases under H2S peak- Dew point for acid components of combustion gases and risk of corrosion in coldpointsapproach- Hydraulic simulation on biogas pipe network- Process simulation of equipment (desulphuration scrubber, gas turbine and flare)- Emissions and corrosion studyresults and conclusions- Flow and compositon of emissions- Cold points to be checked to prevent local corrosion- Re-design of lines and drain points Friction losses Length Header 1 Header 2 C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 20. 1 - Process Engineering 1.1 - Process Simulation 1.2 - Upset Analysis CASE STUDY 1.3 - Sensitive Analysis advanced mechanical engineering advanced energy, thermal and process engineering 2 - Process Equipment Engineering 2.1 - Thermo-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design exothermic reactorobjectiveThermal and Kinetic Simulation of Exothermic Reactor in order to definecooling system and control loop.Following issues were carried out:- Kinetic simulation- Heat transfer simulation between reacting medium and internal cooling coil- Calculation of steady steates Vs cooling fluid temperature- Stability Phase Diagrams- Definition of stable operation conditionsapproach- Kinetic and thermal model- Transient simulation and steady state calculations Vs operational conditionsresults and conclusions- Operational conditions (reacting medium and cooling system) in order toachieve stable steady states.- Sensitive diagrams for main operational variables- Temperature control loop proposal Diagram phase (unstable steady state) Diagram phase (stable steady state) C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 21. 1 - Process Engineering 1.1 - Process Simulation 1.2 - Upset Analysis CASE STUDY 1.3 - Sensitive Analysis advanced mechanical engineering advanced energy, thermal and process engineering 2 - Process Equipment Engineering 2.1 - Thermo-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design biological reactor (Fermenter)objectiveKinetic Simulation of Fermenter in order to determinate stable conditions forstart-up and operation as well as prediction of effects of changes in biomassinlet flow.Following issues were carried out:- Kinetic simulation- Calculation of steady states Vs initial biological substrate concentration- Effect of changes in inlet biomass flow on each steady state- Recirculation effectapproach- Kinetic simulation- Transient simulation and steady states calculation- Methane production optimizationresults and conclusions- Operational conditions to achieve steady state with maximum methaneproduction- Recirculation rate- Control loop proposal based on methane concentration C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 22. 1 - Process Engineering 1.1 - Process Simulation CASE STUDY 1.2 - Upset Analysis 1.3 - Sensitive Analysis advanced mechanical engineering advanced energy, thermal and process engineering 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design lp bog after cooler (air cooled heat exchanger)objectiveThermal-Hydraulic and mechanical validation of air cooler (ACHE) workingas after cooler in gas compression line during start-up (recycled andopened flow)Following issues were carried out: - ACHE thermal rating for each point of start-up ramp - Thermal-hydraulic simulation of tubeside during start-up ramp - Dynamic stress analysis Air side film coefficient Vs time - Fatigue analysis and evaluationapproach- Performance of ACHE during start-up ramp- CFD of tubeside during start-up- FEM analysis of nozzles, headers, finned tubes and tubesheetsduring start-up. Input data extracted from previous CFD output.results and conclusions Inlet flow rate Vs time- Mass flow rate which allows a safety and stable start-up ofline, in order to avoid excessive pressure losses, local absolutepressures and velocities.- Detail thermal performance of ACHE during start-up.- Maximum stress of pressure parts- Maximum allowable number of cycles- Design modifications and aumented inspections proposal forbundle tube supports Tube side Mach number C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 23. 1 - Process Engineering 1.1 - Process Simulation CASE STUDY 1.2 - Upset Analysis 1.3 - Sensitive Analysis advanced mechanical engineering advanced energy, thermal and process engineering 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design HTF expansion vesselobjectiveMechanical design of nozzles and saddles of HTF system equipment(expanssion vessels, buffer tanks, etc.).Thermal shock evaluation under transiend conditions.Following issues were carried out:- Transient thermal calculation of fluid bulk temperature inside based on initial temperature, inlet temperature and flowcurves- Inside heat transfer coefficient for gas and liquid- FEA of nozzles (inlet liquid part)- FEA of saddles- Fatigue analysis and evaluationapproach- Transient thermal simulation (inputs required for FEA)- FEA for pressure parts (shell, heads, nozzles) and saddlesresults and conclusions- Nozzles reinforcement- Saddles geometry- Maximum number of allowable cycles for operating life C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 24. 1 - Process Engineering 1.1 - Process Simulation CASE STUDY 1.2 - Upset Analysis 1.3 - Sensitive Analysis advanced mechanical engineering advanced energy, thermal and process engineering 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design WHB - waste heat boilerobjectiveValidation of conventional thermal and mechanical designof two Waste Heat Boiler (WHB) of a Desulphuration Plantby means of Finite Element Analysis (FEA) in order to studylocal effects from a thermal and mechanical point of view,considering process requirements.Following issues were carried out:- Thermal-Hydraulic design (full) including steam risersand downcomers- Definition of internal refractory lining for channelsto meet minimum and maximum wall temperaturelimits for cold and hot process cases.- Validation of tubesheet lining and ferrules of tubes(Max. tube-tubesheet temperature)- FEA of channels, forged ring/Knucle and tubesheet- FEA of risers and downcomersapproach- Static thermal simulation to determinate tubeside and shell side bulk temperatures and heattransfer coefficients.- FEA to determinate temperature distributionwithin solids- FEA to determinate stress of pressure partsresults and conclusions- Full mechanical design- Channels and tubesheet linning- Forged ring knuckle geometry- Tubesheet thickness- Risers and downcomers stress analysis C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 25. 1 - Process Engineering 1.1 - Process Simulation CASE STUDY 1.2 - Upset Analysis 1.3 - Sensitive Analysis advanced mechanical engineering advanced energy, thermal and process engineering 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design flue gas systemobjectiveValidation of conventional thermal and mechanical designof two Waste Heat Boiler (WHB) of a Desulphuration Plantby means of Finite Element Analysis (FEA) in order to studylocal effects from a thermal and mechanical point of view,considering process requirements.Following issues were carried out:- Definition of internal refractory lining for channelsto meet minimum and maximum wall temperaturelimits for cold and hot process cases.- Validation of tubesheet lining and ferrules of tubes(Max. tube-tubesheet temperature)- FEA of channels, forged ring/Knucle and tubesheet- FEA of risers and downcomersapproach- Static thermal simulation to determinate tubeside and shell side bulk temperatures and heattransfer coefficients.- FEA to determinate temperature distributionwithin solids- FEA to determinate stress of pressure partsresults and conclusions- Channels and tubesheet linning- Forged ring knuckle geometry- Tubesheet thickness- Risers and downcomers stress analysis C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 26. 1 - Process Engineering 1.1 - Process Simulation CASE STUDY 1.2 - Upset Analysis 1.3 - Sensitive Analysis advanced mechanical engineering advanced energy, thermal and process engineering 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design melting zinc furnaceobjective approachOptimization of Zinc Melting Furnace (thermal duty, recirculation - Transient conjugated heat transfer of system solid ingot-liquidrate and geometry) by CFD/CHT zinc (Fluent) - Optimization of process and geometry parametersFollowing issues were carried out:- Transient Ingot Heating simulation during specified melting time- Thermal-Hydraulic simulation of surrounding heating fluid (liquid zinc) results and conclusions- Effect of recirculation rate and chambers geometry - Chambers geometry- Effect of solid ingot in flow profiles during melting process - Recirculation mass flow- Transient study of trayectories of slag inside melting chamber - Thermal duty and position of burners C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 27. 1 - Process Engineering 1.1 - Process Simulation 1.2 - Upset Analysis CASE STUDY 1.3 - Sensitive Analysis advanced mechanical engineering advanced energy, thermal and process engineering 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design thermal energy storageobjectiveDesign of thermal storage system based on concrete withthermal oil acting as heating/cooling fluid by CFD/CHTSystem is able to storage excess energy and to recover itadapted to demand with thermal oil as heating / cooling fluidFollowing issues were carried out:- Definition of tubes geometry and pitch- Thermal-Hydraulic simulation of tubeside (HTF side)- Tridimensional conduction heat transfer inside solid basedon thermal properties (conductivity and heat capacity)- Definition of external isolation in order to minimize heatlossesapproach- Transient conjugated heat transfer of concrete system (Fluent)- Optimization of geometry in order to meet process requirements(heating and cooling ramps)results and conclusions- Heat Exchanger geometry (concrete section and tubes)- Charging and discharging curves Vs time C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 28. 1 - Process Engineering 1.1 - Process Simulation CASE STUDY 1.2 - Upset Analysis 1.3 - Sensitive Analysis advanced mechanical engineering advanced energy, thermal and process engineering 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design finned tubes (recovery heat exchanger)objectiveDetermination of effect of finned tube (thermal inertia basedon heat capacity) on gas temperature during transient periodsin an Air Cooler Heat Exchanger.Definition of temperature control loop and winterizationstrategies.Following issues were carried out:- Thermal air side / tube side simulation- Calculation of heat exchanged based on inlet tube sidetemperature and flow curves.- Performance of finned tube Vs time- Tube side outlet temperature Vs timeapproach- Transient Conjugated Heat Transfer of air - finned tube-gas system- Calculation of effect on outlet gas temperature of heatcapacity of finned tube Vs timeresults and conclusions- Process gas outlet temperature considering thermalinertia of finned tubes- Proposal for "tunning" temperature control loop basedon an adapting fuzzy control loop- Proposal for new set pont for recirculation air temperatureduring winterization strategy C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 29. 1 - Process Engineering 1.1 - Process Simulation CASE STUDY 1.2 - Upset Analysis 1.3 - Sensitive Analysis advanced mechanical engineering advanced energy, thermal and process engineering 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design waste heat boiler (WHB)objectiveThermal, Hydraulic and Mechanical design of Waste Heat Boiler(fired tube type) for a Sulphur Recovery Plant.Following issues were carried out:- Thermal design of Shell and Tube Heat Exchanger (firedtube)- Hydraulic design of riser, downcomers and steam drum- Mechanical design of pressure parts based on designconditions- Thermal and Mechanical evaluation of rating casesapproach- Process design (Thermal and Hydraulic)- Mechanical design of pressure partsresults and conclusions- Thermal and hydraulic design (TEMA Process Data Sheet)- Mechanical Calculation report- Risers and downcomers Stress reportThis scope was complemented with a Thermal-Hydraulic+ FEA analysis for detailed study of local effects as percase study described in section 2.1 C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 30. 1 - Process Engineering 1.1 - Process Simulation CASE STUDY 1.2 - Upset Analysis 1.3 - Sensitive Analysis advanced mechanical engineering advanced energy, thermal and process engineering 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design heat exchangers (biflux, feedwater heaters, closed cooling water, steam superheater, Shell and Tube, etc.)objectiveThermal, Hydraulic and Mechanical design of Biflux HeatExchanger (bayonet type)Following issues were carried out:- Thermal and Hydraulic design- Material selection- Mechanical design of pressure parts based on designconditions- Thermal and Mechanical evaluation of rating caseapproach- Process design (Thermal and Hydraulic)- Mechanical design of pressure partsresults and conclusions- Thermal and hydraulic design (TEMA Process Data Sheet)- Mechanical calculation report C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 31. 1 - Process Engineering 1.1 - Process Simulation CASE STUDY 1.2 - Upset Analysis 1.3 - Sensitive Analysis advanced mechanical engineering advanced energy, thermal and process engineering 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design spray dryerobjectiveDesign of Spray Dryer (drying chamber and cyclon chamber)for lixiviates effluent from landfill.Following issues were carried out:- Atomization system design- Air heating supply design- Volute air inlet design- Drying chamber and cyclon design- Instrumentation and control- Mechanical design of pressure parts and auxiliarystructuresapproach- Fluid-dynamics design of drying chamber and cyclon bymeans of CFD simulation- Static Mechanical design of pressure parts- Mechanical design of auxiliary structuresresults and conclusions- P&ID- Dimensional drawings of drying chamber and cyclon- Atomization system specification- Specification Data Sheet of commercial components- Instrumentation and control strategy C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 32. 1 - Process Engineering 1.1 - Process Simulation CASE STUDY 1.2 - Upset Analysis 1.3 - Sensitive Analysis advanced mechanical engineering advanced energy, thermal and process engineering 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design air coolersobjectiveThermal, Hydraulic and Mechanical design of Air Coolersaccording to API 661.Following issues were carried out:- Thermal design- Rating evaluation- Mechanical design of pressure parts- Instruments and control loop proposalapproach- Thermal design according to API 661- Static Mechanical design of pressure partsresults and conclusions- P&ID- API 661 Process Data Sheet- Control loops C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
  • 33. CSP - Concentrated Solar Power CASE STUDY advanced mechanical engineering advanced energy, thermal and process engineering CSP Pilot Plant Basic and Detail engineering of molten salt Loop objective Complete basic and detail engineering of CSP pilot plant based on molten salt as heat transfer fluid. Following tasks were carried out: - Basic and detail engineering including: - Process design - Design of main process equipment - Mechanical/Structural/Civil Works/Electric engineering results and conclusions - Molten Salt loop process simulation - Thermal and Hydrodynamic simulation: HTF mass flow optimization (mmin / mmax) - Temperature profile inside receiver - Piping Stress and flexibility analysis - Impedance heating - Materials selection (piping, valves, etc.)C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N