Energy, Emissions, and Efficiency

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Energy, Emissions, and Efficiency

  1. 1. Welcome to today’s webcast…Energy, Emissions, and Efficiency:How to address heat exchanger fouling to reduce energy andmaintenance costs while improving plant performanceMarch 31, 2011
  2. 2. Today’s Speaker – Simon PughExpert from IHS • Director of Process Engineering Technology at IHS ESDU and is based in London, UK. • Role includes the management of all ESDU’s heat transfer work, which is undertaken under the guidance of international independent Committees of experts from industry and the Universities. • He leads the Technology Transfer Sub-project of CROF, which includes the management of the interaction and collaboration between the researchers and the oil company members of theSimon Pugh IHS ESDU Oil Industry Fouling Working Party. • He is currently leading a group of engineers working on theDirector development of a range of design guides to oil industry foulingProcess Engineering Technology problems and computer programs for better heat exchanger selection, design and operation, with particularly emphasis onIHS Inc. reducing crude fouling in per-heat trains. He holds a mechanical engineering degree from Brunel University in the UK.Copyright © 2011 IHS Inc. All Rights Reserved. 2
  3. 3. About IHS Inc. A Leading Information Provider • Founded in 1959, IHS is a leading source of information and expert analysis in pivotal areas shaping today’s global businesses • Employs 4,400 colleagues in 30 countries who speak 50 different languages • IHS customers include nearly 70% of the US Fortune1000 and 80% of the Global Fortune 500 • Tens of thousands of customers and hundreds of thousands of end-users in over 100 countries • Public (2005) NYSE: IHS • FY10 revenue $ 1,075 million 3Copyright © 2011 IHS Inc. All Rights Reserved.
  4. 4. Today’s Topics What we will address • About ESDU • Discipline area and industry involvement • Oil Refining, Emissions, and Regulations • Oil production and refinery fouling • Economic and environmental impacts • Application of Research and Technology • Latest advancements from university research and the oil industry • Process innovation and engineering • Best practices and technology approaches • Q&A 4Copyright © 2011 IHS Inc. All Rights Reserved.
  5. 5. IHS ESDUThe Engineering Sciences Data Unit• Founded in London, England in 1940• All work validated by expert International Committees of industry specialists, University experts• Over 20 specialist Technical Committees, including • Heat Transfer Steering Group • Oil Industry Fouling Working Party • Fluid Mechanics, Internal Flow Panel • Engineering Structures, Fatigue Committees • Wind Engineering Panel• Development of design methods, guidelines and software • Delivered online in “series”Copyright © 2011 IHS Inc. All Rights Reserved.
  6. 6. ESDU Technical CommitteesSelection of Participating OrganisationsCopyright © 2011 IHS Inc. All Rights Reserved. 6
  7. 7. Example: Fouling in Cooling SystemsParticipating OrganisationsCopyright © 2011 IHS Inc. All Rights Reserved. 7
  8. 8. Today’s Topics What we will address • About ESDU • Discipline area and industry involvement • Oil Refining, Emissions, and Regulations • Oil production and refinery fouling • Economic and environmental impacts • Application of Research and Technology • Latest advancements from university research and the oil industry • Process innovation and engineering • Best practices and technology approaches • Q&A 8Copyright © 2011 IHS Inc. All Rights Reserved.
  9. 9. Business Pressures – A few examples…Market volatility, regulatory compliance, and sustainability…• Market Economics & Volatility • Oil and gas prices feed into fluctuations in electricity prices • Japan disaster impact on nuclear, coal, LNG, and other energy • Pressures to reduce energy costs• Regulations & Reporting • US – Regional Greenhouse Gas Initiative (RGGI) • US - EPA’s Greenhouse Gas (GHG) Reporting Programme • Europe – EU Emissions Trading Scheme (EU ETS) • France - The Bilan Carbone in France • Australia - National Greenhouse and Energy Reporting Act• Sustainability & Transparency • Shareholders, customers and consumers • Lenders, stock exchanges and investment communities • Carbon Disclosure Project (CDP) • Global Reporting Initiative Reporting (GRI) • Carbon Disclosure Project (CDP)Copyright © 2011 IHS Inc. All Rights Reserved. 9
  10. 10. How does hydrocarbon burning contributeto CO2 emissions? One tonne of hydrocarbon burned releases 2.5 – 3 tonnes of CO2Copyright © 2011 IHS Inc. All Rights Reserved. 10
  11. 11. What are the biggest CO2 producers inrefineries? Around 50% of CO2 and energy from crude heating Efficiency of pre-heat train crucial in energy and CO2 managementCopyright © 2011 IHS Inc. All Rights Reserved. 11
  12. 12. Opportunity – Address Crude Oil FoulingImprovements to energy, efficiency, and emissionsReduce Energy ConsumptionImprove MaintenanceImprove ThroughputReduce EmissionsRegulatory ComplianceReduce CostsCopyright © 2011 IHS Inc. All Rights Reserved. 12
  13. 13. Enablement Strategies – ScenariosHow industry is trying to improve performance• What is the most cost-effective maintenance/cleaning strategy if we operate the refinery with similar throughput and average API?• What effect will running heavier crudes have on maintenance?• Can we flag up severe fouling events in real time, or even predict and prevent?• What can we save in capital, maintenance, energy, CO2 is we re-engineer heat exchangers or change plant piping payout? Does this justify the project?• What happens if we use alternative heat exchanger types or fouling mitigation devices like tube inserts• What happens if we switch the crude from tube side to shell side in heavily fouling heat exchangers?• We use anti-fouling chemicals – what are they saving us?• We want to use anti-fouling chemicals – what will they save us?Copyright © 2011 IHS Inc. All Rights Reserved. 13
  14. 14. Remainder of Slides…. DISTILLATION STORAGE HEATINGCopyright © 2011 IHS Inc. All Rights Reserved. 14
  15. 15. Copyright © 2011 IHS Inc. All Rights Reserved. 15
  16. 16. The heated crude needs a “blast” in the furnace prior to $$$ distillation CO2 $$$ $$$ $$ $Copyright © 2011 IHS Inc. All Rights Reserved. 16
  17. 17. What is the biggest cause of inefficiency inheat exchangers? Fouling! Dirt deposits build up on clean tubes, and efficiency plummets!!Copyright © 2011 IHS Inc. All Rights Reserved. 17
  18. 18. Some economic & environmental effects offouling problems • Energy • increased fuel needed in furnace, pumping costs • Emissions CO2 • Extra fuel burn = increased emissions • Burn 1 Ton of oil, get 2 - 2.5 Tons of CO2 Fouling! Dirt deposits build up on clean tubes, and efficiency plummets!!Copyright © 2011 IHS Inc. All Rights Reserved. 18
  19. 19. Some economic & environmental effects offouling problems • As heat exchanger tubes block, flow rates fall • Exchangers then need to be cleaned • Isolation/shutdown very costly exercise • Most refineries have goal of running continually for 5 or 6 years between shutdowns • Mostly impossible with current designs • Cleaning is an environmental and safety issue • Minimize cleaning schedule to minimize employee risk • Disposal of dirt deposits, cleaning materials and fouled waterCopyright © 2011 IHS Inc. All Rights Reserved. 19
  20. 20. Cleaning! Major maintenance issue Fouling! Dirt deposits build up on clean tubes, and Picture; Wellman Hunt efficiency plummets!! GrahamCopyright © 2011 IHS Inc. All Rights Reserved. 20
  21. 21. Cleaning! Major maintenance issue Fouling! Dirt deposits build up on clean tubes, and Picture; Wellman Hunt efficiency plummets!! GrahamCopyright © 2011 IHS Inc. All Rights Reserved. 21
  22. 22. Fouling is getting worse! • Many refiners are refining heavier, more complex crudes • Canadian tar sands, African, Venezuelan crudes now economic to refine • North Sea crudes getting heavier • Are refineries prepared for more difficult feedstock? Fouling! Dirt deposits build up on clean tubes, and efficiency plummets!!Copyright © 2011 IHS Inc. All Rights Reserved. 22
  23. 23. What does crude oil fouling cost a refinery?• Up to 10% of refinery CO2 footprint directly results from fouling in pre-heat trains• 0.2 – 0.25% entire oil production wasted due to fouling• World: c. 250,000 barrels per day• CO2 emissions due to fouling • World: c. $300 M p.a. • World: c. 30 M tonnes/year extra CO2Copyright © 2011 IHS Inc. All Rights Reserved. 23
  24. 24. Oil Industry Fouling Working PartymembersOil company members of the IHS ESDU Oil Industry Fouling WorkingParty – CROF1Copyright © 2011 IHS Inc. All Rights Reserved.
  25. 25. Next Generation Simulations based on Industry Accepted Best PracticesBest Practice Network Techno-Economics Heat Exchanger Design
  26. 26. Next Generation Simulations based on Industry Accepted Best Practices Best Practice Model Optimize SimulateBest Practice Network Techno-Economics Heat Exchanger Design
  27. 27. Today’s Topics What we will address • About ESDU • Discipline area and industry involvement • Oil Refining, Emissions, and Regulations • Oil production and refinery fouling • Economic and environmental impacts • Application of Research and Technology • Latest advancements from university research and the oil industry • Process innovation and engineering • Best practices and technology approaches • Q&A 27Copyright © 2011 IHS Inc. All Rights Reserved.
  28. 28. Crude Oil Fouling Research (CROF)The CROF programme• Leading R&D in crude oil fouling • $4.5M EPSRC funding over 3 years at: • Imperial College • Cambridge • Bath • IHS ESDU Facilitator and Technology Transfer Partner • Interfacing with the oil companies and their suppliers • Transferring the technology by various means • Reports, data, software, etc. • Ensuring that the results of the programme will be implemented by refiners • Dissemination, training, etc.Copyright © 2011 IHS Inc. All Rights Reserved.
  29. 29. IHS ESDU - Bridge between UniversityResearch and Oil IndustryCROF1 samples A – test crudes and F – larger deposits B – study scale lab interfacial tests in behaviour of tubes deposits properties E – small- H– C – model cell tests on technology heat and crude transfer mass samples transfer models behaviour G – simulate D - model real plant molecular behaviour propertiesCopyright © 2011 IHS Inc. All Rights Reserved.
  30. 30. Intensive research meetings: for example in 2009…Chevron Pembroke Refinery,Sun 19 – Fri 24 April 200950 researchers and industrialists from 4 continents IHS London office, 28 Sept – 1 Oct 2009 55 researchers and industrialists Copyright © 2011 IHS Inc. All Rights Reserved.
  31. 31. IHS ESDU - Bridge between UniversityResearch and Oil Industry• Crude oil fouling mitigation: expected benefits • Higher Furnace Inlet Temp and lower fuel use • CO2 emissions reduction • Increased on-stream time due to reduced downtime for HX cleaning• Benefits of Research Programme now available • Heat exchanger fouling analysis and abatement • Smart Predictive MaintenanceCopyright © 2011 IHS Inc. All Rights Reserved. 31
  32. 32. IHS ESDU - Bridge between UniversityResearch and Oil IndustryCopyright © 2011 IHS Inc. All Rights Reserved. 32
  33. 33. Extracting fouling model from plant (HEN)operating data and fitting fouling models (c) Fit Fouling model to Plant Op data in IHS EXPRESSplus(a) Raw Plant Op data from DCS (b) Convert to fouling prediction using rigourous heat exchanger design methods in ESDU EXPRESSplusCopyright © 2011 IHS Inc. All Rights Reserved. 33
  34. 34. …leading to Smart Predictive MaintenanceDesign and operationalparameters smartPM RefiningCost data and solutionsoperational strategies Cambridge Research considered for the prestigious 2010 Eni Protecting the Environment Award. Copyright © 2011 IHS Inc. All Rights Reserved. 34
  35. 35. …smartPM answers the refiners questions • smartPM uses techno-economic metrics to answer some of the most difficult operational questions • What is the most cost-effective maintenance/cleaning strategy if we operate the refinery with similar throughput and average API? • What effect will running heavier crudes have on maintenance? • Can we flag up severe fouling events in real time, or even predict and prevent? • What can we save in capital, maintenance, energy, CO2 is we re- engineer heat exchangers or change plant piping payout? Does this justify the project? • What happens if we use alternative heat exchanger types like Compabloc or install tube inserts like Spirelf? • What happens if we switch the crude from tube side to shell side in heavily fouling heat exchangers? • We use anti-fouling chemicals – what are they saving us? • We want to use anti-fouling chemicals – what will they save us? smartPMCopyright © 2011 IHS Inc. All Rights Reserved.
  36. 36. Consider the Expertise of IHS ESDUWhat do we offer?• Design Guides • Crude fouling in pre-heat trains, water (sea and fresh) fouling, heat exchanger selection, costing and design…etc• Software • Shell-and-tube exchangers (new design, revamping, new technologies), fouling analysis, esp. crude pre-heat trains, reboilers, process integration, ejectors/jet pumps, physical properties…etc• Exchanger fouling tracking and abatement • Esp. pre-heat trains, water fouling, pre-heat train smart Predictive Maintenance• Expert consultancy • Fouling troubleshooting and anti-fouling strategies, energy optimization, PHT’s, CHP, VSD’s• Training • Engineering of heat exchangers, networks, energy optimizationCopyright © 2011 IHS Inc. All Rights Reserved.
  37. 37. Complimentary Review – IHS AdviceLet IHS discuss your situation and opportunities• IHS Whitepaper • Heat Exchanger Fouling Mitigation • Complimentary for attending • Insight and best practices• Complimentary Review • Discuss your situation • Understand inefficiencies • Improvement opportunitiesCopyright © 2011 IHS Inc. All Rights Reserved. 37
  38. 38. Questions? Send questions and requests for information to: Webcasts@ihs.comCopyright © 2011 IHS Inc. All Rights Reserved. 38

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