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KBC IoE Webinar - HX Monitor and Fouling Studies

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Fouling in heat exchanger preheat trains is a well-known problem in industry. Fouling reduces exchanger performance, increases furnace duty, reduces cooling capacity and increases pressure drop. The resulting increase in fuel costs and loss in throughput can significantly affect profitability.

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KBC IoE Webinar - HX Monitor and Fouling Studies

  1. 1. © 2015 KBC Advanced Technologies plc. All Rights Reserved. HX-Monitor and Fouling Studies KBC Webinar 6 October 2015
  2. 2. Agenda • Introduction • Prevention • Monitoring  HX-Monitor  Potential benefits  Overview of how the software works  Demonstration 6 October 2015 2PROPRIETARY INFORMATION
  3. 3. Effect of Fouling on Heat Recovery 6 October 2015 3PROPRIETARY INFORMATION Time (months) 0.000 0.002 0.004 0.006 0.008 0.010 0.012 0.014 0.016 0.018 FoulingFactor 0.000 0.002 0.004 0.006 0.008 0.010 0.012 0.014 0.016 0.018 FoulingFactor Time (months) 170 180 190 200 210 220 230 240 250 260 FurnaceCoilInletTemperature Time (months) 45 50 55 60 65 70 75 80 85 90 FurnaceDuty(Gcal/h)) ∆CIT Increased Fouling Lower Coil Inlet Temp. 10C 260C 230C 75 GCal/h Fuel Duty 90 GCal/h Fuel Duty Higher Furnace Duty 0 6 12 18 36 4824 30 42 0 6 12 18 36 4824 30 42 0 6 12 18 36 4824 30 42 Lost heat transfer must be made up by increasing fuel utility Higher emissions and emission costs
  4. 4. Fouling 6 October 2015 4PROPRIETARY INFORMATION Typical 100kbpd Crude Unit Additional Energy Consumption Increases cost by $1million/year Net furnace fuel consumption Throughput constraints Over $10million/year lost opportunity Throughput maximisation constraint Furnace duty Rundown temperatures Other Factors $1million/year Increased cleaning costs, complete bundle pulling > Crude Preheat Fouling: – Increases furnace duty – Increases Emissions – Reduces throughput – Increases pressure drop How to tackle fouling? > Stage 1: Prevention – Control the sources of fouling by improving crude management and storage, desalter operation, crude compatibility checks and other “housekeeping” issues. > Stage 2: Monitoring – Monitor the remaining fouling and cleaning potential using a solution based on rigorous simulation
  5. 5. Fouling Prevention 6 October 2015 5PROPRIETARY INFORMATION > Crude Tank Operation (Operational) – Tank inlet location • The incoming crude can stir up settled sediments at the bottom of the tank (inlet is at the bottom) which can be carried with the crude being fed to unit – Holding time • Enough for the crude to dewater and sediments to settle at the bottom of the tank • A period of 24-48 hours is normally sufficient to allow dewatering and settling of solids > Crude Tank Cleaning (Maintenance) – Significant sediment quantities are likely to be present at the bottom of the crude tanks. Therefore, cleaning of crude tanks should be performed regularly. > Preheat Train Simulation (Process) – off-line simulations of the preheat train are used to investigate exchanger fouling tendencies and tube/shell velocities • If low velocities are detected, structural modifications can be suggested in exchangers that significantly affect the performance of the preheat train > Crude Compatibility Analysis (Planning) – Mixtures of oil (and thus also crude) can become unstable, particularly from the residue fraction of the feed • This cause significant issues with sludge formation and crude preheat train fouling
  6. 6. The Fouling Issue…once it happens! 6 October 2015 6PROPRIETARY INFORMATION The key questions are: > Which exchangers to clean? > Why? -> How much is it going to save us? > When? This questions are typically answered by: > Experience – Achieves some savings – Hard to maintain and to consider all factors > In-house monitoring (stand-alone spreadsheet) – Difficult to update/maintain – Limited to showing fouling trends, rather than simulating the benefit of cleaning – Lack of differentiation of UA decrease by fouling or flow decreases > Rigorous simulation
  7. 7. Benefits of Fouling Monitoring Applications 6 October 2015 7PROPRIETARY INFORMATION Crude Preheat Train 100,000 bpd Refinery Desalter Des Offgas E1 Tpa_TrimClr C4 Sp1 Mix1 C3 Furnace Mpa_TrimClr Bpa_TrimClr RCY-2 E6 E2 E7 E3 E4 E5 E8 Kero c1 Desalted Crude Desalter Water TPA_Draw MPA_Draw LGO HGO BPA_Draw Residue Kero Product Residue Product TPA_Return MPA_Return LGO Product HGO Product BPA_Return Hot Crude Mix-E2-Tpa Crude Feed AC-100 Desalter Feed Salty Water TAG__FI1045 TAG__FI1016 ByPass-E2-Tpa ByPass-E7-Bpa 88.8 88.8 88.8 88.8 88.8 88.8 88.8 88.8 88.8 88.8 88.8 88.8 88.8 88.888.8 88.8 88.8 88.8 88.8 88.8 88.8 88.8 88.8 88.8 88.8 88.8 R 88.8 88.8 88.8 88.8 88.8 88.8 88.8 88.8 88.8 88.8 88.8 88.8 88.8 88.8
  8. 8. > Part of Petro-SIM environment > Fouling Monitoring – Monitor amount and cost of fouling over time for each exchanger and whole network – Identify sudden fouling events – Fouling-related KPI development (e.g. duties, UAs, fouling factors, etc) > Cleaning Analysis – Identify which exchangers to clean, when and what the savings will be – Choose the best exchangers to clean if an opportunity suddenly arises (e.g. unscheduled shut-down) – Prioritise the exchangers to clean in a turn-around > Re-usable model – Use the simulation model for other operation and revamp studies • Crude evaluation, throughput studies, revamp projects, pressure drop – Leverage your simulation skills for this purpose HX-Monitor 6 October 2015 8 HX-Monitor Environment Petro-SIM Performance Monitoring  Cleaning Analysis  Online Simulation 
  9. 9. HX-Monitor: How does it work? 6 October 2015 9PROPRIETARY INFORMATION 9 Data Collection • Data Collection • Site’s data historian • LAB data • Temperatures, flows Modelling • Preheat train Modelling in Petro-SIM • Data reconciliation • Fouling monitoring • Real time cleaning decision support Reporting • Database and Reporting • Run automatically or periodically • Graphical interface • KPI Environment
  10. 10. HX-Monitor: Model building 6 October 2015 10PROPRIETARY INFORMATION > Petro-SIM is used to: – Build the model – Run the calculations automatically – Troubleshoot problems – Results exported to site’s data historian > Most users do not need to interact with Petro-SIM > But you may want to use the model for other revamp and operational projects
  11. 11. © 2015 KBC Advanced Technologies plc. All Rights Reserved. HX-Monitor Demonstration KBC Webinar 6 October 2015
  12. 12. Closing > Questions? > Future webinar topics in energy: – Energy-SIM demonstration – Dashboards – Petro-SIM GT model > We welcome suggestions for future topics – please email kbc-marketing@kbcat.com > Next webinar information will go out shortly. > Thank you for joining us! 6 October 2015 PROPRIETARY INFORMATION 12

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