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© 2010 Aspen Technology, Inc. All rights reserved

September 14, 2012

 

Monitoring

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Fouling of Preheat Train: Main Concerns

•• Heat exchanger Fouling leads toHeat exchanger Fouling leads to::- Decrease of the furnace inlet temperature increase of

the amount of combustible (100$/ton of fuel oil)

- Once furnace bottlenecked decrease of the crude feedflow rate

- Possible heat exchan er on-line cleanin to kee the feed

© 2010 Aspen Technology, Inc. All rights reserved | 2

 

flow rate as high as possible

- Shutdown for preheat train cleaning (45 to 90 k$ / train)

Preheat train on every unit: CDU, VDU, HDT, HDS, FCCPreheat train on every unit: CDU, VDU, HDT, HDS, FCC

High financial lossesHigh financial losses

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Fouling Monitoring: Principal

T2out

M1, T1in, density

T1out

M2, T2in, density

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DTLMS

TMCU

  pF

⋅

∆=

CFf 

U1

U1R   −=

• Measured parameters: Flows and Temperatures

• Rigorous calculation of properties Cp , λλλλ, µµµµ = f(T, P fluid type )

• Thermal Balance

Uc calculation = f(heat exchanger geometry, flow rates, fluidproperties)

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Fouling Monitoring: Performance Monitoring

DCS Data

ASW Interface Repository

• DCS data is imported toASW interface

• DCS data is averaged

Data Import to ASW

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HYSYS Shell &Tube Exchangers(Simulation Mode)

Heat Shell &Tube Utility(Maximum

Fouling Mode)

 

(hourly/daily)

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Fouling Monitoring: Performance Monitoring

DCS Data

ASW Interface Repository

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HYSYS Shell &Tube Heat

Exchangers

(Simulation Mode)

Heat Shell &Tube Utility(Maximum

Fouling Mode)

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Fouling Monitoring: Performance Monitoring

DCS Data

ASW Interface Repository

y = 1.9105x - 70294

R2= 0.9192

y = 0.8647x - 31829

 

200

250

300

   4   °   C   h  m   2   /   k  c  a   l   )

HX-114

HX-118

HX-112

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HYSYS Shell &Tube Heat

Exchangers

(Simulation Mode)

Heat Shell &Tube Utility(Maximum

Fouling Mode)

y = 0.4735x - 17405

R2= 0.917

= .

0

50

100

150

01/10/09 20/11/09 09/01/10 28/02/10 19/04/10 08/06/10 28/07/10

   f  o  u   l   i  n  g  r  e  s   i  s   t  a  n  c  e   (

   1   0

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Fouling Monitoring: Performance Monitoring

DCS Data

ASW Interface Repository

© 2010 Aspen Technology, Inc. All rights reserved | 7

HYSYS Shell &Tube Heat

Exchangers

(Simulation Mode)

Heat Shell &Tube Utility(Maximum

Fouling Mode)

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Demo

Show ASW and HYSYS case

Not so robust but the concept can be understood.

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Summary

A frame-work is presented, where

– HYSYS Shell & Tube Utility is used for fouling factor estimation

– ASW is used for data transfer and data storage

– HYSYS Shell & Tube HXs are used for rigorous calculations

ASW framework can also be used for evaluating various

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This interface can be applied easily to any refineryconfigurations (please look at the word document)