energy, emissions, and efficiency
DESCRIPTION
TRANSCRIPT
Welcome to today’s webcast…
Energy, Emissions, and Efficiency: How to address heat exchanger fouling to reduce energy and
maintenance costs while improving plant performance
March 31, 2011
Copyright © 2011 IHS Inc. All Rights Reserved.
Today’s Speaker – Simon Pugh Expert from IHS
Simon Pugh Director
Process Engineering Technology
IHS Inc.
•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 the
IHS ESDU Oil Industry Fouling Working Party.
•He is currently leading a group of engineers working on the
development of a range of design guides to oil industry fouling
problems and computer programs for better heat exchanger
selection, design and operation, with particularly emphasis on
reducing crude fouling in per-heat trains. He holds a mechanical
engineering degree from Brunel University in the UK.
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Copyright © 2011 IHS Inc. All Rights Reserved.
• 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
About IHS Inc. A Leading Information Provider
3
Copyright © 2011 IHS Inc. All Rights Reserved.
• 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
Today’s Topics What we will address
4
Copyright © 2011 IHS Inc. All Rights Reserved.
IHS ESDU
The 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.
ESDU Technical Committees Selection of Participating Organisations
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Example: Fouling in Cooling Systems
Participating Organisations
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Copyright © 2011 IHS Inc. All Rights Reserved.
• 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
Today’s Topics What we will address
8
Copyright © 2011 IHS Inc. All Rights Reserved.
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)
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Copyright © 2011 IHS Inc. All Rights Reserved.
How does hydrocarbon burning contribute
to CO2 emissions?
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One tonne of hydrocarbon burned releases 2.5 – 3 tonnes of CO2
Copyright © 2011 IHS Inc. All Rights Reserved.
What are the biggest CO2 producers in
refineries?
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Around 50% of CO2 and energy from crude heating
Efficiency of pre-heat train crucial in energy and CO2 management
Copyright © 2011 IHS Inc. All Rights Reserved.
Opportunity – Address Crude Oil Fouling Improvements to energy, efficiency, and emissions
Reduce Energy Consumption
Improve Maintenance
Improve Throughput
Reduce Emissions
Regulatory Compliance
Reduce Costs
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Copyright © 2011 IHS Inc. All Rights Reserved.
Enablement Strategies – Scenarios How 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?
13
Copyright © 2011 IHS Inc. All Rights Reserved.
Remainder of Slides ….
14
STORAGE
HEATING
DISTILLATION
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The heated crude needs a
“blast” in the furnace prior to
distillation $$$
$$$
$$$
$$
$
CO2
Copyright © 2011 IHS Inc. All Rights Reserved.
What is the biggest cause of inefficiency in
heat exchangers?
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Fouling!
Dirt deposits build up on clean tubes, and
efficiency plummets!!
Copyright © 2011 IHS Inc. All Rights Reserved.
Some economic & environmental effects of
fouling problems
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• Energy
• increased fuel needed in furnace, pumping costs
• Emissions
• 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!!
CO2
Copyright © 2011 IHS Inc. All Rights Reserved.
Some economic & environmental effects of
fouling problems
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• 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 water
Copyright © 2011 IHS Inc. All Rights Reserved.
Cleaning! Major maintenance issue
20
Fouling!
Dirt deposits build up on clean tubes, and
efficiency plummets!! Picture; Wellman Hunt
Graham
Copyright © 2011 IHS Inc. All Rights Reserved.
Cleaning! Major maintenance issue
21
Fouling!
Dirt deposits build up on clean tubes, and
efficiency plummets!! Picture; Wellman Hunt
Graham
Copyright © 2011 IHS Inc. All Rights Reserved.
Fouling is getting worse!
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• 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.
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 CO2
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Copyright © 2011 IHS Inc. All Rights Reserved.
Oil Industry Fouling Working Party
members
Oil company members of the IHS ESDU Oil Industry Fouling Working Party – CROF1
Heat Exchanger Design
Next Generation Simulations based on
Industry Accepted Best Practices
Network Techno-Economics
Best Practice
Optimize
Heat Exchanger Design
Next Generation Simulations based on
Industry Accepted Best Practices
Network Techno-Economics
Best Practice
Model
Simulate
Best Practice
Copyright © 2011 IHS Inc. All Rights Reserved.
• 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
Today’s Topics What we will address
27
Copyright © 2011 IHS Inc. All Rights Reserved.
• 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.
Crude Oil Fouling Research (CROF) The CROF programme
Copyright © 2011 IHS Inc. All Rights Reserved.
H –
technology
transfer
samples
properties
models
behaviour
F – larger
scale lab
tests in
tubes
A – test
crudes and
deposits B – study
interfacial
behaviour of
deposits
C – model
heat and
mass
transfer
D - model
molecular
properties
G – simulate
real plant
behaviour
E – small-
cell tests on
crude
samples
CROF1
IHS ESDU - Bridge between University
Research and Oil Industry
Copyright © 2011 IHS Inc. All Rights Reserved.
Chevron Pembroke Refinery, Sun 19 – Fri 24 April 2009 50 researchers and industrialists from 4 continents
IHS London office, 28 Sept – 1 Oct 2009 55 researchers and industrialists
Intensive research meetings: for example in 2009…
Copyright © 2011 IHS Inc. All Rights Reserved.
IHS ESDU - Bridge between University Research 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 Maintenance
31
Copyright © 2011 IHS Inc. All Rights Reserved.
IHS ESDU - Bridge between University Research and Oil Industry
32
Copyright © 2011 IHS Inc. All Rights Reserved.
Extracting fouling model from plant (HEN) operating data and fitting fouling models
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(a) Raw Plant Op data from DCS
(b) Convert to fouling prediction using
rigourous heat exchanger design
methods in ESDU EXPRESSplus
(c) Fit Fouling model to
Plant Op data in IHS
EXPRESSplus
Copyright © 2011 IHS Inc. All Rights Reserved.
Cost data and
operational strategies
34
Refining
solutions
Cambridge Research considered for the
prestigious 2010 Eni Protecting the
Environment Award.
Design and operational
parameters smartPM
…leading to Smart Predictive Maintenance
Copyright © 2011 IHS Inc. All Rights Reserved.
smartPM
…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?
Copyright © 2011 IHS Inc. All Rights Reserved.
Consider the Expertise of IHS ESDU What 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 optimization
Copyright © 2011 IHS Inc. All Rights Reserved.
Complimentary Review – IHS Advice Let 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 opportunities
37
Copyright © 2011 IHS Inc. All Rights Reserved. 38
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