kbc ioe webinar - hx monitor and fouling studies
TRANSCRIPT
© 2015 KBC Advanced Technologies plc. All Rights Reserved.
HX-Monitor and Fouling Studies KBC Webinar
6 October 2015
Agenda
• Introduction • Prevention • Monitoring HX-Monitor
Potential benefits Overview of how the software works Demonstration
6 October 2015 2 PROPRIETARY INFORMATION
Effect of Fouling on Heat Recovery
6 October 2015 3 PROPRIETARY INFORMATION
Time (months) 0.000
0.002
0.004
0.006
0.008
0.010
0.012
0.014
0.016
0.018
Foul
ing
Fact
or
0.000
0.002
0.004
0.006
0.008
0.010
0.012
0.014
0.016
0.018
Foul
ing
Fact
or
Time (months) 170
180
190
200
210
220
230
240
250
260
Furn
ace
Coi
l Inl
et T
empe
ratu
re
Time (months) 45
50
55
60
65
70
75
80
85
90
Furn
ace
Dut
y ( G
cal /h
))
∆ C
IT
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 48 24 30 42 0 6 12 18 36 48 24 30 42 0 6 12 18 36 48 24 30 42
Lost heat transfer must be made up by increasing fuel utility
Higher emissions and emission costs
Fouling
6 October 2015 4 PROPRIETARY 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
Fouling Prevention
6 October 2015 5 PROPRIETARY 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
The Fouling Issue…once it happens!
6 October 2015 6 PROPRIETARY 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
Benefits of Fouling Monitoring Applications
6 October 2015 7 PROPRIETARY INFORMATION
CrudePreheatTrain 100,000bpdRefinery
Desalter
DesOffgas
E1
Tpa_TrimClr
C4
Sp1 Mix1
C3
Furnace
Mpa_TrimClr Bpa_TrimClr
RCY-2
E6
E2
E7E3
E4 E5 E8
Kero
c1
DesaltedCrude
DesalterWater
TPA_Draw
MPA_DrawLGO
HGO BPA_Draw Residue
KeroProduct
ResidueProduct
TPA_Return MPA_Return LGOProduct
HGOProduct
BPA_Return
HotCrude
Mix-E2-Tpa
CrudeFeed
AC-100
DesalterFeed
SaltyWater
TAG__FI1045
TAG__FI1016
ByPass-E2-Tpa
ByPass-E7-Bpa88.8
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
88.888.8 88.8
88.8
88.8
88.8
88.8
88.8
88.8
88.8
> 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
HX-Monitor: How does it work?
6 October 2015 9 PROPRIETARY 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
HX-Monitor: Model building
6 October 2015 10 PROPRIETARY 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
© 2015 KBC Advanced Technologies plc. All Rights Reserved.
HX-Monitor Demonstration KBC Webinar
6 October 2015
Closing > Questions? > Future webinar topics in energy:
– Energy-SIM demonstration – Dashboards – Petro-SIM GT model
> We welcome suggestions for future topics – please email [email protected]
> Next webinar information will go out shortly. > Thank you for joining us!
6 October 2015 PROPRIETARY INFORMATION 12