Post on 03-Jan-2022
transcript
Selecting and Enabling Effective
Cost Savings Through Innovative
Heat Transfer Enhancement
Technology
Presented by :
Martin Gough,
CALGAVIN Ltd
hiTRANTM Thermal Systems Working Principles of CALGAVIN Technology
Direction of Flow
How Does hiTRAN™ Technology Work?
• Removes the laminar boundary layer
• Mixes fluid with bulk flow
• Improves heat and mass transfer- changing the mode of heat transfer at the tube wall from conduction to convection – a higher rate of heat transfer
Analytical Engineering – Lube oil air Cooler
Analytical Engineering – Heavy gas oil Cooler
Case Study 1:Graphite Vent Gas Condenser
Improved Product Quality
Condition Before Installation
-50
-40
-30
-20
-10
0
10
0.96
0.97
0.98
0.99
1
0 500 1000 1500 2000 2500 3000
bu
lk t
em
pe
ratu
re [
C]
Vap
or
we
igh
t fr
acti
on
[-]
Tube length [mm]
VaporWeightFraction
BulkTemperature
shell temperature
• Tube side Reynolds number
~ 18000
• Wet wall shear controlled
flow regime
Results After Revamp
0.96
0.97
0.98
0.99
1
0 500 1000 1500 2000 2500 3000
Vap
or
weig
ht
fracti
on
[-]
Tube length [mm]
plain empty hiTRAN
-50
-40
-30
-20
-10
0
10
0 500 1000 1500 2000 2500 3000
Bu
lk t
em
pe
ratu
re [
C°]
Tube length [mm]
plain empty hiTRAN shell temperature
hiTRAN™ inserts performed
as predicted
• ~5 °C lower outlet
temperature
• Minor increase in
pressure drop (5mbar)
• Increased condensate
mass flow more than
10000 kg/year product
recovery
• Avoiding additional
empty tube unit to meet
demand, CAPEX saving
$258634 (reference
Exchanger Optimizer)
Results After Revamp
Case Study 2:Paraxylene Feed/Effluent
Increased Throughput
Feed/Effluent Exchanger Revamp
From operating data client recognised the opportunity for heat recovery in order to increase production
Ruhr OEL, Gelsenkirchen, Germany
Shell Tube
Fluid Paraxylene Effluent Feed
Flow 85940kg/hr 85940kg/hr
Vapour fraction 1 / 0.57 0.32 / 1
Temp. (In/Out) 403°C / 138°C 94°C / 327°C
HTC 975W/m2K 591W/m2K
Duty 19.7 MW
Reynolds (In/Out) 2130 / 68000
TEMA Type AES
Tube dims. 1734 tubes, 20x2x12000mm, 1 pass
Design Data
Heat Transfer Analysis
0
500
1000
1500
2000
2500
0 2000 4000 6000 8000 10000 12000
tube length [mm]
Heat
Tra
nsfe
r [W
/m2K
]
0
0.2
0.4
0.6
0.8
1
1.2
Va
po
ur
Qu
ali
ty [
-]
SS HTC
TS HTC
TS
Vapour Fraction
hiTRAN™ Thermal System Solution
Benefits after hiTRAN™ Installation
• No requirement for larger fired heater
• No changes to pipework
• No additional civil engineering costs
• Heat Transfer in superheated region increased by 48%
• Reduction of the duty for the fired heater saved around 0.8MW
• Saved 1700t/y CO2 calculated
• ROI paid within 18 months
• Achieved 17.5% increased throughput
• Empty tube equivalent capital cost $1042900
(reference Exchanger Optimizer)
CALGAVIN Global References
Indian ReferencesP.NO. COMPANY APPLICATION DESC. CUSTOMER BENEFIT END USER INSTALL COUNTRY TUBESIDE FLUID
Company Type: End User
7223 GEI Industrial Systems Ltd Residue Cooler Reduced Size Indian Oil India Residue
8396 BGR Energy Systems Ltd (Air
Fin Cooler Division)
Oil cooler Reduced Size Oil & Natural Gas Corporation
(ONGC)
India ISO VG46
9011 BGR Energy Systems Ltd (Air
Fin Cooler Division)
Oil cooler Reduced Size Cairn Energy India ISO VG46
10161 BGR Energy Systems Ltd (Air
Fin Cooler Division)
Air fin cooler Improved Duty Chennai Petroleum Corporation
Ltd
India
10481 BGR Energy Systems Limited Lube oil cooler Reduced Size ONGC India Lube oil
10644 BGR Energy Systems Limited Lube oil cooler Reduced Size ONGC India ISO VG 46
10644 BGR Energy Systems Limited Lube oil cooler Reduced Size ONGC India ISO VG 46
10644 BGR Energy Systems Limited Lube oil cooler Reduced Size ONGC India ISO VG 46
10989 BGR Energy Systems Limited Oil cooler Reduced Size SAVAIR Energy Systems Ltd,
Mumbai
India oil
11153 Jord International Lube oil coolers Reduced Size Enpro India India ISO VG 46
11257 BGR Energy Systems Ltd (Air
Fin Cooler Division)
Product Fractionator Bottoms
Cooler - Multiple bidders
Reduced Size Indian Oil Corporation Limited India Frac bottoms
12487 Nuovo Pignone S.r.l. Oil cooler Reduced Size India Lube oil
12487 Nuovo Pignone S.r.l. Oil cooler Reduced Size India Lube oil
12487 Nuovo Pignone S.r.l. Oil cooler Reduced Size India Lube oil
12516 Industrial Manufacturers Twisted Tape - Reliance Improved Duty Reliance Jamnagar Refinery India
12516 Industrial Manufacturers Twisted Tape - Reliance Improved Duty Reliance Jamnagar Refinery India
12558 Robox Heat Technology b.v. Duraclear U tube cooler Improved Duty India Duraclear
P.NO. COMPANY APPLICATION DESC. CUSTOMER BENEFIT END USER INSTALL COUNTRY TUBESIDE FLUID
Company Type: End User
6738 Daurala Organics Limited Falling Film Evaporator
trial
Improved Duty Daurala India Mandelic acid
8492 Shell Research Ltd Crude oil fouling tests Reduced Fouling SHELL India crude oil
8492 Shell Research Ltd Crude oil fouling tests Reduced Fouling SHELL India crude oil
8492 Shell Research Ltd Crude oil fouling tests Reduced Fouling SHELL India crude oil
10822 Hindustan Petroleum
Corporation Limited
New bundle CDU II - see
project folder
Reduced Fouling Hindustan Petroleum
Corporation Limited
India Crude
10822 Hindustan Petroleum
Corporation Limited
New bundle CDU II - see
project folder
Reduced Fouling Hindustan Petroleum
Corporation Limited
India Crude
11816 Linde Engineering India Pvt
Ltd
Twisted Tape Improved Duty Linde India India HC
6627 Kelvion France Oil coolers Reduced Size Essar oil India Crude Oil
6627 Kelvion France Oil coolers Reduced Size Essar oil India Crude Oil
6627 Kelvion France Oil coolers Reduced Size Essar oil India Crude Oil
6627 Kelvion France Oil coolers Reduced Size Essar oil India Crude Oil
6627 Kelvion France Oil coolers Reduced Size Essar oil India Crude Oil
6627 Kelvion France Oil coolers Reduced Size Essar oil India Crude Oil
7016 GEA Batignolles Thermal
Technologies(Changshu)Co.L
Lube oil coolers Reduced Size GAIL India Lube oil
Thank you for listening
Any Questions ?
Visit us on stand B5
martin.gough@calgavin.com