6 Ashdod Refineries

7/30/2019 6 Ashdod Refineries

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Case StudyThe CQM System in Refineries

in Amine Treatment Plant

Udi Siboni [email protected]

CQM Chief Engineer CQM Trat-Yehuda 51 d.n. Hamerkaz 73175 Israel

www.cqm-tech.com

http://www.cqm-tech.com/



Table of Contents

1 DECISION MAKING PROCESS FOR THE INSTALLATION OF C.Q.MPRODUCT AT ASHDOD REFINERIES ............ 3

THE H2S CONDENSER WAS BLOCKED WITH MUD AND

SCALE, AND REQUIRED CLEANING TWICE A YEAR. 5

INSTALLATION OF THE C.Q.M SYSTEM ON THE H2S CONDENSER(C5) .........6

AFTER THE INSTALLATION OF THE CQM SYSTEM ........................ 8

5 ENERGY SAVINGS ............................................................................... 9

1. General ........................................................................................... 9

2. Software Programs used for Test runs and Computation..................9

3. Condenser geometrical and process data........................................... 9

4. Software Run and Computation ........................................................ 10

5. Analysis and Comparison of Results ................................................. 11

6 ASHDOD REFINERIES H2S CONDENSER WATER SAVINGSFOLLOWING THE DISCONTINUATION OF THE EXTERNAL COOLING......13

7 SUMMARY: THE SAVINGS ACHIEVED BY THE INSTALLATION OFATCS IN A H2S CONDENSER AT THE ASHDOD REFINERIES .............14

8 ATTACHMENT ..................................................................................... 15

I. Attachment 1 .................................................................................. 15

II. Attachment 2 .................................................................................. 17

III. Attachment 3 .................................................................................. 19

IV. Attachment 4 .................................................................................. 20

V. Attachment ...................................................................................21

VI. Attachment ...................................................................................23

VII. Attachment .................................................................................... 24

VIII. Attachment ................................................................................... 25

IX. Attachment ................................................................................... 32



1. Decision Making Process for the Installation of C.Q.MProduct at Ashdod Refineries

The decision to build a refinery in Ashdod was taken in 1969. The modernrefinery took around three years to build, and began operations in 1973.

The Ashdod premises cover about 1,000 m2, and have the ability to processaround 4 million tons of crude oil per year. (See more on the Refineries in Attachment 2)

The C.Q.M Automatic Tube Cleaning System (ATCS) was presented toAshdod Refineries technical personnel (managers and maintenance) in aspecial conference on site.The system was demonstrated, the sponge balls cleaning process explained,then the potential savings in energy, manpower and out of pocket expenses

were presented.

The Refineries management then decided to install one system as a pilot.

The management decided to install the ATCS on a very problematic heatexchanger (151 C5) which is critical in the MEA Amine gas cleaning process(see Attachment 3)

This heat exchanger is located in area B, in the Amine Unit, serving to

condense the remainder water vapor in the H2S gas.

Originally, the heat exchanger would get clogged by scale and silt and theheat exchange capacity diminished to the point where external cooling, in theform of water spray over the condenser case, had to be used. The externalwater was only a partial remedy, however it added corrosion and mudded allsurroundings.



The inadequacy of the condensation phase caused many malfunctions in theSulfur recovery plant that is installed after the Amine Unit, and in extremecases even disruption of production.

When the heat exchanger clogged, the effluent gas temperature climbed toabove 70°C and some water penetrated the Sulfur recovery plant aforbidden situation thus causing more clogging by corrosion particles anddiscontinuation of the process. Cleaning the heat exchanger twice yearly didnot correct the situation, it would get clogged again soon after each cleaning

Disruption of the Sulfur retrieval Plant costs tens of thousands of US $ perday. This cost is amplified when the crude oil is of high sulfur content.

Since C.Q.Ms ATCS was installed in October 2003, no additional cleaningwas required, nor any external cooling by spray water. No more malfunctions

were registered in the Sulfur Recovery plant. .

Attachment 1 describes the refining process Attachment 2 describes the Ashdod Refineries Attachment 3 describes the Amine Unit



2. The H2S condenser was blocked with mud and scale, andrequired cleaning twice a year.

As a result of poor heat transfer, water would reach the sulfur recovery plantand cause serious clogging and corrosion problems. Sometimes on hot daysadditional external cooling was required, and water was sprayed onto thecondenser case.

C5 In the amine plant: average temperature of 63° C

Between 30 Dec. 2001 29 Feb. 2002 (The condenser was cleaned in January)



3. Installation of the C.Q.M System on the H2S Condenser (C5)

The C.Q.M ATCS system was installed in October 2003, during a period ofrenovation. At this time, the condenser was cleaned with acid and high-

pressure water, as well as undergoing localized cleaning.



The installed C.Q.M ATCS



4. After the Installation of the CQM System

C5 In the amine plant: average temperature of 45° CBetween 12 Jul. 2002 - 29 Dec. 2003

C5 In the Amine Unit: average temperature of 45° C

Between 30 Oct. 2003 - 29 Dec. 2003

Following the Installation of C.Q.M ATCS.

Renovations2003

Operation of theCQM system



5. Energy Savings

1. General When observing the clogged condenser it is obvious that cleaning it will createbig energy savings. However the complexity of the process made it difficult tocompute exactly the amount of energy to be saved.

Condenser before and after cleaning

To overcome this complexity we hired Galil Engineering, experts in processdesign.(See more about Galil Engineering in Attachment 4)

2. Software Programs used for Test runs and Computation For the energy savings computations we used HYSYS a software program

for modeling the process (see Attachment 5) and HTRI for the computationand design of condensers (see Attachment 6)

3. Condenser geometrical and process data The geometrical data was taken from condenser 131 C4 which is identicalwith 151 C5 (condenser) (see data in Attachment 7)

Cooling Tower: Temperature Differential 7 8 oCTower Temp - oC

(checked on Aug 1, 2004 at 12 noon)Cooling water rate in tower

Condenser: Cooling water rate in condenser (estimate) Gas flow rate (variable) average for computation 1000

3 weeks per month 15001 week per month 200

Gas effluent Temp 56 oCGas Influx Temp (estimate) 87 oC



4. Software Run and Computation

A process model was built with HYSYS and after several test runs withdifferent conditions the data was fed to the HTRI S/ W for the computation ofthe output and other condenser data.

One stage in the HTRI run

Full data from S/W program run for clogged condenser see Attachment 8 Full data from S/W program run for clean condenser see Attachment 9



5. Analysis and Comparison of Results

The test was made on 2 points, H2S effluent Temp from condenser:

70o

C Clogged Condenser 40 oC Clean Condenser

When the condenser is clogged, the fouling factor is 0.003 When the condenser is clean, the fouling factor is 0.0004

The heat transfer coefficient in a clogged condenser is T(h²s) 90 70 (°c)

U=123.27 (kcal/m2·h·0C)Q=309600 (kcal/h)

T(ln)=44.3 (°c)



The heat transfer coefficient in a clean condenser isT(h²s) 90 40 (°c)

U= .2 (kcal/m2-rh-0C)

Q=487000 (kcal/h) T(ln)=24.2 (°c)

The improvement is: 185% in the heat transfer coefficient (U). 157% in the heat capacity (Q).

The implication of the condenser cleanliness is that all the water condensesand none reaches the Sulfur Retrieval Plant with the water. (This happenedfrequently before the ATCS installation, causing the disruption of production inthe Plant)



6. Ashdod Refineries H2S condenser water savings followingthe discontinuation of the external cooling

Data:

1. External cooling was used 5 months per year, 12 hours per day, total of1,800 hours per year

2. Water pressure on line 2 BAR 3. Pipe caliber 2" 4. 26 holes, 3 mm diameter5. Water flow from one hole (measured): 189 liter/hour

Spray water: 189 Liter X 26 X 1,800 = 8,845,200 Liter,Savings at US $ 1 / cubic meter = US $8,845 / year

The condenser is cooled by externally sprayed water



7. Summary: The savings achieved by the installation of ATCSin a H2S condenser at the Ashdod Refineries

1. Energy Efficiency Improvement 185% U (kcal/m2-rh-0C)157% Q (kcal/h)

2. Operating savings: a. Manual cleaning (manpower costs) ca. US $2,500 per year b. Sealing US $600 per year

3. Savings by continual operation of the Sulfur Retrieval Plant (no productiondisruption) US $40,000 50,000 per year

4. Savings of external water cooling US $8,845 per year

Total Savings US $ per yearEnergy Efficiency Improvement 157%

Operating cleaning the condenser 2,500 Sealing 600 continual operation of the Sulfur Retrieval Plant 50,000 spray water 8,845

Total measurable water 61,945



8. Attachment

I. Attachment 1 The Source of Crude Oil and the Refinery Processes

Crude oil comes from the remains of plants and animals that sank to theseabed, layer upon layer. Their own weight and the weight of the seawatercompressed the layers, creating heat and starting a process that continued forhundreds of millions of years. This process turned the remains of theorganisms into oil.

Crude oil is a thick, blackish-brown liquid comprised of a mixture of organicmaterials that contain carbon and hydrogen. Oil is found in undergroundreservoirs, trapped in pockets between the layers of stone.

Refineries process the crude oil and separate it into its fractions(components). The separation process involves heating the oil to atemperature of 500° C. At this temperature, all the fractions vaporize.

The oil vapor is gradually cooled and channeled through pipes that collect thevarious components. The main fractions are: Natural gas boils at the low temperature of 20° C Petrol ether boils at 30-60° C Ligroin boils at 60-90° C Gasoline (car fuel) boils at 85-200° C Kerosene boils at 200-300° C

Heavy gas oil boils at 300-400° C Lubricating oil, grease, wax and bitumen boil at temperatures above 400° C

The products distilled from crude oil are used as fuel and raw material for thepetrochemical industry that produces plastics and chemicals.



Diagram of Refinery Tower

What is produced from crude oil?

Liquefied Petroleum Gas (LPG) - 4.5%

Gasoline & Naphtha - 24.9%

Kerosene - 9.5%

Gas-oil - 26.4%

Fuel oil - 23.3%

Bitumen - 2.7%

Paraffins - 0.5%

Sulfur - 0.3%

Self consumption - 7.9%



II. Attachment 2 Ashdod Refinery

The decision to build a refinery in Ashdod was taken in 1969. The modernrefinery took around three years to build, and began operating in 1973. The

Ashdod premises cover about 1,000 m2

, and have the ability to processaround 4 million tons of crude oil per year.

Production Plant

Area A Refinery PlantThis area is the first station in the process of refining the crude oil. After beingstored in the containers of the container depot, the oil arrives to be drained ofwater and for laboratory tests that check what kind of oil has been delivered.The oil is also tested to enable estimates to be made of the percentages ofthe components that will be derived from the refining process.

The oil is then pumped through a series of heat exchangers, rinsed with waterto remove salts, and heated in enormous ovens to a temperature of around370° C.

The refining process in Area A is divided into three stages:1. Initial refining the heated crude oil is channeled to the first distillationcolumn that separates it into various fractions, according to the boilingtemperature of each. These fractions are further processed in order to makethem suitable for use. 2. Vacuum refining the heavy oil undergoes further heating and is refinedin a vacuum still that allows additional distillates to be obtained, among themheavy vacuum diesel that is used as fuel for the catalytic cracking.3. Thermal cracking the heavy part, the fuel oil that remains in the vacuumafter the refining, undergoes thermal cracking at a high temperature. Thethermal cracking reduces viscosity, thereby allowing additional light distillatesto be obtained.

Area B Treating and Blending PlantThe products obtained in the initial refining are only at the first processingstage, and are not yet ready for use. These facilities improve the quality of the

fractions by taking them through a two-stage process: 1. Sulfur cleaning and removal of other pollutants by catalytic processes2. Further refining and distillation to obtain products that meet the requiredquality and standards

Sulfur Cleaning The sulfur is removed by reduction of the mercaptans (R-S-S-R, which are inthe crude oil) with hydrogen, in order to obtain hydrogen sulfide. This reactionrequires temperatures of 260°- 430° C.

The hydrogen sulfide gas H2S(g) obtained from the reaction is absorbed by

passing the mixture through an amine solution.



Sulfur Recovery The sulfur is recovered by heating the solution to again release the hydrogensulfide and then oxidizing it in the air to obtain clean sulfur.

In the catalytic cracker, the fuel is channeled with a stream of hydrogen over a

platinum catalyst. During this process, the chemical structure of the fuel ischanged and high-octane gasoline is obtained as required by modernengines.

Area C Service FacilitiesIn this area, the following facilities are found: 1. Water treatment plant this plant supplies high quality soft water for theproduction of steam. 2. Steam production plant this plant supplies steam at various pressures attemperatures of around 340° C as needed by the various production facilities. 3. Air compression plant this plant supplies dry air at a pressure of 6

atmospheres to the various facilities. 4. Cooling towers these towers cool the water that flows through the heatexchangers to a temperature of 23° C. The cooling process is assisted by astream of air from huge bellows. 5. Electricity system this system supplies high-voltage electricity to thevarious facilities.

Area D Catalytic CrackingThe catalytic cracker cracks the long hydrocarbon chains of the heavy dieseland turns it into high-octane gasoline.



III. Attachment 3 Area B the Amine Treatment Plant

The amine absorption process removes hydrogen sulfide or carbon dioxidefrom a gaseous mixture. The amine solution flows down through the absorber

column where it makes contact with the gaseous mixture rising up through thetower. The amine solution, now contaminated with hydrogen sulfide or carbondioxide, is discharged from the bottom of the tower to a steam stripper. Here itruns counter to the steam that strips away the hydrogen sulfide or carbondioxide. The amine solution is then returned to the top of the absorptioncolumn for reuse.

Refinery amine treatment systems can be fine-tuned to increase reliability,lower operating costs, reduce corrosion and increase treating capacity.

MEA monoethanol amine is used at the Ashdod refinery.



IV. Attachment 4 Galil Engineering Ltd.

"Galil Engineering ", an Israeli company founded in 1984, is a multidisciplinaryengineering organization which presently employs over 270 engineers,

technicians and administrative staff. Its personnel has substantial experiencein design and construction management of large scale industrial projects

The Company provides most of its engineering services in various disciplinesof engineering on E.P.C.M (Engineering, Procurement, Construction,

Management) basis, from the preliminary design stages through the detaileddesign, procurement, construction stages up to plant commissioning.

The Process Department specializes in the process design for the chemical,pharmaceutical, fine chemical, oil refining, petrochemical, food and textileindustries.

The department undertakes projects from the conceptual stage, up tocommissioning and running in.The Process Department has developed expertise in a wide range oftechnological fields and has been involved in complex projects based on ourown know-how or working in close collaboration with know-how suppliers.

As part of the process design, the Department is experienced in supplyingcreative and unconventional solutions in order to adapt the differenttechnologies to client s specific needs.Our staff includes known leading process engineers with a vast experience ina broad range of industries and technologies. In order to assure the highest quality standards, the Process Departmentmakes use of most advanced software like HYSYS for process simulation.Recently we have joined the HTRI consortium to supply heat exchangehighest design standards.



V. AttachmentHYSIS Software program for models

The goal of program like HYSYS is, of course, to provide engineers with thecapability to design an entire process as completely and accurately as

possible.

HYSYS was created using an open architecture to enable industry-specificcapabilities to be easily added by AspenTech or third-party vendors. Thesehigh-value add-ons fully integrate with HYSYS to provide additionalcapabilities, such as:

Acid gas treating using amines, blended amines and physical solvents

Crude oil characterization from laboratory assay dataMultiphase pipeline correlations for design and troubleshootingOnline or offline process monitoring and optimizationDetailed equipment selection and sizing





VI. AttachmentHTRI S/W Program for the design and computation of heatexchangers

Heat Transfer Research, Inc. (HTRI), the global leader in process heat

transfer and heat exchanger technology, was founded in 1962. Today ourindustrial research and development consortium serves the engineeringneeds of nearly 600 companies in more than 45 countries. We conductapplication-oriented research on pilot-scale equipment at our research facility.HTRI staff use this proprietary research data to develop methods andsoftware for the thermal design and analysis of heat exchangers and firedheaters. In addition to research data and software, we provide technicalsupport and offer training, consulting, and contract services to both membersand non-member companies. Our expertise and dedication to excellenceassure our customers of a distinct competitive advantage and a high level ofoperating confidence in equipment designed with our technology.

HTRI software, used successfully by industry for more than 35 years, isbacked by extensive data collected on industrial-sized heat transferequipment. Program methods documented in our technical publications areimproved through on-going research. As a result of rigorous research analysisand our response to the changing needs of customers, HTRI software isregularly updated.

Heat Transfer Research, Inc. The premier provider of heat transfer technology



VII. AttachmentGeometrical Data of the condenser and the process data



VIII. AttachmentResults when condenser is fouled















IX. AttachmentResults when condenser is clean















AttachmentResults when condenser is clean















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