Energy, Emissions, and Efficiency

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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• 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


• 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

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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”


ESDU Technical Committees Selection of Participating Organisations

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http://images.google.co.uk/imgres?imgurl=http://www.messier-dowty.on.ca/images/Logo_200_53.gif&imgrefurl=http://www.messier-dowty.on.ca/&h=42&w=200&sz=5&hl=en&start=1&tbnid=1ock_b4RCyhEQM:&tbnh=22&tbnw=104&prev=/images?q=messier+dowty+logo&svnum=10&hl=en&lr=&sa=G

http://images.google.co.uk/imgres?imgurl=http://www.statiflo.net/images/logo_bhrgroup.gif&imgrefurl=http://www.statiflo.net/cgi-bin/page.pl?PageID=71&LanguageID=1&h=46&w=200&sz=3&hl=en&start=1&tbnid=Ff8UdDPLj-W-pM:&tbnh=24&tbnw=104&prev=/images?q=bhr+group+logo&svnum=10&hl=en&lr=&sa=G

http://www.columbia.edu/

http://images.google.co.uk/imgres?imgurl=http://amol.org.au/guide/images/instn/jpg/V429.jpg&imgrefurl=http://amol.org.au/guide/instn.asp?ID=V429&h=200&w=200&sz=53&hl=en&start=2&tbnid=trBBKk7bvFMGEM:&tbnh=104&tbnw=104&prev=/images?q=University+of+Melbourne++logo&svnum=10&hl=en&lr=&sa=G


Example: Fouling in Cooling Systems

Participating Organisations

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• About ESDU









• Q&A


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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)

9


How does hydrocarbon burning contribute

to CO2 emissions?

10

One tonne of hydrocarbon burned releases 2.5 – 3 tonnes of CO2


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


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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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


Remainder of Slides ….

14

STORAGE

HEATING

DISTILLATION

Copyright © 2011 IHS Inc. All Rights Reserved. 15


The heated crude needs a

“blast” in the furnace prior to

distillation $$$

$$$

$$$

$$

$

CO2


What is the biggest cause of inefficiency in

heat exchangers?

17

Fouling!

Dirt deposits build up on clean tubes, and

efficiency plummets!!


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!



CO2


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


Cleaning! Major maintenance issue

20

Fouling!


efficiency plummets!! Picture; Wellman Hunt

Graham


Cleaning! Major maintenance issue

21

Fouling!


efficiency plummets!! Picture; Wellman Hunt

Graham


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!




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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Oil Industry Fouling Working Party

members

Oil company members of the IHS ESDU Oil Industry Fouling Working Party – CROF1

http://www.bp.com/home.do?categoryId=1&contentId=2006973

http://www.chevron.com/

http://www.conocophillips.com/

http://www.total.com/en/home_page/

http://www2.petrobras.com.br/portugues/index.asp

http://www3.imperial.ac.uk/portal/page?_pageid=36,32574&_dad=portallive&_schema=PORTALLIVE

http://www.bath.ac.uk/

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


• About ESDU









• Q&A


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• 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



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

http://www3.imperial.ac.uk/portal/page?_pageid=36,32574&_dad=portallive&_schema=PORTALLIVE



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…

http://www.chevron.com/


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


IHS ESDU - Bridge between University Research and Oil Industry

32


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


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


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?


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


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


Questions?

Send questions and

requests for

information to:

[email protected]

mailto:[email protected]

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