24
Revamp of SEA CDU HEN
ERTC EE Conference, Brussels, May 15, 2014
Eva Andersson
Market Manager Refinery
Alfa Laval Lund
www.alfalaval.com © Alfa Laval Slide 3
Content
• Optimize CDU Revamping
– Objectives
• Welded PHE
– Key Features,
– Comparison w S&Ts
– Market penetration
• Case study
– Revamp of SEA CDU HEN – Hydroskimming refinery
www.alfalaval.com © Alfa Laval Slide 4
Max Production
Lowest CAPEX
Best Energy Efficiency
Highest Availability
Optimize CDU Revamping On available plot space…
Objectives
www.alfalaval.com
Why Welded PHEs? Key features
• Maximum efficiency on minimum
plot space and lowest weight
• Maximum ROI
• Minimum operating cost
– Energy & Utility
• Maximum uptime
• Minimum cleaning & repair cost
© Alfa Laval Slide 5
www.alfalaval.com
Why Welded PHEs? Comparison with S&T technology
PROPRIETARY INFORMATION 6
• Compact and light weight
4000 m2 S&T HTA* fits in 2,9 m2 plot space
5-10 x less flooded weight
• High energy efficiency
Temperature approach of 3-5°C
3-5 x higher heat transfer efficiency
• Low fouling tendency & easy to clean
3 times longer operating period in-
between maintenance
1-3 days of down-time for cleaning
• Corrosion-free material,
no inter-plate gaskets
* Equals 850 m2 WPHE area
www.alfalaval.com © Alfa Laval
Introduced in beg of 90’s, gaining market share since beg 00’s
0
50
100
150
200
250
1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012
No HXs p.a.
Year
Total ADU/VDU
Annual volume of
around 200 HXs
Why Welded PHEs? A well-proven technology...
www.alfalaval.com © Alfa Laval
40% of all delivered HXs are for ADU/VDU processes, first introduced in 1994-6
0
100
200
300
400
500
600
700 No HXs
80% of HXs
delivered
Why Welded PHEs? Used in all major refinery processes...
www.alfalaval.com © Alfa Laval
Installations in 50 countries, industry standard in Russia
W Eur Germany
USA
Italy
Russia
S & L Am
Canada
NE Asia
E Eur
Brazil
SEA
ME
China
Australia India
0
100
200
300
400
500
600
700
1990 1992 1994 1996 1998 2000 2002 2004 2006
No HXs
Year of Introduction
50% delivered to
BRIC countries
Why Welded PHEs? In most countries...
www.alfalaval.com
Revamp of SEA CDU HEN Background – 50 kbbl/day hydro-skimming refinery
PROPRIETARY INFORMATION 10
150
50
kbbl/d
140
137 142 105 110 139
115 138
113
141
136
HS Legend:
Preflash OVHD
Kero Prod
Kero PA
Diesel Prod
Diesel PA
LSWR
108
112
Untapped Energy Recovery Potential! P
re-f
lash
er
Desalter
Internal energy audit in 2009 by refinery process engineers identifies
possibility to recover more energy from the LSWR in the last heat recovery
position before the fired heater
www.alfalaval.com
Revamp of SEA CDU HEN Energy efficiency improvement – Design conditions
© Alfa Laval
Preheated Crude
~350°C
Preflashed
Crude
LSWR
~235°C
~210°C
~240°C
5.5 MW
19 MW
© Alfa Laval
Preheated Crude
~350°C
Preflashed
Crude
LSWR
~300°C
~210°C
~230°C
2.3 MW
22 MW
From this To this
www.alfalaval.com © Alfa Laval Slide 12
Revamp of SEA CDU HEN Mitigation of technical risk, installation in 2010
Kept in stand-by mode!
New main exchanger!
www.alfalaval.com © Alfa Laval Slide 13
Revamp of SEA CDU HEN Thermal Performance, start-up in Nov 2010
www.alfalaval.com © Alfa Laval Slide 14
Revamp of SEA CDU HEN Hydraulic Performance, start-up in Nov 2010
www.alfalaval.com © Alfa Laval Slide 15
Revamp of SEA CDU HEN Project pay-back and Energy improvement
www.alfalaval.com © Alfa Laval Slide 16
Max Production
Lowest CAPEX
Best Energy Efficiency
Highest Availability
Optimize CDU Revamping On available plot space…
Objectives
www.alfalaval.com
• Fouling problems in the CDU HEN
• Waxy fouling on crude side gives
hydraulic limitations -> throughput
reduced w 15% at EOR
• Cleaning is required for 10 days every
10 months when the process has to be
shut down
• They plan to add stand-by heat
exchangers and isolation facilities to
enable on-line cleaning for the most
fouling positions.
• Due to minimal plot space, they want to
use Welded PHEs for all stand-by
exchangers
© Alfa Laval Slide 17
Revamp of SEA CDU HEN Parallel Train project, starting in 2011
Max Production
Highest Availability
Objectives
www.alfalaval.com
• Process consultant = Actsys is hired
• Actsys suggests they not only add
stand-by heat exchangers, but that
the WPHEs will be the main
equipment and that with the help of
these they will improve the poor
energy efficiency of the process
• Hysys model comprising Crude PHT,
Pre-flash column, Furnace, Main
crude column + H Naphtha, Kero, L &
H Gasoil stippers and CDU OVHD &
Stabilizer column was used
• Actsys, Mecip (Engineering) and Alfa
Laval together optimized the energy
efficiency for best project ROI
© Alfa Laval Slide 18
Revamp of SEA CDU HEN Parallel Train project, starting in 2011
Lowest CAPEX
Best Energy Efficiency
Objectives
www.alfalaval.com PROPRIETARY INFORMATION 19
150
50
kbbl/d
140
137 142 105 110 139
115 128
113
141
136
HS Legend:
Preflash OVHD
Kero Prod
Kero PA
Diesel
Diesel PA
LSWR
108
112
Pre
-fla
sh
er
Desalter
Revamp of SEA CDU HEN Changes to existing CDU HEN
233 deg C
www.alfalaval.com PROPRIETARY INFORMATION 20 PROPRIETARY INFORMATION 20
50
kbbl/d
112
A/B
HS Legend:
Preflash OVHD
Kero Prod
Kero PA
Diesel
Diesel PA
LSWR
108
A/B
Pre
-fla
sh
er
C-1
16
Desalter
E137B E105C E139B E142C
E140B
E136B
E141B
251 deg C
39 deg C 67 deg C 93 deg C 98.5 deg C 131 deg C
150 deg C 201 deg C 225 deg C
208 deg C
229 deg C
Revamp of SEA CDU HEN New lay-out of CDU HEN
www.alfalaval.com © Alfa Laval Slide 21
Revamp of SEA CDU HEN Performance, PHT inlet pressure
20
22
24
26
28
30
32
34
10/04/2013 10/05/2013 10/06/2013 10/07/2013 10/08/2013 10/09/2013 10/10/2013 10/11/2013 10/12/2013
barg
Old performance
New performance
www.alfalaval.com © Alfa Laval Slide 22
Revamp of SEA CDU HEN Performance, CIT
220
225
230
235
240
245
250
255
260
11/10/2012 11/11/2012 11/12/2012 11/01/2013 11/02/2013 11/03/2013 11/04/2013 11/05/2013
degC
Last cycle before project commissioning
Start-up
www.alfalaval.com © Alfa Laval Slide 23
Project pay-pack calculation
Compabloc cost (6 items), kUSD 1 400
Total project cost, kUSD 3 500
Max production, kUSD* Avoiding throughput decline of 15% at EOR
700
Uptime savings, kUSD*: Avoiding shut-down every 10 months for 10 days
250
Energy savings, kUSD*: Raising CIT from 233 -> 251 degC
1 000
Total savings, kUSD 2 000
Project pay-back time 21 months
* Assuming furnace fuel cost of 40 USD/bbl and refinery margin of 50 cents/bbl
Revamp of SEA CDU HEN Project economics
www.alfalaval.com
Summary
PROPRIETARY INFORMATION 24
By using Welded PHEs, it is possible to
Maximize Energy efficiency
on Minimal Plot space
Maximize uptime & production capacity
Maximize project ROI
Around 500 WPHEs in CDU HENs in 60 different sites!
