Creating Value in Refinery, Petrochemical and Fertilizer ... · PDF fileCreating Value in...

Creating Value in Refinery, Petrochemical and Fertilizer Applications

#GEAM17 #FueltheFuture

Meeting downstream key applications’ challenges

Paolo PecchiEngineering Director Downstream

GE Oil & Gas

Meeting downstream key applications’ challenges

Fertilizer Petrochemical

RejuvenateInnovate

Modularize

Refining: Complexity + Economy

of scale driving growth...

oversupply adding pressure on

margins

Petrochem: Ethylene shortages,

cost advantage feedstock &

healthy integrated margins drive

growth

Fertilizer: Lower ammonia &

Urea prices + oversupply add

pressure on producer's margins...

demand expected increase as of

Refinery

Developments by Product

Steam turbines• Train Modularization• Package Redesign• New Scalable Platforms• Power Density

Multistage centrifugals• Power Density HPRC• Durable Coating solutions• High efficiency Impellers

for Integrally gearcompressors

Overhung compressors• High flow/head impellers• Movable IGV• Anti-fouling features

API 618 Reciprocating• Power Density• New cylinder technology

Pumps• High diffuser pumps family

evolution• High efficiency solutions for

fertilizer

Valves• Flow path optimization• Adv diagnostics and

intelligence• Sustainable design

Steam Turbines

• Train Modularization (Refinery)

• Package Redesign (Electrification)

• New Scalable Platforms (Refinery)

• Power Density (Flow path development)

Machinery SelectionProject Specs + Modules=

Refinery: Hydrogen Recycle

2 4 6 8 10

Steam Turbine

10 000

20 000

30 000

40 000

50 000

60 000

70 000

80 000

BCL300 BCL350 BCL400 BCL450 BCL500 BCL600

m3/h Compressor

SNC1-2/SC1-4

SNC1-3/SC1-6

SNC1-4/SC1-8

Hydrogen Recycle Modules

Recycle Module + | RMRecycle Module | RM Recycle Module ++ | RM

++Back-Pressure Condensing Condensing CondensingBack-Pressure Back-Pressure

8.0 x 4.0 m

44 to 69 tons

9.0 x 4.5 m

30 to 50 tons

SNC1-2/SC1-4 + BCL300/350/400 SNC1-3/SC1-6 + BCL350/400/450

44 to 78 tons

10.0 x 4.5 m

SNC1-4/SC1-8 + BCL450/500/600

Modular Concept Benefits Quick and cost effective solution

Application oriented design

Pre-engineered design

Plug and play, Fast delivery/erection

Valves Electrification

max 30 % oil consumption: no control & trip oil flow required

90% equipment for actuation: control & trip oil system eliminated

maintainability: eliminates oil flushing and filters maintenance

reliability: self-contained design eliminates water and air contamination

Trip ValveControl ValveCurrent Design

• 30% Weight

• 15% Bearing Span

Enable Power Density

• 20% Rotating Speed

Advanced Flow Path

• Simplified steam path

• Best in Class Efficiency

Refinery Steam Turbine Light Platform

Refinery Light Platform – Technology Overview

Advanced Seals• Abradable seals

• Brush seals

• Back spring laby seals

• Traditional strips seals

Advanced HP/IP Stages• Best in class efficiency

• Higher load stages

• 35% blade count

High Speed LP Stages• 20% speed

• 6 pts efficiency

• Scaled down from existing HS family

Centrifugal Compressors

• Power density HPRC (H2 Recycle)

• Coating solutions (3 in 1 Fouling, Erosion, Corrosion)

• Overhung compressors (DH, D series)

BENEFITS:

7 Impellers

7 Diaphragms

1 Size each machine

2% Steam consumption

Baseline

BCL1209 BCL1009 BCL1207

BCL1006 BCL807 BCL1005

STEAM TURBINE

15% smaller footprint and 20% lighter weight

Large multi-phase H2 RecycleHigh Pressure Ratio Compression

Coating Solution IP9188 Sermalon® ENP

Coating type Organic

Topcoat :

Organic

Bond coat:

Metallic-Organic

Metallic

organic

Metallic

Application

methodSpray Spray Bath Immersion

Fouling

resistanceHigh High Medium High Medium

Erosion/abrasion

resistancePoor Poor High Medium High

Corrosion

ProtectionMedium Medium High High High

Baseline solutions Alternative coatings

No geometry

coverage

limits!

Sermalon®

Hydrophilic

ENP+nPTFE

Highly Hydrophobic

1. Higher hydrophobicity

2. Improved erosion

Cracks at the interface

PTFE top coatOrganic layer

Al/Mg bond coat

ENP+PTFE: Fouling & Wear resistant

Base material

ENP + PTFESermalon®

Thight

adhering ENP

3. Improved adhesion & corrosion

3 in 1 Coating Against Fouling – Erosion – Corrosion

DH Series – Product update

Technical Developments

• High Flow: polytrophic efficiency up to

• Movable IGV: 20 efficiency pts at

closed angles

• Built-in antifouling features

• impellers by single piece technology

Robust & Referenced

• Rugged construction and standard

frames

• Easy maintenance: pull-out design

• Unipol LLDPE qualified

• >200# in petrochemical applications

D Series – Product Rejuvenation

Reliable

• Superior availability vs fans and integral gear units

• Designs based on API and other industry standards

Proven Technology

• 500+ units in Refinery, Petrochem, Industrial

service

• Structured frames with low cost single stage design

Performance

• 1600 – 600,000 m3/hr flow rate

• Single piece high head impellers, up to 13,700 m

• Product upgrades: Recent case with +6% efficiency

in soda-ash application

Reciprocating Compressors

• Power density

• New cylinder technology

Power Density Technology in Reciprocating compressor

Market trends:

flow rates with # of units

Footprint and plant layout with Availability & Reliability

Benefits:

• Scaled up compressor: 25% load

capability

• 2 cylinder on a current configuration

• efficinecy up to 4%

Power density

philosophy

Parametric design

Technology and testing+ lower number of high

efficiency cylinders=

New Cylinder Technology

Fast & robust development of dedicated cylinders for all application

optimization

Casting

simulation

Machining

simulation

Test validation

Indicated power reduction

up to 4% measured and

validated on Florence test

Rig (Gas: N2)

Carlo Del VescovoProduct Leader Pumps

GE Oil & Gas

• High efficiecy solutions for fertilizer

• High diffuser pumps family evolution

High efficiency pumps for fertilizers market

Hydro TurbineClutch Pump

Turbine

+4 pts+6 pts -1400 kg/hrof Steam

#Rank 1 in Life Cycle Cost

High efficiency pumps for fertilizers market

Project Scope:

#12 Semi Lean pumps

• #4 trains HPRT-CL-CP-GB-ST

• #4 trains HPRT-CL-CP-EM

• #4 train CP-EM

#8 Lean pumps

• #2 trains CP-GB-ST ;

• #6 trains CP-EM Main efficiency enablers• Ultra-Optimized Hydraulic design

• Wear Rings in composite materials

Project challenges• 14 string test performed

• 20 skids delivered in short cycle.

Plant expected saving $0.5M/yr(*) (*) Rs/KWH 7

RS/MT 2000

Fx RS/$ 1,15

High Power Diffuser Pumps

arrangements

BB5 Barrel Diffuser pumps BB4 Ring Section Diffuser pumps

Main Benefits

• Ultra-Reliability driven by oil and gas API 610 compliant design.

• Flexibility aligned with multiple «Start and Stop» per day.

• Design aligned with Max Theoretical efficiency.

• Customized solutions applicable to each item within pump skid edge.

Up to ~6MWUp tp ~10MW

High Speed BB5 Diffuser pumps for Refinery

Accurate Balancing of entire rotor granted ... API fully compliant

Train configuration EM – GEAR - PUMP

Application Water Washer

Material Class S8

Rotational Speed 5450 rpm

BB5 Diffuser pump

Balancing of entire rotor

Reliability

Control Valves

Stephen James Sales Director Flow and Process Technologies

GE Oil & Gas

• Innovation for advanced refining processes

Building on 130+ years of experience and over 1,000,000 operational

valves in refining and petrochemical plants…How can we do it better?

Desalter

LPGGas Plant

Methane, Propane, Butane

Gasoline

Jet Fuel

Diesel

Hydrotreating

Resid-Hydrocracking

Resid-Hydrotreating

Coking

Hydrocracking

Catalytic Dewaxing

Catalytic Cracking

Light Straight Run Gasoline

Naptha

Kerosene

Middle Distillate

Atm. Gas Oil

heric D

istilla

Lube Oil

Vac. Gas Oil

Gasification

Resid-FCC

Feed Surge

Stripper/Fractionator

Hydrogen Makeup

Compressor

Washwater

Hot High

Pressure

Separator

Cold High Pressure

Separator

Charge

Feed/Effluent

Exchangers

Reactor

Recycle Gas

Compressor

RGC KO

HP Amine

Contactor

HHP Separator

Cooler

Recycle Gas

Exchanger

Charge

Heater

Nitrogen

Booster

Residue Hydrocracking:

74000 series

Application Challenges:

• High Pressure (200+ bar)

• High Particulate Content

• Heavy Erosion

• Flashing

• Outgassing

• Significant Catalyst Carryover

Valve Design Criteria:Single stage trim with streamlined flow

passage to reduce erosion.

Extremely hard trim material.

Traditional Hydrocracking:

77000 series

Application Challenges:

• High Pressure

• Flashing

• Outgassing

• Cavitation

• Particulates

Valve Design Criteria:Multi-Stage trim to minimize cavitation

and contain flashing and off-gassing.

Hydrocracker Hot High Pressure Separator Letdown

Original Top

Entry Design

2100 kg

Original

Bottom Entry

Design 77001

1700 kg

Original Top

Entry Design

2100 kg

Original

Bottom Entry

Design 77001

1700 kg

DESIGN

1000 kg

40 – 50% Mass Reduction Reduced CAPEX

Reduced piping support expense

Easier removal for maintenance

Creating Value in Refinery, Petrochemical and Fertilizer ... · PDF fileCreating Value in...

Documents

Transcript of Creating Value in Refinery, Petrochemical and Fertilizer ... · PDF fileCreating Value in...

New Energy and Industrial Technology Development …Myanmar Myanma Petrochemical Enterprise, Ministry of Energy No. 3 Kyaw Zwa fertilizer factory of Myanma Petrochemical Enterprise

Integration of Petrochemical and Refinery Plants as an ... · Process integration ... petrochemical plants) Utility integration (heat, ... Integration of Petrochemical and Refinery

CIPD Objectives / Deliverables · 2018-05-15 · Hydroelectric Power Plant Infrastructures A Major Port Facility Dam Fossil Fuel Power Plant Petrochemical Refinery Petrochemical Tank

NSRP Refinery and Petrochemical Complex Project Coarse QRA ... · NSRP Refinery and Petrochemical Complex Project Coarse QRA ‘Bidder 1’ Prepared for Foster Wheeler Energy Ltd

LIMS in Petrochemical & Refinery Industriesapps.thermoscientific.com/media/SID/Informatics/PDF/PREZ... · 2011-04-05 · LIMS in Petrochemical & Refinery Industries Steve Kemp –

Read PDIL Official Notification. - Shine · Fertilizer/ Oil & Gas/ Refinery/ Petrochemical/ Chemical industry. Must ... Candidate should have experience of Smart Plant – P&ID software

Handbook on IWS for the Petrochemical and Refinery Sector

Filtration Applications for thejonellin.w12.wh-2.com/Uploads/Groups/117/DocumentGallery...Filtration Applications for the Refinery & Petrochemical Industry 2 In the Refinery and Petrochemical

Barrel Pump for the Refinery and Petrochemical Industries · PDF fileBarrel Pump for the Refinery and Petrochemical Industries Features and Benefits Generous Shaft Diameter results

Refinery & Petrochemical Power Generationassetmatrixenergy.com/asset/wp-content/uploads/2014/05/AMESL-LIN… · Refinery & Petrochemical Power Generation ... integrity and honesty

Engineers India Limited Value Addition through Refinery and Petrochemical Integration.

Refinery/ Petrochemical Integration An option or a ... Petrochemical Integration – An option or a necessity? ... •Who’s next in line for turmoil and production disruption? ...

Merger of Deepak Fertilizer & Petrochemical Corporation Ltd (DFPCL) and Mangalore Chemical Fertilizer Ltd (MCFL)

Refinery & Petrochemical Integration- An IOCL Perspective

Profit Pivot Points in a Refinery-Petrochemical Integrated ...

Rapid market swings create shifting economics for refinery-petrochemical integration

Future Refinery FCCs Role in Refinery Petrochemical Integration

Refinery A TS TEAM Petrochemical Nuclear Power Hydro Refinery Petrochemical ... Proposed Establishment of Advance Test Lab With Facility ... Petrochemical Nuclear Power Thermal Power

Refinery Pivot Points in a Refinery Petrochemical ...

Petrochemical Feedstocks The refinery products are: naphtha; gas oil and catalytic cracker gases. NOTE: In oil industry: gasoline fraction In petrochemical.