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

© 2017 General Electric Company - All rights reserved

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

2017

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

©2016 General Electric


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

MW

Steam Turbine

0

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


Light

• 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

HPRC

BCL1209 BCL1009 BCL1207

BCL1006 BCL807 BCL1005

STEAM TURBINE

STEAM TURBINE

15% smaller footprint and 20% lighter weight

Large multi-phase H2 RecycleHigh Pressure Ratio Compression


Coating Solution IP9188 Sermalon® ENP

ENP

+

PTFE

ENP

+

SiC

Coating type Organic

Topcoat :

Organic

Bond coat:

Metallic-Organic

Metallic

Metallic

organic

nano

doped

Metallic

nano

doped

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

ENP

ENP +

PTFE

ENP +

SiC

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

ENP

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

90%

• 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

FEA

model

CFD

model

CFD

optimization

FEA

optimization

Casting

simulation

Machining

simulation

Test validation

Indicated power reduction

up to 4% measured and

validated on Florence test

Rig (Gas: N2)


Pumps

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

Steam

Turbine

Gear

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

#Rank 1 in Life Cycle Cost


13.8m

2.5m

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

Va

cu

um

Dis

tilla

tio

n

LPGGas Plant

Methane, Propane, Butane

Gasoline

Jet Fuel

Diesel

Hydrotreating

Hydrotreating

Resid-Hydrocracking

Resid-Hydrotreating

Coking

Hydrocracking

Catalytic Dewaxing

Catalytic Cracking

Light Straight Run Gasoline

Naptha

Kerosene

Middle Distillate

Atm. Gas Oil

Atm

osp

heric D

istilla

tio

n

Coke

Lube Oil

Vac. Gas Oil

Gasification

Resid-FCC


HC

Feed

Feed Surge

Drum

Stripper/Fractionator

Hydrogen Makeup

Compressor

Washwater

Pump

Hot High

Pressure

Separator

Cold High Pressure

Separator

Charge

Pumps

Charge

Feed/Effluent

Exchangers

Main

Reactor

Recycle Gas

Compressor

RGC KO

Drum

HP Amine

Contactor

HHP Separator

Cooler

Recycle Gas

Exchanger

Charge

Heater

Nitrogen

Amine

Booster

Pumps


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

77002

2100 kg

Original

Bottom Entry

Design 77001

1700 kg



Original Top

Entry Design

77002

2100 kg

Original

Bottom Entry

Design 77001

1700 kg


NEW

DESIGN

77003

1000 kg

40 – 50% Mass Reduction Reduced CAPEX

Reduced piping support expense

Easier removal for maintenance

More sustainable solution


A) Reduced stage, axial flow, expanding trim

Tailored for Hot High Pressure Separator applications

Decreases valve sub-assembly size and cost

Maintains advantages of existing trim design

B) Reduced plug, seat, and stem diameters

Minimizes actuator thrust requirements

C) Partially balanced trim for 5-stage, high ∆P trim

Further reduces actuator thrust requirements

D) Unbalanced trim for 3-stage, low ∆P trim

Reduces trim cost without increasing required actuator thrust

E) Nested trim assembly

Minimizes clamped height for use at high temperatures

Maintains existing ease of maintenance

F) Inverted actuator linkage

Removes stem side load, improving stem life and LE performance

C

D

F

A

77003 Improved Technical Approach


Resid-Hydrocracker Hot High Pressure Separator Letdown

Original Design

3300

3-4 Year Trim Life

Seat Ring

with Outlet

Venturi

Bull Nose

Plug

Seat

Protection

with Plug

Overlap


Multi-Flow

Channel

Fluted Plug

Seat Ring

with Outlet

Venturi

Resid-Hydrocracker Hot High Pressure Separator Letdown

New Design

74000

6-8 Year Trim Life

~100% Trim Service Life Increase Reduced OPEX

Supports longer time between outages

Reduced inventory levels

More sustainable solution


A) Multi-Path Flow

The 74000 series trim utilizes multiple paths and an expanded area outlet

venture to handle the damaging service conditions

B) Minimize Erosion Damage

Trim avoids direct impingement and smoothly channels the fluid into the

expanded outlet venture to resist erosion caused by solids and heavy flashing

C) Seat Protection

Additional seat protection from the plug design. Seat sits at the tope while the

flute is the throttling surface.

D) Vibration Resistant Design

Upper and lower guiding of the plug improves operational stability and reduces

damage due to severe vibration.

E) Optimized Trim Materials

A wide range of trim materials are selected to provide a balance between

optimal trim life and cost. Advanced materials include tungsten carbide,

ceramic, Inconel, stainless steel and specialty overlays and hard-facing

technologies.

74000 Improved Technical Approach


GE Store – Learning From Each Other

Differential Velocity Device (DVD™)

Patented design uses Differential Velocity

Concept similar to commercial jet engines


Digital Transformation in Downstream

Christina WatersSenior Director Customer Solutions

GE Oil & Gas


Digital essential to unlock productivity

Productivity

• Digital thread

• Brilliant manufacturing

Apps

• Service transformation

• Digital enabled CSAs

Platforms

• Predix Industrial Internet

Operating System

• Digital twin

• Services effectiveness and

efficiencies

• Design and innovation acceleration

• Better outcomes for customers

• Optimize GE/BHI equipment

• Fullstream data analytics

• Leapfrog digital industrial transformation

• Industrial strength, cyber security, scale

• Predix Process and production

optimization

GE for GE GE for customers GE for industry

ProductivityNew offerings/

business models

New revenue

streams/markets

Delivering better customer outcomes and shareholder value


Digital Refinery Demo

#GEAM17 #FueltheFuture

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

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