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FOULING MANAGEMENT IN CRUDE OIL PREHEAT …€¦ · · 2018-02-13FOULING MANAGEMENT IN CRUDE OIL...
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FOULING MANAGEMENT IN CRUDE OIL PREHEAT TRAINS/DHP UNITS
Presenter: Metin BECERProcess Superintendent
Turkish Petroleum Refineries Corporation15/11/16 Lisbon-Portugal ERTC
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Kırıkkale Rafinerisi CCR Ünitesinin Modellenmesi
&Oktan Optimizasyonu
• Petroleum Refinery
• Total of 28,1 M ton refining capacity with 4 refineries
• Privatized in 2006 and owned by Koc Holding (%51)
Turkey’s LeadingIndustrial Enterprise
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Kırıkkale Rafinerisi CCR Ünitesinin Modellenmesi
&Oktan Optimizasyonu
44
55
OUTLINE of the Presentation
The Fouling problem in the Refinery Units
1. The Crude Oil Units,
2. The DHP Units
TUPRAS solution for the FOULING MONITORING
Details about the HEXMON programme
FOULING MANAGEMENT INCRUDE OIL PREHEAT TRAINS
77
FOULING PROBLEM
Fouling in heat exchangers is one of the major problems in chemical process
industries.
In refineries, considered as the main source for energy loss, reaching up to
2% of the refinery’s total energy consumption.
Profound interest in minimizing the energy consumptions due to the
challenging refinery margins
Decrease in thermal and hydraulic performance of the heat exchangers
Higher heat load is required in the furnace which leads more fuel gas/ fuel oil
consumption in the furnace
Increase in greenhouse gas emissions
88
FOULING PROBLEM (cont’d)
E 7108 E 7109 E 7110
E 7115 E 7116 E 7117
E 7111
E 7119E 7118 E 7120
E 7113
Fouling in the crude oil preheat trains is considered as ~20% of all heat exchanger
fouling.
In the current process, the crude oil is being heated via products (and pump-around
streams in first and second pre-heat exchanger trains prior to furnace.
In order to reduce the energy consumption in the furnace, the efficiency of the heat
exchangers in the preheat trains is very crucial.
99
FOULING (cont’d)
Fouling is mainly defined as the formation of deposits on heat exchange surfaces due to sedimentation, crystallization, organic and biological growths, chemical reactions, corrosion products, or their combination ..
The deposit formation due to chemical reactions may be complex in nature, and will include several mechanisms such as autoxidation, polymerization, cracking or coke formation.
If there is ambient oxygen, it will catalyze the gum formation which is usually seen in hydro-processing units.
Gum-like material will also be observed in jet fuel, gas oil and similar products upon heating due to the precipitation of paraffinic hydrocarbon mixtures. Thus, temperature, pressure and flow rate are important operating parameters which affect the fouling formation.
Usually, the temperature increase will lead to an exponential increase in the chemical reaction rates; pressure increases the solubility of the oxygen thus will increase the gum formation rate. Flow rates, however, will have a reverse effect such that higher velocities make it difficult for deposits to attach to the surface.
1010
R&D in TUPRAŞ Refineries
R&D study has been started in the refinery in order to find a better way to monitor the fouling in HEAT EXCHANGERS (CRUDE OIL and DHP units)
The study has been continued both for CRUDE OIL and DIESEL HYDROPROCESSING UNITS and as well as the all prone to fouling heat exchangers throughout the refinery,
The study has been partially sponsored by the government
The main findings related with the CRUDE OIL/DHP plants will be shared in this presentation
The main aim is to monitor the fouling, (to find out the reasons behind the fouling, to make a fouling model for the units) and to estimate and to optimize the cleaning periods of the exchangers
1111
STUDIES ON CRUDE OIL UNIT SITE
1212
ANALYSIS ON SITE
All the exchangers are bypassed
Mechanically cleaned
Steam outed, and the thermocouples
are installed
1313
ANALYSIS ON SITE
1414
ANALYSIS ON LABORATORY
HPLC Total Aromatics ANTEK 9000 S Sulphur Content
ASTM D86- Atm. Distillation Crude Oil Acid/Base
Number
Oxygen Content
Anton Paar
Black Product Density
Anton Paar
White Product Density
In order to calculate the physical properties of the crude oil and product streams and
therefore to better evaluate the parameters effecting to the fouling mechanisms a R&D
laboratory has been established.
1515
SOFTWARE DEVELOPMENT
A Software has been developed by Tupras engineers
Sample screenshot is shown below
1616
SOFTWARE DEVELOPMENT
In the software,
Simple components, hydrocarbon mixtures and petroleum fractions have
been identified
All the physical properties (density, boiling point, condensation point,
viscosity, dew point, vapor pressure, thermal conductivity) of the
components with respect to different operational conditions can be
calculated in the software
All the relevant exchangers has been identified in terms of Data Sheet
specifications,
The algorithm has been adapted in order to calculate the fouling factor of the
heat exchangers in the real time operational conditions (temperature,
pressure, flow, distillation data) and by taking the heat exchangers design
specifications into consideration.
1717
FOULING MANAGEMENT ALGORITHM
ALGORITHM calculates the Uc (clean
heat transfer coefficient) for the heat
exchangers at the operational
conditions by using Kern (tube side)
and Bell-Delaware (shell side)
approaches
THEN, the fouling factor (Rf) for the
heat exchangers are calculated by
using the Ud (calculated from the
operational data)
A METHOD for MONITORING Rf is
developed.. Needs an exact
knowledge of the overall thermal
resistance of the exchangers in the
same flow and operational conditions,
but not fouled
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SIMULATION RESULTS, a Comparison
The output of the programme has been compared with the commercial
software when the exchangers are clean, Rf = 0 (just after maintanence),
Both for 1st and 2nd preheat trains, the simulated tube-shell outlet temperatures
are in well coincidence with the real data and as well as the commercial
outputs.
1919
SIMULATION RESULTS (cont’d)
Operational tube outlet temperatures of the clean heat exchangers were
found to be consistent with the calculated outlet temperature
Software is capable of simulating the clean case.
Also observed that the results of the software were closer to the operational
data in comparison to the commercial software in SOR conditions
2020
CRUDE OIL UNIT 1ST PREHEAT TRAIN
2121
SIMULATION RESULTS, CRUDE OIL
1st PREHEAT TRAIN SIMULATION RESULTS
Simulation result of crude oil-mid pumparound heat exchanger after
the cleaning time to 1 year period
-0,008
-0,006
-0,004
-0,002
0
0,002
0,004
0,006
0
20
40
60
80
100
120
140
160
26.2.11 17.4.11 6.6.11 26.7.11 14.9.11 3.11.11 23.12.11 11.2.12 1.4.12 21.5.12 10.7.12
Sıca
klık
( C
)
E 7107
Tube Outlet Temp Tube Outlet Temperature Simulation Result Rf
-0,008
-0,006
-0,004
-0,002
0
0,002
0,004
0,006
0
20
40
60
80
100
120
140
160
26.2.11 17.4.11 6.6.11 26.7.11 14.9.11 3.11.11 23.12.11 11.2.12 1.4.12 21.5.12 10.7.12
Sıca
klık
( C
)
E 7107
Shell Outlet Temp Shell Outlet Temperature Simulation Result Rf
2222
SIMULATION RESULTS, CRUDE OIL
1st PREHEAT TRAIN SIMULATION RESULTS for Rf values
-0,001
0
0,001
0,002
0,003
0,004
0,005
0,006
11.2.2012 1.4.2012 21.5.2012 10.7.2012 29.8.2012 18.10.2012 7.12.2012 26.1.2013 17.3.2013 6.5.2013 25.6.2013
Rf-7107
Simulation result of crude oil-mid pumparound heat exchanger after
the cleaning time for 1 year period.
2323
Rf values (2013-2016)
2424
SIMULATION RESULTS, CRUDE OIL
1st PREHEAT TRAIN SIMULATION RESULTS
IMPACT of INORGANICS, METAL, API ETC..
Subject of Phase II study of this project
20
25
30
35
40
45
6.6.11 26.7.11 14.9.11 3.11.11 23.12.11 11.2.12 1.4.12 21.5.12 10.7.12
Tuz
( m
g/L)
SALT
25
27
29
31
33
35
37
39
6.6.2011 26.7.2011 14.9.2011 3.11.2011 23.12.2011 11.2.2012 1.4.2012 21.5.2012 10.7.2012
API
2525
2nd PREHEAT TRAIN
Atm resid is 360 C, crude oil is around 200 C
2626
SIMULATION RESULTS
2nd PREHEAT TRAIN SIMULATION RESULTS
0
0,001
0,002
0,003
0,004
0,005
0,006
0,007
0,008
Rf E-7113
Simulation result of crude oil-atm resid. Heat exchanger after the
cleaning time to the mid 2012
-0,002
-0,0015
-0,001
-0,0005
0
0,0005
0,001
0,0015
0,002
0,0025
0
50
100
150
200
250
0.1.00 19.2.00 9.4.00 29.5.00 18.7.00 6.9.00 26.10.00 15.12.00 3.2.01 25.3.01
Sıca
klık
( C
)
E 7119
Tube Outlet Temp Tube Outlet Temperature Simulation Result Rf
Simulation result of crude oil-Mid PA. Heat exchanger after the
cleaning time to the mid 2012
0
0,0005
0,001
0,0015
0,002
0,0025
0,003
0,0035
0,004
0
50
100
150
200
250
26.2.11 17.4.11 6.6.11 26.7.11 14.9.11 3.11.11 23.12.11 11.2.12 1.4.12 21.5.12 10.7.12
Sıca
klık
( C
)
E7118
Tube Outlet Temp Tube Outlet Temperature Simulation Result Rf
Simulation result of crude oil-heavy diesel Heat exchanger after the
cleaning time to the mid 2012
0
0,0005
0,001
0,0015
0,002
0,0025
0,003
0,0035
0
20
40
60
80
100
120
140
160
180
200
26.2.11 17.4.11 6.6.11 26.7.11 14.9.11 3.11.11 23.12.11 11.2.12 1.4.12 21.5.12 10.7.12
Sıca
klık
( C
)
E 7117
Tube Outlet Temp Tube Outlet Temperature Simulation Result Rf
Simulation result of crude oil-bottom PA. Heat exchanger after the
cleaning time to the mid 2012
-0,001
0
0,001
0,002
0,003
0,004
0,005
0
20
40
60
80
100
120
140
160
180
26.2.11 17.4.11 6.6.11 26.7.11 14.9.11 3.11.11 23.12.11 11.2.12 1.4.12 21.5.12 10.7.12
Sıca
klık
( C
)
E 7116
Tube Outlet Temp Tube Outlet Temperature Simulation Result Rf
Simulation result of crude oil-heavy diesel Heat exchanger after the
cleaning time to the mid 2012
-0,03
-0,025
-0,02
-0,015
-0,01
-0,005
0
0
50
100
150
200
250
26.2.11 17.4.11 6.6.11 26.7.11 14.9.11 3.11.11 23.12.11 11.2.12 1.4.12 21.5.12 10.7.12
Sıca
klık
( C
)
E 7110
Tube Outlet Temp Tube Outlet Temperature Simulation Result Rf
Simulation result of crude oil-light diesel Heat exchanger after the
cleaning time to the mid 2012
-0,02
-0,01
0
0,01
0,02
0,03
0
50
100
150
200
250
26.2.11 17.4.11 6.6.11 26.7.11 14.9.11 3.11.11 23.12.11 11.2.12 1.4.12 21.5.12 10.7.12
Sıca
klık
( C
)
E 7109
Tube Outlet Temp Tube Outlet Temperature Simulation Result Rf
Simulation result of crude oil-atm. resid Heat exchanger after the
cleaning time to the mid 2012
-0,004
-0,0035
-0,003
-0,0025
-0,002
-0,0015
-0,001
-0,0005
0
0
20
40
60
80
100
120
140
160
180
26.2.11 17.4.11 6.6.11 26.7.11 14.9.11 3.11.11 23.12.11 11.2.12 1.4.12 21.5.12 10.7.12
Sıca
klık
( C
)
E 7108
Tube Outlet Temp Tube Outlet Temperature Simulation Result Rf
Simulation result of crude oil-top PA. Heat exchanger after the
cleaning time to the mid 2012 (totally 1 year)
2727
SIMULATION Rf results (2nd train)
2828
SIMULATION RESULTS, CRUDE OIL
2nd PREHEAT TRAIN SIMULATION RESULTS
IMPACT of ASPHALTENES, SULPHUR, API, SURFACE TEMPERATURE,
ATM. RESID ETC..
Subject of Phase II study of this project
0
0,5
1
1,5
2
2,5
6.6.11 26.7.11 14.9.11 3.11.11 23.12.11 11.2.12 1.4.12 21.5.12 10.7.12
Asf
alte
n (
% M
/M)
ASPHALTENE
0,000
0,500
1,000
1,500
2,000
2,500
3,000
3,500
6.6.11 26.7.11 14.9.11 3.11.11 23.12.11 11.2.12 1.4.12 21.5.12 10.7.12
Kü
kürt
( %
M/M
)
SULPHUR
25
27
29
31
33
35
37
39
6.6.2011 26.7.2011 14.9.2011 3.11.2011 23.12.2011 11.2.2012 1.4.2012 21.5.2012 10.7.2012
API
FOULING MANAGEMENT INDHP Unit PREHEAT TRAINS
3030
ANOTHER STUDY
TUPRAS has also completed another study in DIESEL
HYDROPROCESSING UNIT HEAT EXCHANGERS FOULING
Dealing with the FOULING mostly due to oxygen in the imported diesel feed
and also refinery cracked diesel streams
3131
DHP Unit preheat exchangers
3232
DHP Unit preheat exchangers
Subject to FOULING (due to autoxidation and free radical polymerization
reactions) especially when having feed from storage or cracked feed stocks
Have a huge impact on furnace duty/unit cycle time
Careful MONITORING is a MUST
3333
DHP PREHEAT EXCH. Rf values (2006-2016)
FINALLY UNDER CONTROL
Chemical treatment programme/O2
stripper column/H2 sweeping
3434
DHP PREHEAT EXCH. FOULING (2010-2016)
3535
DHP Unit preheat exchangers
Hexmon monitoring is an important tool for both the unit engineers and the
control operators and is widely used in TUPRAS refineries
The changes in feed rate/feed quality/reactor temperatures/import-storage
tank ratio/cracked feed ratio are all have impacts on the FOULING
mechanisms
The fouling trends are daily monitored and any change is noted. Thus the
furnace duty is aimed to be under control together with the catalyst
deactivation rates.
3636
RESULTS and DISCUSSION
TUPRAS owns a simulation program that has the capability of simulating the
clean overall heat transfer coefficient at the current operating conditions and
by gathering data from the real time values, calculates the FOULING
FACTOR
FUTURE STUDY: As the fouling starts to occur in the exchangers, the
parameters effecting to the fouling will be determined by laboratory analysis
program, then the fouling models will be derived, and OPTIMIZATION of
cleaning (by-passing) will be decided with a optimizer tool adapted to the
program
In the network simulation, the impact of any exchanger’s fouling and extra
duty to the furnace will be determined
A better CLEANING time schedule by REAL TIME MONITORING will mean
LESS LOSS due to FOULING
3737
SUMMARY
FOULING monitoring is a highly critical parameter for the refineries.
THEN, one may decide on the excellent time about the unit or heat
exchanger shut down/bypass by taking in to account of furnace duty.
With the help of the HEXMON programme, TUPRAS engineers are easily
adapting their critical and prone to fouling heat exchangers to the system
and routinely monitoring the fouling trends.
Widely used in all of the 4 refineries in nearly all units.
3838
Kırıkkale Rafinerisi CCR Ünitesinin Modellenmesi
&Oktan Optimizasyonu
Thank you for your time and consideration.