GTC- Energy Service Technologies

16 April Le Meridian Hotel

New Delhi

GTC Technology Day

GTC Technology Day

GTC Energy Service Portfolio Worldwide

GTC Energy

Services

Technologies

Online Heater

Chemical Cleaning

Online Ceramic

Coating Insulation

Emissivity Coating

for Fired Heaters

Online Air Fin Cooler

Chemical Cleaning

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Online Heater Chemical Cleaning

• With rising pressure to reduce energy costs and improve refinery margins, an efficient operation of fired heaters in a refinery is extremely critical.

• GTC’s advanced online fired heater/boiler Chemical Cleaning Technology facilitates to achieve this objective by cleaning refinery heaters and boiler tubes without shutting down the plant operations.

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Heater Problems

• Fouling in convectionCaused by condensed & hardened ash

• Slag in radiationCaused by Alkali (Na, K), Metal (V, Ni, etc.) &

Compound molten ash

• Low Efficiency

Leads to higher fuel cost & lower throughput

• High Temperature Corrosion

Leads to shorter T/A interval & tube rupture

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Chemical Measures

• Principle of Chemical reaction• Increases fusion point of Alkali/Metal

compounds

• Chemical * V205: 1,100 °C (Solid)

• V205 Compounds: 600-800 °C (Molten)• Increases Breakability (crystal defect &

point defect)

• Improves tube surface by removing

debris

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Technology Comparison

Competitor GTC

Chemical Type Granule/Liquid Liquid

Injection Pressure High Low

Cleaning MethodPhys/blast direct

contact Chemical Gas flow

CoverageFull coverage

(convection/radiation)

Full coverage

(convection/radiation)

Application Small - large size Small - large size

Heater efficiency

rise~ 3% ~ 5%

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Experience2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 Total

Company Name Heater Name No of Cleaning

GS Caltex (Korea) CDU, VDU, Hydrotreater, Reformer, Aromatics, and Boiler 1 69 89 85 123 84 86 22 559

Pan Asia Korea (Korea) Boiler 4 2 6

YNCC (Korea) SM 1 1

Kumho P&B Fired Heater 2 1 3

ISU ( Korea) Pacol Charge Heater 3 3

Reliance (India) DTA/SEZ- CDU-1 & 2, VDU-1 & 2 20 5 5 3 14 8 8 3 8 8 82

HPCL Visakha (India) CDU, VDU, DHDS 2 18 7 10 18 18 73

HPCL Mumbai (India) CDU, VDU 6 10 16

MRPL (India) VDU 1 4 7 6 4 0 4 3 29

ESSAR(India) CDU, VDU, VBU ,CDU-2 1 1 1 4 12 9 9 37

PTMN Balikapapan NHT & CDU, VDU 5 6 11

FPCC (Taiwan) CDU 1 1

Tupras Izmir CDU, VBU,Hydrocracker 6 9 4 19

Tupras Izmit CDU, VDU 7 8 8 23

Orlen (Lithuania) CDU 1 8 9

TAIF CDU 1 1

Saratov CDU 1 1

Moscow CDU, VDU 5 5

Yanos CDU 2 2

Liaoyang PX(China) PX Reboiler 3 3

DAC China Aromatic Heater 5 5

889

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Heater Cleaning Performance - Overall

Furnace

Parameters

Before Cleaning After Cleaning Deviation

Feed, M3/hr 399 446 47 (12%up)

CIT, ℃ 236 237Delta T(COT-CIT)

13℃ upCOT, ℃ 349 363

BWT, ℃ 845 743 -102

Ex. Conv., ℃ 478 434 -44

Stack Temp., ℃ 198 166 -32

TST, ℃ 412 398 -14

CDU Charge heater, 31F1(HPCL Mumbai)

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Heater Cleaning Effect I - Temperature

#1 (A) 31ti315.pv 9/17/2009 11:01:12 767.18 DEGC (Avg @1 Sec) 31-F-1 CONVECTION**

900.00

600.00

9/9/2009 11:05:10 9/17/2009 11:05:1031F1 BWT Variations @ 8d0h0m0s: HPCL

MUMBAI

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Customer Feedback

• Client Feedback: HPCL Mumbai, March 2010

“…The heater is working fine and we have Increased

feed rate from 398.74㎥ /hr to 445.74㎥ /hr at BWT

743°C and we’ve got paid back within 30days 2hrs”

(Payout 30days)

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Online Ceramic Insulation Coating

• High performance ceramic- based insulation material

• VOC- free, Non-Toxic, Non-Flammable.

• Applicable to high temperature up to 1000℃ and is corrosion preventive.

• Effective insulation for difficult areas such as Flanges, Valves, Strainer, Manifold, etc.

• Installable during operation (Doesn't need shutdown).

• Reduces heater transfer due to low thermal conductivity.

• Long-lasting life and Easy to repair.

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Insulation Concept

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Online Ceramic Insulation Coating

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Online Ceramic Insulation Coating

Ceramic Coating Perlite

Material & Installation

Cost

Higher Base

Maintenance Cost Lower Base

Heat Transfer, W/m.k 0.052 0.065

Insulated Material

Corrosion

None Possible

Application Points All Difficult for irregular

points such as Flange,

etc.

Installation during

operation

Yes No (Shutdown required)

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Economics– LG Chemical- South Korea

Application : Plant

Pay Out : 0.3 Year

Location Before (℃) After (℃) Area(㎡) Thickness(mm)Effect

(kcal/hr)

Lower Flange 301 80 1.8 9.0 10,471

Upper Flange 340 49 0.9 15.0 7,170

Total 314 70 2.7 11.0 17,640

Before 301℃ After 79.8℃

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Emissivity Coating for Fired Heaters:

• Emisspro® high emissivity coatings contain materials capable of absorbing and re‐radiating thermal energy.

• Emisspro® is designed to provide high coating film strength, higher abrasion resistance, good thermal shock resistance, thermal expansion characteristics similar to their intended substrates, and adequate bond strength with the substrate.

• Emisspro® high emissivity coating is used in high temperature industrial applications such as fired heaters, furnaces, kilns and petrochemical industry, etc.

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Fundamentally, High emissivity coating helps increase emissivity which helps reduce the heat loss

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Emisspro®

High absorptivity & emissivity

Good thermal strength & Thermal shock resistance

Good chemical & Abrasion resistance

Good adhesion

Eco-friendly

Simple operation

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Emissivity coating for Fired Heater

Conventional coating Emisspro® coating

• Sintering temperature: ~1,150 °C• Low temperature:

• Physical bonding• Low strength

• High temperature: • High shrinkage• High stress at interface• Low thermal shock resistivity• Peeling-off/Short service life

• Sintering temperature: ~500 °C• Low temperature:

• Chemical bonding• High strength

• High temperature: • Low shrinkage• Low stress at interface• High thermal shock resistivity• Longer service life

GTC Technology Day

Online Air Fin Cooler Chemical Cleaning Technology:

• Air-cooled heat exchangers (AFC) frequently have heat transfer problem due to reduced air flow rate which is the single most important variable in the operation of air-cooled heat exchangers. GTC’s AFC cleaning technology can provide the effective solution to these problems during normal operation without business loss using high performing chemicals.

• AFC Chemical Cleaning: Between the scheduled turnaround periods, GTC’s AFC cleaning technology allows clients to maintain their AFC at high efficiency without any operational loss.

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Online Air Fin Cooler Chemical Cleaning Technology:

• Proprietary High Performing Chemicals: GTC proprietary chemicals detach slag/foul from the fin tube surface. The benefit of the cleaning effect has been well justified through visual inspection.

• Environmental and Damage Control: GTC uses various types of chemicals and cleaning know-how to control environmental emission and avoid any damage on AFC fin tubes. For a period of 4 years of application from different types and various processes of AFC in refinery/chemical industry, no environmental or fin tube damage has been reported.