Optimize CDU Revamping - wraconferences.com CDU Revamping CIS Conference, Baku, Dec 1-3, 2015 Eva...
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Transcript of Optimize CDU Revamping - wraconferences.com CDU Revamping CIS Conference, Baku, Dec 1-3, 2015 Eva...
Optimize CDU Revamping
CIS Conference, Baku, Dec 1-3, 2015
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
– Major CDU HEN revamp:
1 E. European refinery, CDU capacity increase & energy
efficiency
www.alfalaval.com © Alfa Laval Slide 4
Max Production Yield
Lowest CAPEX
Best Energy Efficiency
Highest Availability
Optimize CDU Revamping On available plot space…
Objectives
www.alfalaval.com
Why Welded PHEs? Key features
• Maximal
‒ Efficiency with minimal plot
space & weight
‒ Energy recovery
‒ Uptime
• Minimal
‒ Maintenance & repair
requirement
Best Project ROI
© 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
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No HXs
Year
Total ADU/VDU
Annual volume of
around 200 HXs
Why Welded PHEs? A well-proven technology...
www.alfalaval.com © Alfa Laval
45% of all delivered CPs are for ADU/VDU processes, first introduced in 1994-6
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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
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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
Russian ADU/VDUs with WPHEs
• >400 Welded PHEs in 21 different sites
– First in Rosneft Tuapse, AR/Crude (2002)
• 18 Complete ADU & VDU preheat trains
– First in Slavneft Yaroslav, VDU PHT (13 WPHEs in 2005)
• 26 OVHD condensers (ADU & VDU)
– Both for vapour condensign & crude preheating
– First in Moscow Refinery (2006)
© Alfa Laval Slide 10
www.alfalaval.com
ADU OVHD condenser Crude preheating – >70 units Country
# units Delivery
Year
MOC Status
Switzerland 2 1996 Titanium In operation
Bulgaria 2 2006 HC276 In operation
US 4 2007 & 12 SMO / HC In operation
Russia 2 2008 SMO254 In operation
China 28 2008 - 13 SMO254 / Ti 70% in operation
Croatia 5 2009 HC276 In operation
Italy 3 2009 & 14 HC276 2 in operation
Malaysia 2 2013 & 14 SMO254 In operation
Korea 4 2013 HC276 In operation
Thailand 1 2014 HC276 In operation
Singapore 2 2014 HC2000 Not yet
Spain 3 2014 HC276 In operation
Taiwan 8 2014 SMO254 Unknown
Turkey 8 2015 HC276 Not in operation © Alfa Laval Slide 11
www.alfalaval.com
CDU REVAMP IN E. EUROPE CDU capacity increase & energy efficiency
© Alfa Laval Slide 12
www.alfalaval.com
E. European Refinery CDU capacity increase & energy efficiency project
• 750 m3/h, 2 types of crude (API 29 & 36)
• Objective is to
– Increase capacity to 1000 m3/h
– Increase fired heater efficiency from 75 to 93%
– Increase CIT from 230 to 295 degC
• Basic Engineering was done in 2012 by FW (Italy & Turkey)
• Lots of modification to existing PHT (around 20 positions).
• 5 new heat exchanger positions added in PHT
• 2 new heat exchanger positions added on side streams
© Alfa Laval Slide 13
www.alfalaval.com © Alfa Laval Slide 14
Item No Duty Type
E-7125A/D T-7202 OVHD-Crude New Equipment = Plate
E-7102A/B AR / Crude Fluids in existing S&T will swop sides
E-7124A/D T-7201 OVHD-Crude New Equipment = Plate
E-7111 LGO / desalted crude Existing S&T will be changed to new position & service
E-7109A/B AR / desalted crude Existing S&Ts will be changed to new position
E-7126 AR / desalted crude New Equipment - S&T
E-7110 & 17 BPA / desalted crude Existing S&Ts will be changed to parallel service
E-7110 will be changed to new service
E-7122A/D Diesel / desalted crude New Equipment – S&T
E-7104A/B TPA / desalted crude Existing S&T will be changed to new position & service
E-7120A/D AR / desalted crude Existing S&Ts will be changed to 2 * 2 installation
instead of 4 exchangers in series
E-7123A/B AR / desalted crude New Equipment = Plate
E-7113A/B BPA / flashed crude Existing S&Ts will be changed to new position & service
E-7127 A/D AR / flashed crude New Equipment - S&T
E-7309 Stabilised / unstabilised naphtha New Equipment = Plate
E-7212 Kerosene/Fuel Gas New Equipment = Plate
All existing exchangers are subject to bundle modification except E-7305A/B, E-7306A/B & E-7307
E. European Refinery Modifications required
www.alfalaval.com
Desalter
1000
m3/h
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AB
25
A
D
03 08
AB
HS Legend:
PF OVHD vapor
OVHD vapour
TopPA
Mid PA
Btm PA
AR
LGO
HGO
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AB 07
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A
D
Pre
-fla
sh
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AB 27
A
D
295
deg C
E. European Refinery New PHT Lay-Out
www.alfalaval.com © Alfa Laval Slide 16
E. European Refinery PF & Main column OVHD condensers
E-7124A-D E7125A-D
Vapour PF Main
Heat Load, MW 7-13 29-32
MTD, deg C 11-18 37-43
T cross, deg C 3-4 No
dP, kPa 15 20
MOC HC276 HC276
Plot space, m 4 * 1,5 * 1,5 4 * 1,5 * 1,5
Weight, tonnes 4 * 18,3 4 * 18,3
www.alfalaval.com © Alfa Laval Slide 17
E. European Refinery AR vs Desalted Crude
E-7123A-B
Heat Load, MW 23
MTD, deg C 33
T cross, deg C 8
dP, kPa 30
Vaporization, % 12
MOC 316L
Plot space, m 1,5 * 3,2
Weight, tonnes 2 * 23
www.alfalaval.com
E. European Refinery Project Economics
• Total project cost: 72 MUSD +/- 30%
• Savings:
– Energy: 40 Gcal/hr
– Yearly saving: 19,5 MUSD
– NPV: ~ 15 year 62 MUSD
– IRR: ~ 15 year 42%
– EII reduction: 6,6 points
© Alfa Laval Slide 18
www.alfalaval.com
Summary
PROPRIETARY INFORMATION 19
By using Welded PHEs, it is possible to
Maximize uptime & production capacity
Maximize Energy Efficiency
Minimize cleaning & repair cost
Minimize project TIC
Around 900 WPHEs in CDU HENs in 60 different sites!
