Optimize Energy Recovery in Refineries Copyright : Evae Andersson The material in this presentation may not be reproduced or transmitted in any form without the permission of the copyright holder. Alfa Laval Slide 2
Optimize Energy Recovery in Refineries Using Compact Plate Heat Exchangers Eva Andersson
CPHEs in Refinery industry With the Kyoto protocol and EU regulations, refineries for the future has to start looking into lowering emissions through reducing energy consumption Cutting down on energy consumption i refineries means Changing from residue fuel to NG Upgrade process equipment Compact plate heat exchangers (CPHEs) such as the Compabloc and Packinox heat exchangers have proven to be indispensable tools in the quest for high performance process equipment meeting this challenge > 1000 CPHE references in refineries world-wide: 350 Packinox, 600 Compabloc Alfa Laval Slide 4
Heat Recovery Annual Savings Annual savings for 1 MW of increased heat recovery, resulting in a 1 MW reduction in net energy needs in the heater Savings Ton/year and MW $/year and MW Heater fuel 970 300 000 CO2 emissions 2 500 50 000 SOx and NOx emissions 30 30 000 Based on fuel cost of $40/bbl and heater efficiency of 65%, CO2 credit cost of $20/ton and SOx and NOx content in the fuel of 0,6% and 0,25% respectively, to a value of $1000 /ton Alfa Laval Slide 5
Typical CPHE Product description Plate heat exchanger Gasket-free Globally counter-current flow Complete accessibility Alfa Laval Slide 6
Typical CPHE Operation In Hot medium Cold medium Out Hot medium Cold medium Click on picture for animation Alfa Laval Slide 7
Typical CPHE Efficiency Corrugated plate design promotes: High turbulence Efficient heat transfer 3-5 times higher in liquid/liquid applications 2-3 times higher in 2-phase applications Minimised fouling 5-10 times higher wall shear stress Alfa Laval Slide 8
Typical CPHE Heat Recovery Designed for: Temperature-cross and close temperature approach Close temperature approach: down to 3 C In Out T 1 T 2 T 1 Temperature cross Out T 2 In High efficiency in Heat recovery Alfa Laval Slide 9
Typical CPHE Corrosion resistance Fewer units Less heat transfer surface Thinner plate material Cost-efficient in corrosionfree material HTA: Σ 1000 m 2 Yearly inspections not required Corrosion problems eliminated Fouling due to corrosion products eliminated Alfa Laval Slide 10 HTA: 170 m 2
Typical CPHE S&T comparison Wall shear stress Heat transfer efficiency Heat transfer area Pressure drop Temperature pinch Footprint Service area Weight empty Weight full Hold-up volume Installation cost Compabloc 5 8 3 5 1 1 1,5 3 5 C 1 1 1 1 1 1 Shell & Tube 1 1 3 5 1 N/A 5 10 4 10 1,5 4 2 5 30 40 1,5 2 Alfa Laval Slide 11
Energy consuming refinery processes Crude preheating Fluid Catalytic Cracking Catalytic Reforming Alfa Laval Slide 12
Atmospheric distillation Distillation tower ~40 C ~25-175 C Petroleum Gas & Light Naphtha Heavy Naphtha Crude oil feed ~150-260 C Kerosene Fired heater ~235-360 C Light Gas Oil (LGO) ~350-370 C ~330-380 C Heavy Gas Oil (HGO) Atmospheric residue Preheated Crude oil ~250-280 C Alfa Laval Slide 13 Click on the highlighted products to get more information!
Economical study Crude preheaters S&T HEN Alfa Laval Slide 14
Economical study Crude preheaters PHE HEN Alfa Laval Slide 15
Economical Studies Crude preheating USA 75,000 bbl/day Crude Train Heater Charge Temperature ( C) Exchanger Cost Exchanger Cost, Installed Number of Shells Exchanger Flooded Weight, tons Heater Fuel Savings / Year, Million USD @ $7/MMBTU Emissions Savings/ Million USD / Year Compabloc 299 X 2X 7 X $2.41 $1.411 S&T 238 1.5X 4.5X 14+ 3X 0 0 Installed cost = 3,6 MUSD -> less than one year pay-back time Alfa Laval Slide 16
Economical Studies Crude preheating USA Duty: HVGO 298 271 C Crude oil 263 239 C Q = 7.0 MW Crude = mix of Mexican Mayan and Canadian Heavy In operation since 2004 Installed cost for 2 CPs Annual savings in fuel cost Annual savings in emissions Total annual savings Pay back Alfa Laval Slide 17 $ Check with AL $2.2 million/year $0.5 million/year $2.7 million /year ~ less than 12 months
Fluid Catalytic Cracking, FCC Main fractionator C4 and lighter Steam Flue gas Regenarator Reactor Spent Catalyst Reactor effluent O heads condenser Gasoline Gas Oil Heavy Gas Oil Condenser Distillate coolers and PAs FCC feed FCC mix Regenerated Catalyst Clarified slurry oil cooler FCC bottoms cooler Alfa Laval Slide 18 Click on the highlighted products to get more information!
Economical Studies BFW preheating, Canada 1st Stage Heat recovery: Overhead vapour 141 87 C BFW 128 43 C 2nd Stage Cooling: Overhead vapour 87 29 C Cooling water 45 24 C Total recovered heat: 14 MW In operation since 2002 Installed cost for 8 CPs in HC Annual savings in fuel cost Annual savings in emissions: Total annual savings Pay back Alfa Laval Slide 19 $ check with AL $4.3 million/year $1.1 million/year $5.4 million /year ~ less than 15 months
Catalytic Reforming Fired heater Reactor Fired heater Reactor Fired heater Reactor Reformate overheads Stabilizer Condenser Reactor Cooler Feed/effluent heat exchanger Recycle gas compressor Reboiler HP separator Alfa Laval Slide 20 Feed/bottoms Reformate cooler Click on the highlighted products to get more information!
Economical Study Feed/Effluent heat exchanging CRU Reduced number and weight Number & Weight S&T option: 4 S&Ts, 275 tons Number & Weight PKX option: 1 PKX, 150 tons Reduced installed cost savings HX (4,5 MUSD vs 5 MUSD) Increased heat recovery in Feed/effluent Packinox heat exchanger Hot Approach Temperature S&T option 44 C, 123 MW Hot Approach Temperature PKX option 28 C, 130 MW Heater duty lowered with 7 MW, annual energy savings of 3,1 MUSD, additional annual savings in emission of 560 kusd Cooler and heater savings 500 kusd * Based on a CCR capacity of 50 000 bbl/day with a crude oil price of 40 USD/bbl, CO2 cost of 20 USD/ton, NOx and SOx cost of 1100 USD/ton Alfa Laval Slide 21
Summary - CPHEs Possible to reduce energy consumption and emissions due to Increased heat transfer efficiency Maximized energy recovery With a Typical Investment Pay Back period of around a year Alfa Laval Slide 22
French Contact Johannes DOUCET Key account manager / Business development Responsable marché raffinage France Tel 01 30 81 82 41 Fax 01 30 81 81 11 Mob 06 16 24 37 49 Mail : johannes.doucet@alfalaval.com Alfa Laval Slide 23