Energy, Emissions, and Efficiency

Welcome to today’s webcast…

Energy, Emissions, and Efficiency:
How to address heat exchanger fouling to reduce energy and
maintenance costs while improving plant performance

March 31, 2011

Today’s Speaker – Simon Pugh
Expert from IHS

• Director of Process Engineering Technology at IHS ESDU and
is based in London, UK.

• Role includes the management of all ESDU’s heat transfer
work, which is undertaken under the guidance of international
independent Committees of experts from industry and the
Universities.

• He leads the Technology Transfer Sub-project of CROF, which
includes the management of the interaction and collaboration
between the researchers and the oil company members of the
Simon Pugh IHS ESDU Oil Industry Fouling Working Party.

• He is currently leading a group of engineers working on the
Director development of a range of design guides to oil industry fouling
Process Engineering Technology problems and computer programs for better heat exchanger
selection, design and operation, with particularly emphasis on
IHS Inc. reducing crude fouling in per-heat trains. He holds a mechanical
engineering degree from Brunel University in the UK.

Copyright © 2011 IHS Inc. All Rights Reserved. 2

About IHS Inc.
A Leading Information Provider

• Founded in 1959, IHS is a leading source of information and expert analysis in
pivotal areas shaping today’s global businesses

• Employs 4,400 colleagues in 30 countries who speak 50 different languages

• IHS customers include nearly 70% of the US Fortune1000 and 80% of the
Global Fortune 500

• Tens of thousands of customers and hundreds of thousands of end-users in
over 100 countries
• Public (2005) NYSE: IHS
• FY10 revenue $ 1,075 million

3
Copyright © 2011 IHS Inc. All Rights Reserved.

Today’s Topics
What we will address

• About ESDU
• Discipline area and industry involvement

• Oil Refining, Emissions, and Regulations
• Oil production and refinery fouling
• Economic and environmental impacts

• Application of Research and Technology
• Latest advancements from university research and the oil industry
• Process innovation and engineering
• Best practices and technology approaches

• Q&A

4

IHS ESDU
The Engineering Sciences Data Unit
• Founded in London, England in 1940

• All work validated by expert International Committees of
industry specialists, University experts
• Over 20 specialist Technical Committees, including
• Heat Transfer Steering Group

• Oil Industry Fouling Working Party

• Fluid Mechanics, Internal Flow Panel

• Engineering Structures, Fatigue Committees

• Wind Engineering Panel

• Development of design methods, guidelines and software
• Delivered online in “series”


ESDU Technical Committees
Selection of Participating Organisations


Example: Fouling in Cooling Systems
Participating Organisations


Today’s Topics

• About ESDU



• Q&A

8

Business Pressures – A few examples…
Market volatility, regulatory compliance, and sustainability…

• Market Economics & Volatility
• Oil and gas prices feed into fluctuations in electricity prices
• Japan disaster impact on nuclear, coal, LNG, and other energy
• Pressures to reduce energy costs

• Regulations & Reporting
• US – Regional Greenhouse Gas Initiative (RGGI)
• US - EPA’s Greenhouse Gas (GHG) Reporting Programme
• Europe – EU Emissions Trading Scheme (EU ETS)
• France - The Bilan Carbone in France
• Australia - National Greenhouse and Energy Reporting Act

• Sustainability & Transparency
• Shareholders, customers and consumers
• Lenders, stock exchanges and investment communities
• Carbon Disclosure Project (CDP)
• Global Reporting Initiative Reporting (GRI)
• Carbon Disclosure Project (CDP)


How does hydrocarbon burning contribute
to CO2 emissions?

One tonne of hydrocarbon burned releases 2.5 – 3 tonnes of CO2

What are the biggest CO2 producers in
refineries?

Around 50% of CO2 and energy from crude heating
Efficiency of pre-heat train crucial in energy and CO2 management

Opportunity – Address Crude Oil Fouling
Improvements to energy, efficiency, and emissions

Reduce Energy Consumption

Improve Maintenance

Improve Throughput

Reduce Emissions

Regulatory Compliance

Reduce Costs


Enablement Strategies – Scenarios
How industry is trying to improve performance
• What is the most cost-effective maintenance/cleaning strategy if we operate
the refinery with similar throughput and average API?

• What effect will running heavier crudes have on maintenance?

• Can we flag up severe fouling events in real time, or even predict and
prevent?

• What can we save in capital, maintenance, energy, CO2 is we re-engineer
heat exchangers or change plant piping payout? Does this justify the project?

• What happens if we use alternative heat exchanger types or fouling
mitigation devices like tube inserts

• What happens if we switch the crude from tube side to shell side in heavily
fouling heat exchangers?

• We use anti-fouling chemicals – what are they saving us?

• We want to use anti-fouling chemicals – what will they save us?

Remainder of Slides
….

DISTILLATION

STORAGE

HEATING


The heated crude needs a
“blast” in the furnace prior to $$$
distillation
CO2
$$$

$$$

$$

$


What is the biggest cause of inefficiency in
heat exchangers?

Fouling!
Dirt deposits build up on clean tubes, and
efficiency plummets!!


Some economic & environmental effects of
fouling problems

• Energy
• increased fuel needed in furnace, pumping costs

• Emissions CO2
• Extra fuel burn = increased emissions
• Burn 1 Ton of oil, get 2 - 2.5 Tons of CO2

Fouling!


Some economic & environmental effects of
fouling problems

• As heat exchanger tubes block, flow rates fall
• Exchangers then need to be cleaned
• Isolation/shutdown very costly exercise

• Most refineries have goal of running continually for 5
or 6 years between shutdowns
• Mostly impossible with current designs

• Cleaning is an environmental and safety issue
• Minimize cleaning schedule to minimize employee risk

• Disposal of dirt deposits, cleaning materials and fouled water


Cleaning! Major maintenance issue

Fouling!
Picture; Wellman Hunt
efficiency plummets!! Graham


Fouling is getting worse!

• Many refiners are refining heavier, more complex
crudes
• Canadian tar sands, African, Venezuelan crudes now economic to refine

• North Sea crudes getting heavier

• Are refineries prepared for more difficult feedstock?

Fouling!


What does crude oil fouling cost a refinery?
• Up to 10% of refinery CO2 footprint directly results from
fouling in pre-heat trains
• 0.2 – 0.25% entire oil production wasted due to fouling

• World: c. 250,000 barrels per day

• CO2 emissions due to fouling
• World: c. $300 M p.a.
• World: c. 30 M tonnes/year extra CO2


Oil Industry Fouling Working Party
members

Oil company members of the IHS ESDU Oil Industry Fouling Working
Party – CROF1


Next Generation Simulations based on
Industry Accepted Best Practices

Best Practice

Network Techno-Economics Heat Exchanger Design

Next Generation Simulations based on
Industry Accepted Best Practices

Best Practice

Model Optimize

Simulate
Best Practice

Network Techno-Economics Heat Exchanger Design

Today’s Topics

• About ESDU



• Q&A

27

Crude Oil Fouling Research (CROF)
The CROF programme

• Leading R&D in crude oil fouling
• $4.5M EPSRC funding over 3 years at:
• Imperial College
• Cambridge
• Bath
• IHS ESDU Facilitator and Technology Transfer Partner
• Interfacing with the oil companies and their suppliers
• Transferring the technology by various means
• Reports, data, software, etc.
• Ensuring that the results of the programme will be implemented by
refiners
• Dissemination, training, etc.


IHS ESDU - Bridge between University
Research and Oil Industry

CROF1 samples
A – test
crudes and
F – larger deposits B – study
scale lab interfacial
tests in behaviour of
tubes deposits

properties

E – small- H– C – model
cell tests on technology heat and
crude transfer mass
samples transfer

models
behaviour
G – simulate D - model
real plant molecular
behaviour properties


Intensive research meetings:
for example in 2009…

Chevron Pembroke Refinery,
Sun 19 – Fri 24 April 2009
50 researchers and industrialists from 4 continents

IHS London office,
28 Sept – 1 Oct 2009

55 researchers and
industrialists


• Crude oil fouling mitigation: expected benefits
• Higher Furnace Inlet Temp and lower fuel use
• CO2 emissions reduction
• Increased on-stream time due to reduced downtime for HX
cleaning
• Benefits of Research Programme now available
• Heat exchanger fouling analysis and abatement
• Smart Predictive Maintenance


Extracting fouling model from plant (HEN)
operating data and fitting fouling models

(c) Fit Fouling model to
Plant Op data in IHS
EXPRESSplus

(a) Raw Plant Op data from DCS

(b) Convert to fouling prediction using
rigourous heat exchanger design
methods in ESDU EXPRESSplus

…leading to Smart Predictive Maintenance

Design and operational
parameters
smartPM Refining
Cost data and solutions
operational strategies
Cambridge Research considered for the
prestigious 2010 Eni Protecting the
Environment Award.
34

…smartPM answers the refiners questions

• smartPM uses techno-economic metrics to answer some
of the most difficult operational questions
• What is the most cost-effective maintenance/cleaning strategy if we
operate the refinery with similar throughput and average API?
• What effect will running heavier crudes have on maintenance?

• Can we flag up severe fouling events in real time, or even predict and
prevent?
• What can we save in capital, maintenance, energy, CO2 is we re-
engineer heat exchangers or change plant piping payout? Does this
justify the project?
• What happens if we use alternative heat exchanger types like
Compabloc or install tube inserts like Spirelf?
• What happens if we switch the crude from tube side to shell side in
heavily fouling heat exchangers?
• We use anti-fouling chemicals – what are they saving us?
• We want to use anti-fouling chemicals – what will they save us?
smartPM


Consider the Expertise of IHS ESDU
What do we offer?

• Design Guides
• Crude fouling in pre-heat trains, water (sea and fresh) fouling, heat
exchanger selection, costing and design…etc
• Software
• Shell-and-tube exchangers (new design, revamping, new technologies),
fouling analysis, esp. crude pre-heat trains, reboilers, process
integration, ejectors/jet pumps, physical properties…etc
• Exchanger fouling tracking and abatement
• Esp. pre-heat trains, water fouling, pre-heat train smart Predictive
Maintenance
• Expert consultancy
• Fouling troubleshooting and anti-fouling strategies, energy optimization,
PHT’s, CHP, VSD’s
• Training
• Engineering of heat exchangers, networks, energy optimization


Complimentary Review – IHS Advice
Let IHS discuss your situation and opportunities

• IHS Whitepaper
• Heat Exchanger Fouling Mitigation
• Complimentary for attending
• Insight and best practices

• Complimentary Review
• Discuss your situation
• Understand inefficiencies
• Improvement opportunities


Questions?

Send questions and
requests for
information to:

Webcasts@ihs.com


Energy, Emissions, and Efficiency

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