A Systematic Approach to Improving Heater Absorbed Duty

Transcription

1 A Systematic Approach to Improving Heater Absorbed Duty Texas Industrial Energy Management Forum S. Chatterjee March 1, 2012 lyondellbasell.co m

2 lyondellbasell.co m Company Profile

3 LyondellBasell is One of the world s largest olefins, polyolefins, chemicals and refining companies with revenues of $41billion (2010) The global leader in polyolefins technology, production and marketing A pioneer in propylene oxide and derivatives A producer of fuels and refined products, including biofuels Dedicated to ongoing research and development programs that meet the ever-changing requirements of our customers, including the creation of new catalysts, processes and products Listed on the New York Stock Exchange (NYSE) as a publicly traded company. Ticker symbol: LYB 3

4 Fast facts Third-largest independent chemical company in the world Olefins and Polyolefins Americas Five business segments Olefins and Polyolefins Europe, Asia and International Intermediates and Derivatives Refining and Oxyfuels Technology Delivers exceptional customer value across the petrochemical chain Vertically integrated facilities Broad product portfolio Manufacturing flexibility Superior technology base Operational excellence 4

5 Global reach 58 plants in 18 countries More than 14,000 employees worldwide Sales in more than 100 countries 5

6 Diversified and vertically integrated portfolio Wellhead Refining Crude Natural Gas Liquids Capturing value along the chain Refining Olefins Aromatics Fuels Olefins Crackers Olefins Technology Olefin Derivatives Oxy Fuels Polyethylene Polypropylene Polybutene-1 Propylene Oxide Acetyls Ethylene Oxide Styrene 2nd Level Derivatives PP Compounding Compounding Catalloy Process Resins Glycols Glycol Ethers Butanediol Glycols Glycol Ethers Olefins & Polyolefins Americas Olefins & Polyolefins Europe Asia & International Intermediates & Derivatives Refining & OxyFuels Technology 6

7 Our product lines and the end markets we serve Olefins & Polyolefins Americas Europe, Asia & Int l Intermediates & Derivatives Refining & Oxyfuels Technology Ethylene Propylene Polyethylene Polypropylene Catalloy process resins PP Compounds Polybutene-1 Propylene Oxide Styrene Monomer PG and PGE Acetyls C4 Chemicals Ethylene Oxide EG and EOD Gasoline Diesel Olefins Feed Oxyfuels Process Licensing Catalyst Sales Technology Services New Ventures End Uses Food Packaging Textiles Automotive Appliances Films Flexible Piping End Uses Insulation Home Furnishings Adhesives Consumer Products Coatings End Uses Automotive Fuels Aviation Fuels Heating Oil Industrial Engine Lube Oils End Uses Polyolefin and Chemical Manufacturers 7

8 A Systematic Approach to Improving Heater Absorbed Duty Texas Industrial Energy Management Forum S. Chatterjee March 1, 2012 lyondellbasell.co m

9 Improving Process Absorbed Duty - Houston Refinery lyondellbasell.co m

10 Houston Refinery- Strong Energy Focus Million Dollars Million Btu per Hour Annual Reduction ($MM) Act Cumul MMBtuH Goal Cumul MMBtuH Equivalent to: Annual power consumption of over 110,000 homes Carbon dioxide reduction of over 500,000 Metric tons 10

11 Energy Footprint The Refinery energy source is predominantly fuel gas Consider steam from a FG/NG fired source FG/ NG footprint is ~ 65% Total firing duty ~ 1,800 Million Btu/ Hr Maintaining desired level of heater efficiency is critical Heater evaluation beyond basic operating practices Can improve efficiency without costly Capital 11

12 Focus Area: Process Absorbed Duty Overall Heater Efficiency Components Process Absorbed Efficiency Combustion Efficiency Focus Area Excess air Burner Design/ Oper Stack temp Heater tuning Air PreHeaters 12

13 Refinery Heater Heat Balance First Step : Validate Heater performance data Heat Balance Q Absorbed Duty = Q Firing - Q Stack Loss - Q Radiation Loss OR (Q Convection + Q Radiation ) = (Q FG + Q Stoich.Air + Q Excess Air ) - Q Stack Flue Gas Q Radiation 13

14 Methodology 5 Steps 1. Perform Heat balance Convection section Radiant Section Heat Absorption Percent Heat Absorption Fluid Mass Flow Rate Volumetric Flow Actual / Calculated Process Radiant Section Convection Section Total MMBTU / hr Lb / hr bbl / hr 2. Complete design vs actual analysis for top 15 heaters Normalize data for actual feed rate and composition 3. Rationalize, validate the gap and develop corrective scope 4. Identify funding source 5. Include in execution planning Inlet Conditions Radiant Section Convection Section Total Temperature F Pressure psig Liquid Flow Lb / hr Vapor Flow bbl / hr Weight Percent Vapor Molecular Weight Lb / Lbmole Vapor Viscosity cp Specific Heat BTU / lb F Thermal Conductivity BTU / hr ft F Outlet Conditions Radiant Section Convection Section Total Temperature F Pressure psig Liquid Flow Lb / hr Vapor Flow bbl / hr Weight Percent Vapor Molecular Weight Lb / Lbmole Vapor Viscosity cp Specific Heat BTU / lb F Thermal Conductivity BTU / hr ft F Combustion Design Conditions Heater Radiant Section Convection Section Total Excess Air % Calculated Heat Release MMBTU / hr Guaranteed Efficiency HR% Calculated Efficiency HR% Radiation Loss HR% Flue Gas Temperature F Radiation Loss MMBTU / hr Flue Gas Loss MMBTU / hr 14

15 Heater Process Data Collection Flow MBPH T in C in H vap Tout C int T in H vap T out C out 15

16 Heater Combustion Data Collection Draft and O2 FG Comp Tout Draft and O2 Radiation Loss FG Btu/SCF FG Flow MSCFH Combustion Air Temp T in 16

17 Actual vs. Design Heater Performance Pareto Chart 17

18 Absorbed Duty Gap (Design Actual) Convection deficiencies Radiation deficiencies Under performing Over performing Systematically develop Flow and Temp trends for each suspect heater pass 18

19 Examples of Process Variables Impacting Absorbed Duty FG Flow maldistribution - Heater passes BPH/FG Ratio Note data separation for passes 19

20 Examples of Process Variables Impacting Absorbed Duty Coil Outlet temp variations at Heater passes Coil Outlet temp deviation trend 20

21 Examples of Process Variables Impacting Absorbed Duty Charge Flow rate variations at Heater passes Charge Flow deviation trend 21

22 Other Reasons for Deficiency Further engineering analysis & heater examination reveals other gaps due to following : Radiant : Instrument accuracy and calibration Control system design FG currents in fire box Flame impingement causing coking Improper flame pattern with poor heat flux Net loss in performance due to underperforming convection Convection: Lower feed temp and different composition characteristics FG Channeling, not using effective convection surface area High Burner flame height, Internal coke deposit External coil fouling, high DP 22

23 Funding Options Simple remediation done with routine maintenance, such as Instr. Calibration, Analyzer verification Items that will require shut down and be incorporated into TA planning, such as pigging, cleaning convection coils etc Maintenance Turnaround Capital Energy Program Permanent asset upgrades, additions such as redesign burners, add convection modules, etc. Non Capital Funding dedicated to improve energy efficiency such as, IR scans, Refractory, etc. 23

24 Execution Planning Capital LRP 3-5 yrs TA Planning 2 yrs Energy Program 3-6 mos Maintenance 1 mo 24

25 Conclusion Comparison against Design provides a benchmark for acceptable performance Systematic analysis of Design versus Actual heat balance provides deeper learnings about gaps Further improvements can be applied to new findings that otherwise may have been overlooked 25

26 Disclaimer and trademarks Catalloy, Spheripol, Spherizone, Hostalen and Lupotech are trademarks owned and/or used by the LyondellBasell family of companies. Spheripol, Spherizone and Hostalen are registered in the United States Patent and Trademark Office. All information ( Information ) contained herein is provided without compensation and is intended to be general in nature. You should not rely on it in making any decision. LyondellBasell accepts no responsibility for results obtained by the application of this Information, and disclaims liability for all damages, including without limitation, direct, indirect, incidental, consequential, special, exemplary or punitive damages, alleged to have been caused by or in connection with the use of this Information. LyondellBasell disclaims all warranties, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose, that might arise in connection with this information. LyondellBasell does not sell PB-1 for use in pipe applications intended for use in North America, and requires its customers not to sell products made from PB-1 into pipe applications for North America. LyondellBasell Industries Holdings, B.V