Make Your Energy Efficiency Project Fly

Transcription

1 Make Your Energy Efficiency Project Fly ERTC, Athens, November 2017 Eva Andersson Refinery Industry Manager Alfa Laval

2 Poll: What is the most important parameter to get your energy efficiency project approved? Impact on Company bottom line Investment Pay-back time / ROI / IRR Project cost Project complexity Implementation time Improvement of plant reliability Technical risk of solution Slide 2

3 Make Your Energy Efficiency Project Fly! SELECT THE RIGHT CASE Impact - Refinery bottom line - KPIs (EII) - Environmental footprint Complexity - Modification to existing process? - Ground installation vs Structure? - Internal project vs External input? Technical Risk Implementation Time - On line or Major T/A? Project TIC - Budget? - Approval levels? Pay-Back time/roi/irr Reliability Improvement

4 The Right Case! THE LAST POSITION(S) IN THE CRUDE PHT LPG & Light Naphtha M Crude oil feed Heavy Naphtha Q CO 2 Kerosene LGO HGO Preheated Crude oil Atmospheric residue

5 The Right Solution WELDED PLATE HEAT EXCHANGERS, WPHEs Maximal Energy Efficiency with Minimal Heat Transfer Area and Number of Exchangers Cost-efficient solution MOC upgrade at low cost = Increased reliability Low Project TIC Project funding easily available & approved 3 S&Ts in CS replaced by 1 WPHE in SS Slide 5

6 The Right Solution! WELDED PLATE HEAT EXCHANGERS, WPHEs Compact & Light Weight Simplified installation Original S&T exchanger(s) in stand-by = Eliminated technical risk! Exchanger redundancy improves plant reliability Hot Start-up Possible Installation in by-pass line or tie-in points No need to wait for TAR = Fast implementation Original S&T in stand-by to new WPHE with double heat capacity Slide 6

7 The Right Solution! WELDED PLATE HEAT EXCHANGERS, WPHEs Low Fouling Tendency Maximal energy efficiency over time Minimized risk of energy or capacity loss due to cleaning in between TAR Maximal plant run-length Reduced cleaning cost Ease of Access for & Cleaning Improved reliability of TAR planning Increased plant availability Slide 7 No need for special tool to pull out bundle Both hot and cold side fully accessible to HP water jet, max 1,2 m

8 The Right Solution! WELDED PLATE HEAT EXCHANGERS, WPHEs Around 2200* WPHEs delivered to refineries world-wide Used in all refinery processes* First ADU/VDU installations in mid 1990 s* Today, > 950* WPHEs delivered to ADU/VDU processes > 950 WPHEs since mid 90 s * Based on Alfa Laval WPHE deliveries only

9 Reduced Fouling & Increased Reliability ASIAN OIL MAJOR CDU PHT, 165 KBBL/D Project Scope: Replace high-fouling S&T in last position of CDU PHT using VHVGO as heating media Keep original S&T in stand-by Pipe up new WPHE as back-up for another critical exchanger service Project Result: Drastically reduced fouling tendency No unplanned stop when critical S&T exchanger failed Slide 9 S&T and WPHE fouling trends 300 days of operation Crude outlet T = 280 deg C

10 Increased CIT PETRONAS KERTEH CDU PHT, 50 KBBL/D Project Scope: Replace S&T in last position of CDU PHT, using LSWR as heating media Design new WPHE for doubled heat capacity Project Result: Energy reduction of 0,0053 GJ/bbl or 0,44 MUSD/y 9,2% energy reduction in furnace EII reduction of 3 points Pay-back time of 1 year Slide 10 Equals 410 vs 440 kusd

11 Increased CIT & Product yield PREEM LYSEKIL CDU PHT, 210 KBBL/D Project Scope: Modify sequence of S&T exchangers downstream of desalter in PHT A Replace low capacity S&T exchangers downstream of desalter in PHT B with a WPHE with double heat capacity Increased stripping steam to lift valuable products from AR Project Result*: Reduced energy consumption in CDU furnace of 10 MW Increased yield benefits of 11,6 MUSD * Evaluated by Slide 11

12 Using WPHEs in hot end of CDU PHT TYPICAL PROJECT PAY-BACK TIME Energy savings through fouling mitigation alone months Energy savings through increased heat duty 6 12 months Energy savings in combination with Capacity / Yield improvements < 6 months. Slide 12

13 Make Your Energy Efficiency Project Fly! BY USING WPHEs IN THE HOT END OF THE CDU PHT, YOUR PROJECT WILL HAVE: Major Impact on Refinery Bottom Line Minimal Complexity & NO Technical Risk Short Implementation Time & Ease of Funding Excellent Pay-Back Time & Impact on Refinery Reliability > 950 WPHEs delivered to CDU/VDU /refinery

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