Exploiting the Use of Compact Heat Exchangers on Preheating Trains

(AIChE 2008 Spring Meeting 165d)

PETROBRAS R&D Center CENPES

Antonio V. S. de Castro*, M.Sc. Alan T. Vilas Boas Claudio L. M. Kuboski Diomedes C. da Silva, M.Sc. Roberto A. Oliveira, M.Sc. Washington de O. Geraldelli, Ph.D.

Introduction Higher prices of energy and oil Crude oil distillation unit is one of the highest energy consumers in a refinery. Opportunities for heat integration:
In revamps to process advantageous crudes Special Metallurgy higher heat recovery

Threats:
Special Metallurgy due to naphtenic acids - higher investments at preheating train increase on plot area due to increase on heat recovery - might be a constraint

Introduction Compact Welded Plate Heat Exchanger:

Special Metallurgy (Titanium, SMO, etc.) leads to attractive costs compared to a S&T Compact (less plot area) Lower temperature approaches than S&T Innovative solution Refinery designers don't have enough information regarding the performance:
Fouling Mechanical resistance Operational cautions, such as start-up and shut-down

PETROBRAS Experience
End of 2001, PETROBRAS Engineers visited a Refinery, in Europe, where a Compabloc CP75 was installed
Overhead Condenser with Crude Special Metallurgy required due to Chloride 4 years without maintenance

August, 2002. Service with two heavy fluids

13 exchangers at refinery since 1994 Maintenance during winter shut-down Focus on Process Issues

Visit to refinery with two parallel units (one stand-by) Sep,2005

Ref.: ALFA LAVAL

HVGO vs. Crude Oil (high temperature) Problems during the start-up (blocked pipe) Operating since November,2004

PETROBRAS Experience
June,2002 ALFA LAVAL trained PETROBRAS Engineers how to design Compabloc using CAS200 (ALFA LAVAL software) September,2006 Two-phase fluid ALFA LAVAL course, concerning crude oil vaporization
Lack of data for temperature x shear stress x fouling rate

May,2006 Visit to ALFA LAVAL factory in France:

- Maintenance/Inspection/Cleaning Requirements - Manufacturing Process

PETROBRAS Cases

CASE 1
P-68324A/B Ovhd Gas Heater

Sour Water Stripping Unit:

Feed preheater Overhead Condenser Ovhd Gas Heater Reboiler

P-68323A/B Ovhd Condenser

P-68322A/B Feed pre-heater

P-68325A/B Reboiler

Plot area constraints Fouling at Feed pre-heater Leakage at Ovhd Gas Heater

PETROBRAS Cases
Fouling at Feed preheater Leakage at Ovhd Gas Heater

Inadequate H2S Stripping Tower Operation corrosion

Actual Flow Rate (90m3/h) Design (160m3/h) Actual Shear Stress (22Pa) Design (60Pa)

Material replacement:
From Titanium to SMO

Mitigation:

Increase passes number ( Shear Stress) Control Review (by-pass) Self-cleaning Strainers

CASE 1, cont.

PETROBRAS Cases

CASE 2
Basic Engineering Design - Crude Distillation Unit Revamp:
Increase Feed Rate Heat Integration Plot Area Constraints

3 Services: MVGO (2) and VR 220,000 bbl/d Start-up: 2011

PETROBRAS Cases

CASE 3
Conceptual Design (Revamp) 140,000 bbl/d

- Metallurgical Adaptation (TAN=2.1) - Operational Debottlenecking - Heat Integration Study Pinch Analysis - Plot Area and Shutdown time constraints - Full Compabloc new preheat train suggested.

Compabloc Test at Refinery

During conceptual design, necessity of a performance test. A Compabloc CP30 unit has been installed, in order to evaluate the performance of this equipment under unit conditions Vacuum Residue preheating Crude before the Desalter Low Crude Temperature: ~100 to 115C Operational and Maintenance experience

Compabloc Test at Refinery

Vacuum Residue

172

Crude Oil
103

E-106D
113

160

E-150

Compabloc Test at Refinery

Step
1

Flow rate (design basis)

100%

Period
6 months

Objective
Thermal performance

Procedure
a) Check pressure drop; b) Compare design X operational data using CAS200.

50%

2 months

Fouling

a) Check pressure drop b) if fouling, go to phase 1; if not, go to phase 4.

100%

2 months

Thermal performance and fouling Fouling

a) Check pressure drop; b) Auto cleaning capabity. a) Check pressure drop; b) Equipment shut-down for 10 days and restart it.

25%

2 months

Cleaning

a) Open the equipment to check deposits; b) Cleaning with hidroblasting.

100%

3 months

Similar to phase 1.

Compabloc Test at Refinery

1st Phase Results:

Crude side measured pressure drop was from 29 to 47% of calculated values by CAS200; VR side measured pressure drop was from 123 a 167% of calculated values by CAS200; Difference in global heat transfer coefficients (HTC) was much lower. Measured values were from de 88 a 111% of calculated values by CAS200; Problems with Instrumentation could be the cause of such difference in pressure drop

Compabloc Test at Refinery Compabloc Opening after 1st step (8 months) Deflected Baffle (mechanical resistance) it was
not designed for that purpose

Crude Inlet

Vacuum Residue Inlet

Compabloc Test at Refinery

Pressure drop results - phases 2, 3 and 4
2.00 1.80 1.60 1.40 1.20 1.00 0.80 0.60 0.40 0.20 0.00 1-Sep 2-Oct 2-Nov 3-Dec 3-Jan 3-Feb 6-Mar 6-Apr 7-May 7-Jun 8-Jul 8-Aug 8-Sep 9-Oct

pressure drop, kgf/cm

50% flow rate

25% flow rate

100% flow rate

CRUDE VACUUM RESIDUE

Period from 2006 up to 2007

Compabloc Test at Refinery

Flow Rate Vacuum Residue vs Crude

Ad-Hoc Trend 3000 1210-FI-299 160.63 M3/D 1210-FI-298 28.689 M3/D

2500

2000

1500

1000

500

0 01/08/05 00:00:00

2.14 Year(s)

20/09/07 00:00:00

Compabloc Test at Refinery

Positive Aspects:
- Equipment kept its thermal performance; - Design, Operational and Maintenance experience

Negative Aspects:
- Mechanical Resistance (Leakage and Baffle); - Aspects not related to exchanger (instrumentation, flow fluctuation, )

- No fouling observed

Compabloc Test at Refinery

Pressure

Crude Side
Period: Jul/16/07 up to Sep/20/07 Zero Flow Rate for about 3 weeks.

Flow Rate

No abnormal pressure variation.

Compabloc Test at Refinery

Pressure

Vacuum Residue Side

Period: 16/Jul/07 up to 20/Sep/07 Zero Flow Rate for 10 days. Significative pressure and flow rate variation.

Flow Rate

Pressure Sep/01 to 17

Compabloc Test at Refinery Inlet Pressure VR vs Crude (Accordeon Effect)

Compabloc Test at Refinery

Problem Leakage Baffle Deflection Root Cause Joint Failure Overpressure or fatigue Consequense Vacuum Residue Leakage Thermal performance loss

ALFA LAVAL:
Development of new gasket; Adoption of reinforced baffles (for high viscous fluids);

PETROBRAS:
Avoid surge pressure (hydraulic hammer):
Startup and shutdown procedures; Slow valve action;

Drain the equipment, in case of several days of shutdown. Panels bolting hot retightening after startup Deposits prevention:
Strainers;

PETROBRAS Cases

CASE 3

Basic Engineering Design (Oct/07)

Preheat Train before Desalter
Carbon Steel Equivalent Cost

Preheat Train between Desalter and PreFlash Tower

Crude Vaporization Special Metallurgy Parallel Arrangement

PETROBRAS Cases

CASE 3

Basic Engineering Design (Oct/07)

After PreFlash Tower Preheat Train (High Temperature Special Metallurgy)

SERVICE E-166 A/B (x HVGO) E-167 A/B (x HD) E-169 C/D (x BPA)

Shear (Pa) 112 113 113

WALL TEMPERATURE ( C) 264 289 295

Petrobras Current Case

CASE 4

Basic Engineering Design CDU Grass root Refinery

CS

CS

AE V

CS

CS

HT

HT

CB

CB

HT

HT

HT

CB Compabloc CS Carbon Steel HT High Temperature AE accordion Effect V Crude Vaporization

PETROBRAS Current Case

CASE 4

Basic Engineering Design CDU Grass root Refinery

COMPARISON OF EQUIPMENT COSTS SERVICE P-10 P-11 Compabloc (US$) x y Shell and Tube (US$) ~ 5.6 x ~ 3.8 y

* Installation costs not included; * Equipment designed with the same allowable pressure drop; * Compabloc design and budget by Alfa Laval; * Shell and Tube budget by Aspen Icarus (Brazil Base)

Compabloc Design

Design Parameters:
Minimum Shear Stress Higher Pressure drop Countercurrent Pinch Analysis Strainers / Maintenance facilities Parallel Arrangement (flexibility) Accordeon Effect Crude Vaporization High temperature

Next Compabloc Tests

Next Step at the same refinery:
Operational practice and fouling at high temperatures; Service: Not defined yet; Wall temperature above 270C (target 300C)

Test at Case 2 refinery :

Operational practice and fouling with crude vaporization; Service: Not defined yet (desalted crude vs heavy diesel) Crude Temperature from 150C to 220C

Thank you very much!

Antonio V. S. de Castro, antonio.castro@petrobras.com.br Alan T. Vilas Boas Claudio L. M. Kuboski Diomedes C. da Silva Roberto A. Oliveira Washington de O. Geraldelli