HELIXCHANGER® Heat Exchanger

February 12, 2010

© Lummus Technology Heat Transfer

 HELIXCHANGER heat exchanger

 Helically-baffled shell-and-tube heat exchanger

ƒ Quadrant-shaped baffle plates are arranged at an angle to the
tube axis in a sequential pattern, which guide the shellside fluid
to flow in a helical path over the tube-bundle
 Designed to TEMA R, API 660, ISO 16812, Client Specifications,
ASME Sec.VIII Div.1 and other mechanical design codes

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HELIXCHANGER Heat Exchanger - 2
 Helixchanger Applications

 Refining
ƒ CDU/VDU – Crude Preheat Train, Overhead Condensers
ƒ HCU,
CU, HDS S - Feed/Effluent
eed/ ue Heat ea Exchangers,
c a ge s, Process
ocess Heat
ea Exchs.
c s
ƒ VBU, DCU - Feed Preheaters, Reboilers
ƒ FCCU - Debutanizer Reboilers, Process Heat Exchs.
ƒ Cat. Reformer - Feed/ Effluent Exchs, Rx. Effluent Cond., Column Rblrs
 Petrochemicals
ƒ Ethylene – Charge Gas Comp. Aftercoolers, C3-C5 Condensers, TLEs
ƒ Olefins Conversion – Feed/Effluent Exchs, C3-C4 Condensers
ƒ Styrene – SM Column Condensers
ƒ Butadiene – Feed Vaporizer, Propyne/Butadiene Cond., Solvent Coolers
 Chemicals – Chlorine, Ammonia, PTA, EO/EG
 Off h
Offshore/Gas
/G Processing
P i – LNG,
LNG FPSO,
FPSO Gas
G Coolers,
C l Condensers/Vaporizers
C d /V i
 Oil-Sands – Bitumen preheaters, Emulsion exchs, Sales oil coolers
 Polymers – Reactor coolers, condensers
 Power HVAC,
Power, HVAC Pharmaceuticals,
Pharmaceuticals Pulp & Paper Industries

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HELIXCHANGER Heat Exchanger - 3
 Slovnaft VDU preheat train

Inspection Turnaround 1996

• 38 Exchangers in VDU Preheat Train

• Crude on shellside
After six years in operation
operation,
• Total shellside ΔP = 6 bar (1996)
• Tube-bundles showed little fouling

© Lummus Technology Heat Transfer

HELIXCHANGER Heat Exchanger - 4
 Crude preheat train, Refinery in USA
Inspection 2002

 Two parallel trains of two shells-in-series, just before crude heater. Desalted crude
(tubeside) is preheated with hot tar (shellside).
 Earlier segmental bundles required cleaning once per year
 HELIX bundles, installed in 1999-2000, achieved more than 50% higher heat duty
than the earlier segmental bundles. This was a result of significantly reduced fouling
accumulation on the tubes and the enhanced heat transfer p performance achieved in
the HELIX design.
 HELIX bundles achieved 2-3 longer run-lengths between cleaning than the earlier
segmental bundles.
 The higher average heat transfer performance of the HELIX bundles resulted in
valuable fuel cost savings in the downstream heater.

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HELIXCHANGER Heat Exchanger - 5
 Crude Ovhd Condenser, Refinery in Canada

„ Crude overhead condenser service (4 parallel x 2 series)

„ 50% capacity upgrade was offered using HELIFIN bundles within limited
shellside pressure drop
„ Plant has confirmed achieving the capacity upgrade
„ The HELIX bundles have achieved more than 3 years of continuous
operation
„ Earlier segmental bundles required 3-4 times cleaning in this time period

© Lummus Technology Heat Transfer

HELIXCHANGER Heat Exchanger - 6
 FCCU Debutanizer Reboiler, Refinery in USA

„ Existing Segmental Bundle: Severe olefin polymerization, 10 month

run-length
„ Replacement HELIX Bundle: Installed 1997
„ Achieved 4-5 times longer run-length, the spare unit was not required

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 Hydrotreating Unit F/E Exch., Netherlands
Coldest HELIX Bundle, 1999 Hottest HELIX Bundle, 1999

„ Four ‘BEU’ shells

F h ll iin series
i with
ith reactor
t effluent
ffl t condensing
d i iin th
the ttubes
b and
d
reactor feed vaporizing on the shellside, UOP Hydrobon® process
„ Earlier segmental bundles experienced severe shellside fouling requiring
cleaning twice per year
„ HELIX bundles were installed in 1998
„ Plant has reported extending the unit run-length by 3-4 times and achieving
25% larger throughput with these HELIX bundles
bundles.

© Lummus Technology Heat Transfer

HELIXCHANGER Heat Exchanger - 8
 HELIXCHANGER® Heat Exchanger

Reduce shellside fouling & Capital Cost

Extend run length to Savings
3- 4 times 15 - 25%
Reduce heat
transfer
surface up to
35%

Reduce
Increase Maintenance
process Reduce shellside related down
capacity up pressure drop
drop, time
to 40% Save pumping costs
and downstream
heating costs Eliminate vibration and
acoustic rumbling
Contact: Helix@cbi.com Visit: www.lummusonline.com
© Lummus Technology Heat Transfer
HELIXCHANGER Heat Exchanger - 9