MINIMIZATION OF ATMOSPHERIC EMISSIONS IN THE HYDROCARBON PROCESSING INDUSTRY WITH HIGH EFFICIENCY PLATE-AND-SHELL HEAT EXCHANGERS Texas Technology

Showcase 2003

Texas Technology Showcase 2003 - 1

Outline
Atmospheric Emissions from Use of Energy in the HPI Heat Integration Thermal Pinch PSHE as Best Equipment to Minimize the Pinch Case Story: Diesel Hydrotreater Case Story: Catalytic Reforming Case Story: Pygas Hydrotreater Summary

Slides 3-4

5 6 7-11 12-13 14 15-16 17

Texas Technology Showcase 2003 - 2

Atmospheric Emissions from Use of Energy in the HPI

Fired Heaters are Typically the Largest Consumers of Energy and the Largest Contributors to Atmospheric Emissions by Oil Refineries. Example of Utility Consumption at a Particular Diesel HDS Unit

Fired Heater Compressor Product Cooler

19 / bbl 6 / bbl 1 / bbl

6 lb. GHG / bbl (*) (*)

Energy Consumption is Usually the Second or Third Largest Cost Center of a Refinery

First = Crude Oil Supply Next is either Personnel or Energy

Texas Technology Showcase 2003 - 3

Atmospheric Emissions from Use of Energy in the HPI

Conclusion:

Minimizing the Use of Fired Heaters is both:

Good for the Refinerys Bottom Line Economics An Excellent Method to Reduce Atmospheric Emissions.

This Paper Suggests a Method and a Tool to REDUCE THE NEED FOR MANY FIRED HEATERS IN A REFINERY

Texas Technology Showcase 2003 - 4

Heat Integration

Heating Side of HE Fired Heater

Cooling Side of HE Reactor Cooler

H HE HE C
LESS Heat Integration MORE Heat Integration

HE

HE

Feed In

C
Product Out

Texas Technology Showcase 2003 - 5

Thermal Pinch Inside the HE

Minimize Delta T at hot end to Minimize Charge Heater Duty
F Reactor Effluent Into the HE Feed Out of the HE and to the Heater
ng ati He

ng oli Co

Effluent Out

Heat Recovery is Limited By Thermal Pinch Inside the HE

MM BTU / hr

Feed Into the HE

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PSHE as Best Equipment to Achieve Minimum Pinch

Barriers to Reducing the Pinch:

The LMTD Diminishes Rapidly with the Pinch, and the Required Heat Transfer Surface Area Increases just as Fast The Tube Length Equivalent Increases Rapidly Complete Vaporization of the Feed is Needed

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PSHE as Best Equipment to Achieve Minimum Pinch

Heat Transfer Through Very Large Corrugated Plates:

Huge Surface Area in a Compact Design Very Long Tube Length Equivalent Corrugations Give High Turbulence to Help Complete Vaporization

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PSHE as Best Equipment to Achieve Minimum Pinch

Corrugated Surface Works as a Static Mixer Maintains high Turbulence and Promotes Twophase Flow Distribution Allows Easy Superheating

Texas Technology Showcase 2003 - 9

PSHE as Best Equipment to Achieve Minimum Pinch

Plate Bundle Liquid Spray bars

Liquid Feed Injectors Allow Very Good Control of Liquid - Vapor Feed Distribution Allows Better Heat Transfer Inside the Plate Bundle
Vapor Distribution Grid Vapor Inlets
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Plate-and-Shell HE as Best Equipment to Achieve Minimum Pinch

Feed Outlet Effluent Inlet

Plate Bundle

The Protection of a Pressure Vessel Allows the Plate Bundle to Operate at High T and P

Pressure Vessel Effluent Outlet Spray Bars for Liquid Feed Recycle Gas inlet

Texas Technology Showcase 2003 - 11

Case Story: Diesel Hydrotreater

Two 65.000 bpd Units at Formosa Petrochemical

Charge Heater Q (operating) = 5 MW = 17 MM BTU/hr Q (design) = 12 MW

744 680

8950

Quench gas 210 t/d R1

776 662 657 716

Q E3 = 7 MW

464

Eliminated:

689

45
MP Steam 100 t/d

75% of Heater Duty 40% of Compressor HP 40% of Cooler Duty

PACKINOX 94 MW 320 MM BTU/hr

131 217 Recycle Gas 320 t/d
P1 0.9 MW

Wash Water 430 t/d 110F Recycle Gas Comp.

419 460

= 2.20 MW = 2950 hp
783 624

Q (E4) = 23 MW Q (design) = 30 MW

PACKINOX 39 MW 133 MM BTU/hr

129 158 8640 120
Q E9 = 4 MW Q (design) = 5

520 122

On line Since 12/2000 Savings per Unit:

MW

CAPEX > $5 Million OPEX > $3 Million / yr

SOUR GASOIL FEED 8 630 t /d = 65.000 bpd 122F - Temp. (F) - Pressure(PSI) - Flow (t/d)

FRESH H2 70 t /d 110F

Cold Gas Oil 8 190 t/d

Selected PFD with PACKINOX Exchangers

Texas Technology Showcase 2003 - 12

Case Story: Diesel Hydrotreater

Two 65.000 bpd Units at Formosa Petrochemical

Charge Heater Q (operating) = 23 MW = 78 MM BTU/hr Q (design) = 25 MW

8950 744 680
R1 Quench gas 210 t/d

813 581 716 657 649 583 Shell-&-Tubes E2 A/E 68 MW 232 MM BTU/hr
Q E3 = 17 MW

464

45
MP Steam 100 t/d Wash Water 430 t/d 110F Recycle Gas Comp.

Same Unit based on S&T: Heater: 78 MM BTU/hr v. 17 MM BTU/hr Compressor: 5000 hp v. 2950 hp Cooler: 133 MM BTU/hr v. 78 MM BTU/hr

347 460
Q (E5 A/B)

336 Recycle Gas 320 t/d 284

P1 0.9 MW

3.73 MW 5000 hp
850
Q (E4) = 39 MW Q (design) = 40 MW

586 129 246

29 MW 99 MM BTU/hr
Q E8 = 6 MW 20 MM BTU/hr (HDS Feed) Q E9 = 8 MW Q (design) = 10 MW

122 171
to / from E8

520 8640 120

SOUR GASOIL FEED 8 630 t /d = 65.000 bpd 122F - Temp. (F) - Pressure(PSI) - Flow (t/d)

FRESH H2 70 t /d 110F

Cold Gas Oil 8 190 t/d

Planned PFD with Shell-&-Tube Exchangers

Texas Technology Showcase 2003 - 13

Case Story: Catalytic Reforming

1000 900 Temperature, Degrees F 800 700 600 500 400 300 200 100 0 0 100.00 200.00 300.00 400.00 500.00 Heat Duty, MM BTU/hr Feed Effluent

More than 50 Units Retrofitted Around the World

Two Reduction Samples in North America: 59.000 tons CO2 Equiv. / yr on a 40.000 bpd Reformer 16.500 tons / yr on a 26.000 bpd Reformer

Texas Technology Showcase 2003 - 14

Case Story: Pygas Hydrotreater (Mitsui, Japan)

BFW

Unit with S&T before Revamp with PSHE

H2 Heater 300C

Heater 28

MM BTU/hr

Reactor

Fuel gas consumption 13.9 tonnes/day

Off Gas Recycle H2 Comp.

Operation Restricted by Limits on Air Pollution

Shell-&-Tube Exchangers
330 C
H2 Pre-heater - II AG Feed Pre-heater

130 C
H2 Pre-heater - I HP Effluent Cooler

Stabilizer

SW AG

Re-boiler

HPG

Texas Technology Showcase 2003 - 15

Case Story: Pygas Hydrotreater (Mitsui, Japan)

Eliminated:

100% of

BFW H2 Heater
- normally Off-line

Heater Duty after WarmUp

300C

Reactor

Fuel gas consumption 0 tonnes/day

Off Gas Recycle H 2 Comp.

On line since 1995 Allows to Operate during Air Emissions Restriction

330 C

Combined Feed Packinox Exchanger (AG + H ) 2

80 C
HP Effluent Cooler

Stabilizer

SW

AG

12 Bar.g Steam
Re-boiler

HPG

Texas Technology Showcase 2003 - 16

Summary

High Efficiency Shell & Plate Heat Exchangers

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