engineering and technology partner

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A A - S P A I N

TA B L E O F C O N T E N TS your engineering and technology partner

COMPANY BUSINESS CONCEPT R&D PHILOSOPHY CAPABILITIES AND SERVICES

PROCESS ENGINEERING Process Simulation Upset Analysis Sensitive Analysis PROCESS EQUIPMENT Thermal-Hydraulic and FEA CHT - Conjugated heat transfer Equipment Design

CASE STUDIES
PROCESS ENGINEERING Process Simulation Upset Analysis Sensitive Analysis PROCESS EQUIPMENT Thermal-Hydraulic and FEA CHT - Conjugated heat transfer Equipment Design

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C A D E s o l u c i o n e s d e i n g e n i e r i a E S P A A S P A I N

C O M P A N Y
adding value to our partners
CADE is an expert provider of advanced and specialized engineering, technology and R&D services focused on process and mechanical engineering, serving as a technology partner to its cliens. Since the beginning of its activities in 2003, CADE's philosophy has been focused on developing close collaborative relationships with its clients. This objective is achieved by becoming an extension of our clients' engineering and R&D staff, working together to face any challenge. In order to meet all of the client's requests, CADE takes on each and every project guided by the company's three main principles: SPECIALIZATION, FLEXIBILITY AND EXCELLENCE

P OW E R

G E N E R A T I O N

R E N E WA B L E S

O I L & G A S

R E F I N E R Y

P E T RO C H E M I S T R Y

BUSINESS CONCEPT
advanced engineering and technolgy develompent
Nowadays, it is essential to face any complex problems associated with the development, operation and upgrade of existing or new technologies and the related equipment by applying multiple engineering and technolgy approaches. With the goal of obtaining the best solution available and maximizing effectiveness and efficiency, it is necessary to understand the implicit problems of these technologies and the related equipment during all stages. This task can only be achieved by applying all the engineering disciplines involved in the design, fabrication, start-up and operation phases together with a comprehensive knowledge and vast experience in different industrial fields. CADE combines advanced capabilities in process and mechanical engineering working collectively with its clients to achieve these objectives. CADE supports its client by providing custom-made advanced engineering solutions adjusted to suit the nature of the client's projects and technical capabilities. A full range of advanced engineering capabilities are applied for reaching your goals.

Focus: advanced mechanical and process engineering

industries served
- POWER GENERATION (CONVENTIONAL, NON CONVENTIONAL) - RENEWABLE ENERGY - REFINERY PLANTS - PETROCHEMICAL INDUSTRY - WASTE TREATMENT - WASTE TO ENERGY - CHEMISTRY AND PHARMACY - FOOD INDUSTRY

customers and parnters

PLANT OWNERS AND OPERATORS TECHNOLOGY LICENSORS EPC CONTRACTORS PACKAGE UNIT SUPPLIERS MANUFACTURING COMPANIES ENGINEERING COMPANIES

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developing technology and applications

R & D P H I L O S O P H Y

Due to specialized nature of CADE's activities, new applications, potential upgrades and transfers of technology from one sector to another are commonly required in order to take on our client's most challenging projects. CADE actively integrates internal R&D activities within its business structure in order to face these challenges and generate knowledge that allow us to develop new technologies, applications and products. CADE takes advantage of being integrated in the ALBACETE SCIENTIFIC AND TECHNOLOGICAL PARK in order to count on the most significant institution in technology and R&D for support and collaborative work.

R &D approach and methodology

Within the scope developed by CADE for its internal R&D projects as well as those developed jointly with its clients/partners, the following R&D methodology is regularly applied: Technology needs assesment/design basis State of the art research Potential technological solution/upgrade Pilot Plant / Prototype design/construction Experiments design Process simulation and optimization Definition of scaling models Feasibility research Industrial scaled design

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s t rategic R &D fields

- SOLAR - CSP Technologies (process & equipment) - CSP plants - Energy Storage - Supercritical fluids tecnologies - Extracting applications - Reacting medium - Thermodynamic cycles - Waste Treatment and Enviromental Technologies - Biomass / Biogas - Waste Heat Recovery - Refrigeration and cooling - Steam generation - Drying technologies - Biodiesel - Mixing equipment and processes

s o l u c i o n e s d e i n g e n i e r i a

ongoing internal R &D projects

- Design and development of innovative SPRAY DRYER - Design and development of hydrogen production technology from humid biomass waste based on supercritial fluid technology - HTF System optimization of CSP plants - Thermal Energy Storage based on concrete

E S P A A S P A I N

CAPABILITIES AND SERVICES

1 - Process Engineering 1.1 - Process Simulation
1.2 - Upset Analysis 1.3 - Sensitive Analysis 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design

advanced mechanical engineering advanced energy, thermal and process engineering

key points

- Complex systems (streams, variables, etc.) - Transient State - Multi-component systems - Multi-phase flow - Reacting medium - Optimization Needs

CADE's approach

PROCESS SIMULATION Steady State Transient State

PROCESS OPTIMIZATION - Design State - Operational State

SCOPE Hydraulic Thermal Thermodynamics Separation Process Reacting Medium

PFDs Vs. Operational Conditions Operational Variables Optimization Feasibility analysis (technical - economical) Improvement and upgrades proposal Inputs for HAZOP

software tools

ASPEN HYSYS MATHCAD HTFS (ASPEN) ANSYS

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CAPABILITIES AND SERVICES

1 - Process Engineering
1.1 - Process Simulation

advanced mechanical engineering advanced energy, thermal and process engineering

1.2 - Upset Analysis

1.3 - Sensitive Analysis 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design

key points

- High pressure and temperature (equipment) - High influence of operational parameters of performance - High sensibility processes - Complex control systems - Low control grade - Unstable processes

approach
P R O C E S S VA L I D A T I O N / R E - D E S I G N PROCESS SIMUL ATION UNDER UPSET CONDITIONS Transient State Pressure Relief Systems Re-Design (operational condtitions, materials, etc.) By Pass Systems Control Loops SIL Levels Process Instrumentation Inputs for HAZOP

MECHANICAL ANALYSIS UNDER UPSET CONDITIONS FEA Static / Transient State

M E C H A N I C A L VA L I D A T I O N / R E - D E S I G N Thermal - Structural FEM analysis Fatigue analysis Temperature/stress distribution over solid model (metal) Pressure parts reinforcement (tubesheets, nozzles, etc.) Internal refractory lining

software tools

ASPEN HYSYS MATHCAD HTFS (ASPEN) ANSYS

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CAPABILITIES AND SERVICES

1 - Process Engineering
1.1 - Process Simulation 1.2 - Upset Analysis

advanced mechanical engineering advanced energy, thermal and process engineering

1.3 - Sensitive Analysis

2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design

key points

- Unestable equilibrium state - High sensibility processes - High Dependance between variables - High Performance assurance

CADE's approach

SENSITIVE STUDY Transient State

P R O C E S S VA L I D A T I O N / R E V I E W Change of Operational Parameters Phase Diagrams Control Strategies Definition of Control Loops Re-Tuning of Control Loops Relationships between variables "What If" Studies Inputs for HAZOP

software tools

ASPEN MATHCAD

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CAPABILITIES AND SERVICES

1 - Process Engineering 1.1 - Process Simulation 1.2 - Upset Analysis 1.3 - Sensitive Analysis

advanced mechanical engineering advanced energy, thermal and process engineering

2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis

2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design

key points

- High pressure and temperature - Dynamic processes - Thermal and Mechanical Performance importance - High Stress requirements - Cycle operation (Start Up, Shut Down). Fatigue phenomena - Heat Bridges, Heat Losses, Internal Lining - Flow Effect: Vibrations, noise, pressure drop, turbulence - Fitness for Service Assessment API 579 - Compressibility effects (gases)

CADE's approach

P R O C E S S VA L I D A T I O N / R E - D E S I G N THERMO - HYDRAULIC ANALYSIS CFD SIMUL ATION Steady State Transient State Flow Distribution Heat Transfer Profiles Temperature Profiles Pressure Profiles Velocity Profiles

MECHANICAL ANALYSIS FEA

M E C H A N I C A L D E S I G N / VA L I D A T I O N Thermal - Structural FEM analysis Fatigue analysis Short and long term cycle perfomance Temperature/stress distribution over solid model (metal) Full dynamic response, spectrum, harmonic, modal analysis Fitness for Service Assessment API 579

Steady State Transient State

software tools

CFD (Computational Fluid Dynamics) FLUENT, CFX, OPENFOAM MATHCAD ANSYS

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CAPABILITIES AND SERVICES

1 - Process Engineering 1.1 - Process Simulation 1.2 - Upset Analysis 1.3 - Sensitive Analysis

advanced mechanical engineering advanced energy, thermal and process engineering

2 - Process Equipment Engineering

2.1 - Thermal-Hydraulic and FEM Analysis

2.2 - CHT - Conjugated Heat - Transfer

2.3 - Process Equipment Design

key points

- Transient heating of solid / fluid - Tridimensional Heat Transfer inside solid / fluid - Heat Transfer controlled by Heat Capacity of solid - Phase change of solid / fluid - Large thickness equipment under cycle operation - Liquid/Gas circulation inside solid - High mass ratio solid/fluid systems - Heat transfer inside solid assumed as not negligible

CADE's approach

P R O C E S S D E S I G N / CFD VA L I D A T I O N CONJUGATED HEAT TRANSFER CFD Transient State Heat Transfer between fluid and solid Temperature Profiles (solid and fluid) Exchanged Power Profiles Vs Time Local Effects (extended surfaces) Heating demand by solid (heating applications) Heat recovered (heat recovery applications)

MECHANICAL ANALYSIS FEA

M E C H A N I C A L D E S I G N / VA L I D A T I O N Thermal-Structural FEM analysis Short and long term cycle perfomance Fatigue analysis Full dynamic response, spectrum, harmonic, modal analysis Fitness for Service Assessment API 579

Steady / Transient State

software tools

CFD (Computational Fluid Dynamics) FLUENT, CFX, OPENFOAM ANSYS

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CAPABILITIES AND SERVICES

1 - Process Engineering 1.1 - Process Simulation 1.2 - Upset Analysis 1.3 - Sensitive Analysis

advanced mechanical engineering advanced energy, thermal and process engineering

2 - Process Equipment Engineering

2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer

2.3 - Process Equipment Design

key points

- Heat Transfer - Hydraulic regimen influence - Mass Transfer - Gas-Liquid Systems - Solid-Fluid Systems - Heat Recovery - Reacting medium

Air Cooler TEMA Heat Exchanger HRSG / Waste Heat Boiler Steam Drum Steam Dryer Deaerator Separation Equipment Reactor Dynamic Mixer

CADE's approach
P RO C E S S D E S I G N REFERENCE CASE Design Case Rating Case Main Dimensions Internals Reference P&ID Reference PFD (design and rating cases) Process Data Sheet (design and rating cases)

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MECHANICAL DESIGN

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Design according to codes Static / Dynamic FEA Steady / Transient State FEA

M E C H A N I C A L D E S I G N / VA L I D A T I O N Mechanical design Piping stress analysis Thermal - Structural analysis Short and long term cycle perfomance Fatigue analysis Full dynamic response, spectrum, harmonic, modal analysis

THERMO-HYDRAULC CFD SIMULATION + F E M A N A LY S I S

CFD + FEA as per point 2.1 Fitness for Service Assessment API 579

Steady / Transient State

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Mathcad ASPEN Hysys HTFS (ASPEN) PVELITE CAESAR II CFD - FLUENT, CFX, OPENFOAM ANSYS

design codes

ASME AD2000 EN CODAP BS

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1.2 - Upset Analysis 1.3 - Sensitive Analysis 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design

CASE STUDY
advanced mechanical engineering advanced energy, thermal and process engineering

flare gas recovery system

objective
Thermal and Hydraulic simulation of exhaust gas pipe network (including relief valves behaviour) and flare stack. Mechanical validation of pipes, KO Drum and flare stack. Following issues were carried out: Simulation of relief valves Heat transfer simulation between gas and external ambient (hot case, cold case, rain, etc.) Friction pressure losses and vacuum simulation of pipe network CFD simulation for obtaining temperature and pressure profiles inside the flare stack in transient conditions. Mechanical validation of pipes and KO Drum under vacuum conditions. Mechanical validation of flare shaft considering temperature profile along the shaft for hot and cold cases. Upgrading mechanical proposal for KO Drum and Flare according to current corrosion status.

approach
- Thermal and Hydraulic simulation - Mechanical pipe network validation under vacuum according to ASME B31.3 - FEA validation of KO Drum and shaft flare including temperature influence on guyed stack

results and conclusions

- Pressure and temperature profiles along pipe network - Pressure and temperature profiles along flare shaft - Upgrading mechanical proposal for vessels (KO Drum) and shaft flare

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1.2 - Upset Analysis 1.3 - Sensitive Analysis 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design

CASE STUDY
advanced mechanical engineering advanced energy, thermal and process engineering

steam generator train in CSP (concentrated solar power) plants

objective
Thermal design of a Steam Generator Train for a CSP Power Plant (Solar Parabolic Trough) unde steady state operational conditions and transient simulation during Steam Turbine Start Up. Following issues were carried out: Transient Performance of Steam Generator Train (Steam temperature, pressure and mass flow Vs time) Solar field simulation Vs time (HTF temperatures and flow curves Vs time) Thermal design under steady state conditions Redesign of Heat Exchanger Train to meet Steam Requirements during turbine start up

approach
- Thermal steady state design - Simulation of HTF System (Solar field, steam generation train and steam turbine) - Optimization of steam generator train to meet steam turbine start up ramp (design)

results and conclusions

- Optimized geometry of Steam Generation Train - Performance curves

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1.2 - Upset Analysis 1.3 - Sensitive Analysis 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design

CASE STUDY
advanced mechanical engineering advanced energy, thermal and process engineering

HTF system sizing optimization in CSP plants

objective
Size optimization of HTF pipe network in Solar Parabolic Trough Power Plant according to real solar irradiation (DNI) on plant location. Following issues were carried out. Simulation of solar irradiation Simulation of solar collectors performance within solar field Calculation of HTF temperature and mass flow curves withing solar field Hydraulic simulation of pipe network in order to determinate friction losses. Thermal simulation of pipe network in order to determinate heat losses. Size optimization of individual parts of pipe network from aneconomical and energetic point of view.

approach
- Simulation of solar field - Thermal and Hydraulic simulation of HTF pipe network - Optimization algorithm

results and conclusions

- Optimum size of individual parts of HTF pipe network

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1.2 - Upset Analysis 1.3 - Sensitive Analysis 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design

CASE STUDY
advanced mechanical engineering advanced energy, thermal and process engineering

downstream treatment and combustion of a compressed Syngas

objective
Simulation of Downstream treatment and Combustion in a Gas Turbine of a compressed Syngas stream. Following issues were carried out. - Simulation of Downstream treatment (cooling, depressurization, solubility and gas-liquid separation) - Gas turbine simulation - Optimization of process variables in order to maximize electric power from turbine - Hydraulic simulation of pipe network in order to determinate friction losses. - Integration useful thermal energy of exhaust hot gases from turbine in actual process plant - Feasibility

approach
- Simulation of Downstream Process - Simulation of Gas Turbine - Optimization algorithm

results and conclusions

PFD P&ID Optimized Downstream Treatment variables Technical-Economical feasibility study

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1.2 - Upset Analysis 1.3 - Sensitive Analysis 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design

CASE STUDY
advanced mechanical engineering advanced energy, thermal and process engineering

advanced gasification processes (reacting medium)

objective
Optimization of Pressure and Temperature for a biomass gasification process in order to maximize Low Heating Value (LHV) of Syngas. Following issues were carried out. Simulation of kinetic of Gasification Process Study of influence of Pressure and Temperature in kinetic and composition of Syngas Performance curves Vs pressure and temperature Optimization of process variables to maximize LHV of Syngas Proposal of gasification reactor dimensions Economical study for optimization case.

approach
- Simulation of process - Optimization algorithm - Feasibility study

results and conclusions

Optimized process variables Performance of reactor for optimized variables Technical-Economical feasibility study for optimized cases Proposal of gasification reactor main dimensions

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1 - Process Engineering
1.1 - Process Simulation

CASE STUDY
advanced mechanical engineering advanced energy, thermal and process engineering

1.2 - Upset Analysis

1.3 - Sensitive Analysis 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design

heat recovery steam generator (HRSG)

objective
Influence evaluation of two upset conditions from a process and mechanical point of view on HRSG (fired tube type). Conditions to be evaluated: by-pass system failure and steam line depressurization. Following issues were carried out: Thermal and Hydraulic simulation under upset conditions (tube side and shell side) Refractory lining performance (channels, tubesheet, and tubes) Temperature distribution of pressure parts by performing transient FEA Stress distribution of pressure parts by performing transient FEA Proposal to minimize effects of upset conditions under consideration

approach
- Thermal-Hydraulic simulation - Transient Thermal and Mechanical FEA

results and conclusions

- Temperature and pressure distribution of cold and hot fluids - Temperature and stress distribution of pressure parts - Remediation and prevention process measures

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1 - Process Engineering
1.1 - Process Simulation

CASE STUDY
advanced mechanical engineering advanced energy, thermal and process engineering

1.2 - Upset Analysis

1.3 - Sensitive Analysis 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design

water knock-out drum with internal tube heat exchanger

objective
Simulation of Water Knock-Out (3-phase configuration) under failure of temperature control valve of steam supply line for internal coil. Following issues were carried out: Maximum steam flow through control valve Temperature and evaporation rate of water under maximum steam flow Turbulence inside vessel Performance of separator (composition of each phase) Performance of demister under upset conditions (flow temperature, pressure and gas composition)

approach
- Heat transfer simulation between internal tube exchanger and fluid) - Hydrodynamic simulation of liquids under evaporation conditions - Thermodynamic equilibrium of phases

results and conclusions

- Separation Efficiency for each phase - Composition of each phase - Maximum temperature of each phase

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1 - Process Engineering
1.1 - Process Simulation

CASE STUDY
advanced mechanical engineering advanced energy, thermal and process engineering

1.2 - Upset Analysis

1.3 - Sensitive Analysis 2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design

biogas line
objective
Simulation of influence of failure in Methane composition Control Loop on biogas line equipment (H 2 S removal, gas turbine, flare and related equipment ) Following issues were carried out: - Calculation of maximum flow and composition of biogas under uncontrolled captation. - Simulation of effect over hydraulic seals of biogas line (biogas leak to atmosphere) - Response simulation of H2S removal system under biogas peak flow (peak of H2S content in outlet stream) - Composition of combustion gases under H2S peak - Dew point for acid components of combustion gases and risk of corrosion in cold points

approach
- Hydraulic simulation on biogas pipe network - Process simulation of equipment (desulphuration scrubber, gas turbine and flare) - Emissions and corrosion study

results and conclusions

- Flow and compositon of emissions - Cold points to be checked to prevent local corrosion - Re-design of lines and drain points

Friction losses

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1 - Process Engineering
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CASE STUDY
advanced mechanical engineering advanced energy, thermal and process engineering

1.3 - Sensitive Analysis

2 - Process Equipment Engineering 2.1 - Thermo-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design

exothermic reactor

objective
Thermal and Kinetic Simulation of Exothermic Reactor in order to define cooling system and control loop. Following issues were carried out: Kinetic simulation Heat transfer simulation between reacting medium and internal cooling coil Calculation of steady steates Vs cooling fluid temperature Stability Phase Diagrams Definition of stable operation conditions

approach
- Kinetic and thermal model - Transient simulation and steady state calculations Vs operational conditions

results and conclusions

- Operational conditions (reacting medium and cooling system) in order to achieve stable steady states. - Sensitive diagrams for main operational variables - Temperature control loop proposal

Diagram phase (unstable steady state)

Diagram phase (stable steady state)

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CASE STUDY
advanced mechanical engineering advanced energy, thermal and process engineering

1.3 - Sensitive Analysis

2 - Process Equipment Engineering 2.1 - Thermo-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design

biological reactor (Fermenter)

objective
Kinetic Simulation of Fermenter in order to determinate stable conditions for start-up and operation as well as prediction of effects of changes in biomass inlet flow. Following issues were carried out: Kinetic simulation Calculation of steady states Vs initial biological substrate concentration Effect of changes in inlet biomass flow on each steady state Recirculation effect

approach
- Kinetic simulation - Transient simulation and steady states calculation - Methane production optimization

results and conclusions

- Operational conditions to achieve steady state with maximum methane production - Recirculation rate - Control loop proposal based on methane concentration

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CASE STUDY
advanced mechanical engineering advanced energy, thermal and process engineering

2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis

2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design

lp bog after cooler (air cooled heat exchanger)

objective
Thermal-Hydraulic and mechanical validation of air cooler (ACHE) working as after cooler in gas compression line during start-up (recycled and opened flow) Following issues were carried out: ACHE thermal rating for each point of start-up ramp Thermal-hydraulic simulation of tubeside during start-up ramp Dynamic stress analysis Fatigue analysis and evaluation

Air side film coefficient Vs time

approach
- Performance of ACHE during start-up ramp - CFD of tubeside during start-up - FEM analysis of nozzles, headers, finned tubes and tubesheets during start-up. Input data extracted from previous CFD output.

results and conclusions

- Mass flow rate which allows a safety and stable start-up of line, in order to avoid excessive pressure losses, local absolute pressures and velocities. - Detail thermal performance of ACHE during start-up. - Maximum stress of pressure parts - Maximum allowable number of cycles - Design modifications and aumented inspections proposal for bundle tube supports

Inlet flow rate Vs time

Tube side Mach number

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CASE STUDY
advanced mechanical engineering advanced energy, thermal and process engineering

2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis

2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design

HTF expansion vessel

objective
Mechanical design of nozzles and saddles of HTF system equipment (expanssion vessels, buffer tanks, etc.). Thermal shock evaluation under transiend conditions. Following issues were carried out: - Transient thermal calculation of fluid bulk temperature inside based on initial temperature, inlet temperature and flow curves - Inside heat transfer coefficient for gas and liquid - FEA of nozzles (inlet liquid part) - FEA of saddles - Fatigue analysis and evaluation

approach
- Transient thermal simulation (inputs required for FEA) - FEA for pressure parts (shell, heads, nozzles) and saddles

results and conclusions

- Nozzles reinforcement - Saddles geometry - Maximum number of allowable cycles for operating life

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CASE STUDY
advanced mechanical engineering advanced energy, thermal and process engineering

2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis

2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design

WHB - waste heat boiler

objective
Validation of conventional thermal and mechanical design of two Waste Heat Boiler (WHB) of a Desulphuration Plant by means of Finite Element Analysis (FEA) in order to study local effects from a thermal and mechanical point of view, considering process requirements. Following issues were carried out: - Thermal-Hydraulic design (full) including steam risers and downcomers - Definition of internal refractory lining for channels to meet minimum and maximum wall temperature limits for cold and hot process cases. - Validation of tubesheet lining and ferrules of tubes (Max. tube-tubesheet temperature) - FEA of channels, forged ring/Knucle and tubesheet - FEA of risers and downcomers

approach
- Static thermal simulation to determinate tube side and shell side bulk temperatures and heat transfer coefficients. - FEA to determinate temperature distribution within solids - FEA to determinate stress of pressure parts

results and conclusions

Full mechanical design Channels and tubesheet linning Forged ring knuckle geometry Tubesheet thickness Risers and downcomers stress analysis

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1 - Process Engineering 1.1 - Process Simulation 1.2 - Upset Analysis 1.3 - Sensitive Analysis

CASE STUDY
advanced mechanical engineering advanced energy, thermal and process engineering

2 - Process Equipment Engineering 2.1 - Thermal-Hydraulic and FEM Analysis

2.2 - CHT - Conjugated Heat - Transfer 2.3 - Process Equipment Design

flue gas system

objective
Validation of conventional thermal and mechanical design of two Waste Heat Boiler (WHB) of a Desulphuration Plant by means of Finite Element Analysis (FEA) in order to study local effects from a thermal and mechanical point of view, considering process requirements. Following issues were carried out: - Definition of internal refractory lining for channels to meet minimum and maximum wall temperature limits for cold and hot process cases. - Validation of tubesheet lining and ferrules of tubes (Max. tube-tubesheet temperature) - FEA of channels, forged ring/Knucle and tubesheet - FEA of risers and downcomers

approach
- Static thermal simulation to determinate tube side and shell side bulk temperatures and heat transfer coefficients. - FEA to determinate temperature distribution within solids - FEA to determinate stress of pressure parts

results and conclusions

Channels and tubesheet linning Forged ring knuckle geometry Tubesheet thickness Risers and downcomers stress analysis

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1 - Process Engineering 1.1 - Process Simulation 1.2 - Upset Analysis 1.3 - Sensitive Analysis

CASE STUDY
advanced mechanical engineering advanced energy, thermal and process engineering

2 - Process Equipment Engineering

2.1 - Thermal-Hydraulic and FEM Analysis

2.2 - CHT - Conjugated Heat - Transfer

2.3 - Process Equipment Design

melting zinc furnace

objective
Optimization of Zinc Melting Furnace (thermal duty, recirculation rate and geometry) by CFD/CHT Following issues were carried out: Transient Ingot Heating simulation during specified melting time Thermal-Hydraulic simulation of surrounding heating fluid (liquid zinc) Effect of recirculation rate and chambers geometry Effect of solid ingot in flow profiles during melting process Transient study of trayectories of slag inside melting chamber

approach
- Transient conjugated heat transfer of system solid ingot-liquid zinc (Fluent) - Optimization of process and geometry parameters

results and conclusions

- Chambers geometry - Recirculation mass flow - Thermal duty and position of burners

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1 - Process Engineering 1.1 - Process Simulation 1.2 - Upset Analysis 1.3 - Sensitive Analysis

CASE STUDY
advanced mechanical engineering advanced energy, thermal and process engineering

2 - Process Equipment Engineering

2.1 - Thermal-Hydraulic and FEM Analysis

2.2 - CHT - Conjugated Heat - Transfer

2.3 - Process Equipment Design

thermal energy storage

objective
Design of thermal storage system based on concrete with thermal oil acting as heating/cooling fluid by CFD/CHT System is able to storage excess energy and to recover it adapted to demand with thermal oil as heating / cooling fluid Following issues were carried out: - Definition of tubes geometry and pitch - Thermal-Hydraulic simulation of tubeside (HTF side) - Tridimensional conduction heat transfer inside solid based on thermal properties (conductivity and heat capacity) - Definition of external isolation in order to minimize heat losses

approach
- Transient conjugated heat transfer of concrete system (Fluent) - Optimization of geometry in order to meet process requirements (heating and cooling ramps)

results and conclusions

- Heat Exchanger geometry (concrete section and tubes) - Charging and discharging curves Vs time

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1 - Process Engineering 1.1 - Process Simulation 1.2 - Upset Analysis 1.3 - Sensitive Analysis

CASE STUDY
advanced mechanical engineering advanced energy, thermal and process engineering

2 - Process Equipment Engineering

2.1 - Thermal-Hydraulic and FEM Analysis

2.2 - CHT - Conjugated Heat - Transfer

2.3 - Process Equipment Design

finned tubes (recovery heat exchanger)

objective
Determination of effect of finned tube (thermal inertia based on heat capacity) on gas temperature during transient periods in an Air Cooler Heat Exchanger. Definition of temperature control loop and winterization strategies. Following issues were carried out: - Thermal air side / tube side simulation - Calculation of heat exchanged based on inlet tube side temperature and flow curves. - Performance of finned tube Vs time - Tube side outlet temperature Vs time

approach
- Transient Conjugated Heat Transfer of air - finned tube -gas system - Calculation of effect on outlet gas temperature of heat capacity of finned tube Vs time

results and conclusions

- Process gas outlet temperature considering thermal inertia of finned tubes - Proposal for "tunning" temperature control loop based on an adapting fuzzy control loop - Proposal for new set pont for recirculation air temperature during winterization strategy

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1 - Process Engineering 1.1 - Process Simulation 1.2 - Upset Analysis 1.3 - Sensitive Analysis

CASE STUDY
advanced mechanical engineering advanced energy, thermal and process engineering

2 - Process Equipment Engineering

2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer

2.3 - Process Equipment Design

waste heat boiler (WHB)

objective
Thermal, Hydraulic and Mechanical design of Waste Heat Boiler (fired tube type) for a Sulphur Recovery Plant. Following issues were carried out: - Thermal design of Shell and Tube Heat Exchanger (fired tube) - Hydraulic design of riser, downcomers and steam drum - Mechanical design of pressure parts based on design conditions - Thermal and Mechanical evaluation of rating cases

approach
- Process design (Thermal and Hydraulic) - Mechanical design of pressure parts

results and conclusions

- Thermal and hydraulic design (TEMA Process Data Sheet) - Mechanical Calculation report - Risers and downcomers Stress report This scope was complemented with a Thermal-Hydraulic + FEA analysis for detailed study of local effects as per case study described in section 2.1

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1 - Process Engineering 1.1 - Process Simulation 1.2 - Upset Analysis 1.3 - Sensitive Analysis

CASE STUDY
advanced mechanical engineering advanced energy, thermal and process engineering

2 - Process Equipment Engineering

2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer

2.3 - Process Equipment Design

heat exchangers
(biflux, feedwater heaters, closed cooling water, steam superheater, Shell and Tube, etc.)

objective
Thermal, Hydraulic and Mechanical design of Biflux Heat Exchanger (bayonet type) Following issues were carried out: - Thermal and Hydraulic design - Material selection - Mechanical design of pressure parts based on design conditions - Thermal and Mechanical evaluation of rating case

approach
- Process design (Thermal and Hydraulic) - Mechanical design of pressure parts

results and conclusions

- Thermal and hydraulic design (TEMA Process Data Sheet) - Mechanical calculation report

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1 - Process Engineering 1.1 - Process Simulation 1.2 - Upset Analysis 1.3 - Sensitive Analysis

CASE STUDY
advanced mechanical engineering advanced energy, thermal and process engineering

2 - Process Equipment Engineering

2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer

2.3 - Process Equipment Design

spray dryer
objective
Design of Spray Dryer (drying chamber and cyclon chamber) for lixiviates effluent from landfill. Following issues were carried out: - Atomization system design - Air heating supply design - Volute air inlet design - Drying chamber and cyclon design - Instrumentation and control - Mechanical design of pressure parts and auxiliary structures

approach
- Fluid-dynamics design of drying chamber and cyclon by means of CFD simulation - Static Mechanical design of pressure parts - Mechanical design of auxiliary structures

results and conclusions

P&ID Dimensional drawings of drying chamber and cyclon Atomization system specification Specification Data Sheet of commercial components Instrumentation and control strategy

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1 - Process Engineering 1.1 - Process Simulation 1.2 - Upset Analysis 1.3 - Sensitive Analysis

CASE STUDY
advanced mechanical engineering advanced energy, thermal and process engineering

2 - Process Equipment Engineering

2.1 - Thermal-Hydraulic and FEM Analysis 2.2 - CHT - Conjugated Heat - Transfer

2.3 - Process Equipment Design

air coolers
objective
Thermal, Hydraulic and Mechanical design of Air Coolers according to API 661. Following issues were carried out: Thermal design Rating evaluation Mechanical design of pressure parts Instruments and control loop proposal

approach
- Thermal design according to API 661 - Static Mechanical design of pressure parts

results and conclusions

- P&ID - API 661 Process Data Sheet - Control loops

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CSP - Concentrated Solar Power

CASE STUDY
advanced mechanical engineering advanced energy, thermal and process engineering

CSP Pilot Plant Basic and Detail engineering of molten salt Loop
objective
Complete basic and detail engineering of CSP pilot plant based on molten salt as heat transfer fluid. Following tasks were carried out: Basic and detail engineering including: Process design Design of main process equipment Mechanical/Structural/Civil Works/Electric engineering

results and conclusions

Molten Salt loop process simulation Thermal and Hydrodynamic simulation: HTF mass flow optimization (mmin / mmax) Temperature profile inside receiver Piping Stress and flexibility analysis Impedance heating Materials selection (piping, valves, etc.)

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