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Alfa Laval

• Group Presentation 2006

Presented by Bernard FONTAINE
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Markets ??
Energy Utilities ???????
Oil Gas, Power, Water, Environment,
?????,??,???,??.
Process Industry ????
Refinery, Chemical, Petrochemicals, Life Science,
Starch, Natural Resources, .. ??,
??,??,????,??,????..
Food Food related ???????
Brewery Beverages, Vegetable oil, Proteins,
Concentrates, ?????,???, ???,???...
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Key technologies ????
Separators Decanters ??????????
Heat Exchangers ???
Flow Equipment Membranes ??????
Other Equipment ????
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Alfa Laval

• Heat Exchangers ???

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Heat Exchangers ???

• Plate Heat Exchanger ?????
• Spiral Heat Exchanger ???????
• Welded Heat Exchanger Compabloc ???????
• Welded Heat Exchanger AlfaRex ????????
• Welded Heat Exchanger Packinox ?????????
• Plate Evaporator ?????
• Plate Condenser ?????
• Miscellaneous HEs ???????

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General refinery overview
Gas plant
Light ends
Sulphur
LPG
Isomerization
Light naphtha
Gasoline
Cat. reforming
Aromatics
Desalting
Gasoline treatment
Naphtha hydrotreating
Crude oil
Naphtha
Gasoline
Lt distillate hydrotreating
Light distillate
Atmospheric distillation
Kerosine and jet fuel
Diesel treatment
Heavy distillate hydrotreating
Heavy distillate
Diesel and heating oil
Atmospheric gas oil
FCC
Alkylation
Gas oil hydrotreating
Atmospheric residue
Hydrogen generation
Hydrocracking
LVGO
Lube treating
Gas oil
Vacuum distillation
HVGO
Lube oils
Coke
Coking
Vacuum residue
Heavy fuel oil
Visbreaking
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Alfa Laval Packinox

• Introduction
• ???????????
• ??

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Alfa Laval PackinoxOrders in M ???? (??????)
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Heat Exchangers
Catalytic Reforming ????
Stripper ???
Hydrotreater ??
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Alfa Laval Packinox

• Emissions
• ???????????????????

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Heater stack emissions NOx???????NOx

• Thermal NOX ????NOx
• Primarily function of flamme temperature
• ???????????
• Estimate 3 tons per year (tpa) / process MW
• ?????? ??????MW?????3?
• Fuel NOX ?????NOx
• Depends on Nitrogen in fuel (N wt.)
• ?????????(N?????)
• Emission 36N tpa / process MW
• ??? ??????MW?????36x???????
• Estimate N 0,25 9 tpa / MW
• ?????????N 0.25, ??????MW??9?
• Total NOX Thermal Fuel NOX ??NOx???????NOx??
  ???NOx
• Estimate 12 tpa / MW ?? ??NOx???12????MW
• Valuation 1000 USD / ton ? 12,000 / MW /
  year
• ?? 1000 ??/?? ? ??????MW 1?2????

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Heater stack emissions SOx???????SOx

• SOX
• Function of Sulfur in Heater fuel (S wt)
• ??????????(S?????)
• Typically much higher S in fuel oil than in fuel
  gas
• ???????????????????
• Emission 27S tons per year (tpa) / process MW
• ??? 27xS(?????)?/ ?MW??
• Estimate S 0.6 ? 16 tpa / MW
• ?? S 0.6, ???? 27x 0.6 16 ??MW??
• Valuation 1000 USD ton ? 16,000 / MW /
  year
• ?? 1000 ??/?, ? ? 1?6???/?MW??

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Heater stack emissions GHG??????? ????

• Greenhouse Gas (GHG) ????
• Carbon in fuel transformed into CO2 during
  combustion
• ??????????????CO2
• Average carbon content in fuel 71 wt.
• ????????71 ?????
• GHG emission 2500 tons per year (tpa) / process
  MW
• ??????? 2500 ?/??,?MW
• Valuation 20 USD / ton ? 50,000 / MW /
  year
• ?? 20 ??/??, ?, ???????5???/??, ?MW
• Kyoto Accord ?????
• In effect as of 16 February 2005, ?2005?2?16???
• Europe Shortfall fine set at 40 Euros / ton
  (gt50 USD / ton)
• ???, ????????40?? (gt50??/??)

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Heater stack emissions???????
SUMMARY Value of 1 MW Duty Gain at the CFE
????????MW?????????????
Primary Assumptions
Primary Assumptions ????
Rule Of
-
0.6 S in Fuel???????????
-
50 USD per BOE ??50??/?
-
-
-
Heater not equipped with SOX or NOX
-
65 Heater ????????65
-
-
Thumb ????
abatement devices (Scrubbers, SCR,
0.25 N ???????????
-
-
etc.) ???????SOX ?NOX ??
Fuel Cost Savings at
100
380,000
100
Heater ???????
NOX SOX Emissions
10
28,000
10
28,000
Savings ??NOX?SOX ????
GHG Emissions
15
50,000
15
50,000
Savings??????????
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Alfa Laval Packinox??????????????

• Hydro Desulfurization
• ???????????
• Cleaning by Controlled Combustion
• ???????

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Alfa Laval PackinoxHydro Desulfurization ??????
Stripper ??????
Combined Feed Effluent ???? ???
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Alfa Laval PackinoxHydro Desulfurization
?????????
Plate Bundle ?? Stainless steel 304, 321 or 316,
??? 304,321 ?316 Thickness 0.8 to 1.5 mm,
?? 0.8 ? 1.5mm Bellows ??? Cold side?? Inconel
625, Hot Side ?? Incoloy 800 or 825 Pressure
vessel ???? Cr-Mo steels 1.25 Cr-0.5 Mo, 2.25
Cr-1 Mo, Cladded Stainless steel, Carbon steel ,
???,?????,??
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Alfa Laval PackinoxHydro Desulfurization ??????
Combined Feed Effluent Heat Exchanger ???????
- One shell, vertical ?????? - Pressure plates
on bundle ??????? - 5 bar diff. pressure
reversal ??5bar?? - Two manholes on shell
????????
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Alfa Laval PackinoxHydro Desulfurization??????
Stripper Liquid Liquid Heat Exchanger
?????-????? One bundle, vertical ??????
Pressure plates on bundle ??????? x bar diff.
pressure reversal ??x bar??
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Alfa Laval PackinoxHydro Desulfurization??????
FLOW DIAGRAM ???
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Alfa Laval Packinox ??Diesel Hydrodesulfuration
Formosa Petrochemical???????????????

• AXENS license ??AXENS ???
• Two parallel units of 65,000 bpd each
  ??65000?/?????
• Heat / material balance optimized with Packinox
  ?PACKINOX?????????????????
• Optimization with a Packinox on Stripper bottoms
  ????PACKINOX????????????
• Capital cost reduction ?????? 5.0 million
  5????
• Energy savings per unit ???????? 3.3 million/y
  330???(??2.5?2006??)
• GHG emission valorisation ?????????? 1.2
  million/y 120??? (??2.5?2006??
• On line since 4Q2000 2000?????????
• Now under revamp for ULSD ?????????????

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Alfa Laval PackinoxDiesel Hydrodesulfurization,
Formosa Petrochemical??????????????????
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Alfa Laval PackinoxDiesel Hydrodesulfurization,
Formosa Petrochemical??PACKINOX?????????
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Alfa Laval Packinox ????Diesel Hydrodesulfuration
Formosa Petrochemical
Low Temperature Separator ?????
Eliminated ?? 75 ?????of Heater Duty 40
?????of Compressor HP 40 ?????of cooler duty
Utility consumption Shell tubes Packinox Unit ?
??? ???
??? ?? Fire heater???
19 4 cents
(US)/bd Recycle compressor ?????? 6
4 cents (US)/bd Total ?? 25
8 cents (US)/bd
Basis year 2000 ??2000???? 1 BTU 1 kJ 1 MM
BTU 4 1kWh 0.045 345 stream days /
year 65 000 bpd or 3 Million t/y ??345????,
????300??
CAPEX Savings ?????? 500???Million USD OPEX
Savings/y ??????/? 3 80???Million USD/y GHG
Reduction/y ??????/? 5 ??CO2/?tons CO2/y
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Alfa Laval PackinoxDiesel Hydrodesulfuration
Formosa Petrochemical???????????????
Capacity 3 Million t/y, 300???????
Savings according 2006 energy cost
??2006?????,????
CAPEX Savings?????? 600??? Million USD OPEX
Savings/y??????? 950??? Million USD/y GHG
reduction/y??????? 5??CO2 50 000 tons CO2/y SOX
reduction/y ???SOX 320 ? tons SOX/y NOX
reduction/y ???NOX 240 ? tons
NOX/y Emission savings ?????? 150??? Million
USD/y
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Alfa Laval PackinoxPyrolysis Gasoline HDS
MITSUI???????????????? --- ????

• Feed from an Ethylene Cracker ????????
• One diolefine pre-Reactor ?????????
• 1 Packinox replaces 3 x Shell Tubes
  ??Packinox????3????
• Unit runs without using external energy (heater
  duty lowered from 8.3 MW to 0 MW)
• ????????????? (?????????8.3MW??0)
• No capacity reduction during emissions
  restriction period
• ????????????, ??????????.
• On line since 1995 ???1995????
• Energy savings 1 Million USD/y (2005 energy
  cost)
• ??2005????, ??????100???
• Emission valorisation 150,000 USD/y (2005 energy
  cost),
• ??2005???,?????????????15???/?

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Alfa Laval PackinoxPyrolysis Gasoline HDS
MITSUI???????????????? -- ???? (???)
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Alfa Laval PackinoxPyrolysis Gasoline HDS
MITSUI???????????????? -- ???? (??)
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Alfa Laval PackinoxPETROBRAS (Repar) distillate
HDS??????????????

• Cenpes / Petrobras Technology
• New 32,000 bpd Gasoil HDS unit??????32000?/????
• 90 Bar / 1300 psi ??90?
• Heat / material balance optimized with Packinox
• ?PACKINOX?????????????????
• PFD very similar to that of Formosa ???????PFD??
• 16C / 29F Hot End Approach ???? 16C / 29F
• Significant CAPEX and OPEX reduction
  ??????????????
• On line since early 2004 ??????????

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Alfa Laval Packinox Distillate HDS
OMV?????????????? OMV ??

• 5 ppm Sulphur Diesel ????5ppm?????
• Capacity 45,000 BPD ????45000?/?
• Design Press 80 bar ????80?
• Single Shell Design Start Up 4Q 2003 ????,
  2003????
• 44 MW ??? 44MW
• Preheat Duty Modulated with Partial Liquid Feed
  By-pass to Maintain HHPS Temperature
• ?????????????????????, ??????????
• Small, Variable Duty at Make-Up Charge Heater
• ???????????????.

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Alfa Laval PackinoxDistillate HDSOMV??????????
???? OMV ??
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Alfa Laval PackinoxHydrotreatment Installation
Recommendations (1)??????????????? (1)

• Equipment ??
• Filters on liquid feed 25 micron, ??????25?????
• Chloride guard bed on hydrogen supply,????????????
  
• Screen on Reactor effluent line (500 microns to 1
  mm),
• ?????????50???1?????
• Stainless steel lines between
• feed filter and Packinox inlet,
• reactor outlet and Packinox inlet,
• ?????, ?????????????????, ????????

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Alfa Laval PackinoxHydrotreatment
Installation Recommendations (2)
?????????? ????? (2)
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Alfa Laval PackinoxHydrotreatment Installation
Recommendations (3)??????????????? (3)

• Liquid Feed Contamination ??????
• Limitation for Naphtha Free water lt 150 ppm
• ????????????lt 150 ppm
• Good retension time inside surge drum, Deep boot
  on surge drum, Drain boot frequently (twice every
  shift), ?????????????, ???????, ?????(??????)
• Limitation for Naphtha Chlorine lt 5 ppm
• ????????????lt 5 ppm
• Iron particules ????? (???????, ?????????)
• (corrosion from upstream, possibility of magnetic
  filter core)
• Oxygen Max 1 ppm (oxygen is a strong coke
  promoter),
• ????????1PPM (????????????)
• Straigth run feed as much as possible ????????)
• Feed tanks Nitrogen blanket (Floating roof not
  acceptable) ??????????(??????)

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Alfa Laval PackinoxHydrotreatment Chlorine
impacts?????????? ??????

• No ammonium salt deposit in Alfa Laval Packinox
  heat exchanger in two-phase service
• ??????Packinox???????????
• corrugated plate geometry eliminates low
  turbulence and low velocity areas (static mixer
  effect)
• ???????????????????(????????)
• design prevents low liquid local
  velocity????????????
• liquid gas oil wets and washes all the plates (no
  dry points)
• ????????????????(???)

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Alfa Laval PackinoxCleaning by Controlled
CombustionPackinox ??????????
ALFA LAVAL PACKINOX HEAT EXCHANGERS CLEANING BY
CONTROLLED COMBUSTION (DECOKING)??????????Packino
x ??(??) Issued by Gilles Cazin Revised by
Bernard Fontaine
PACKINOX WON THE 2004 TECHNOLOGY INNOVATION
AWARD FOR THIS DEVELOPMENT
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Alfa Laval PackinoxCleaning by Controlled
CombustionPackinox ??????????

• Usual Cleaning Methods ??????
• Chemical Wash ????
• Cold Oxidation ????
• Vacuum / Rupture Disk (back blowing)
• ????????

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Alfa Laval PackinoxCleaning by Controlled
Combustion Packinox ??????????

• Cleaning Hardened Gums ???????
• Chemical Cleaning had Only Produced Partial
  Recovery ?????????????
• Hydro-blasting is not an Option for welded plate
  heat exchangers ?????????????????

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Alfa Laval PackinoxCleaning by Controlled
Combustion Packinox ??????????

• Cleaning Hardened Gums ??????
• SOLUTION ????
• Carbon burn by steam-air decoking ????-???????
• (similar to that is used to burn carbon deposits
  in fired heater tubes). ??????????????
• CHALLENGE ?????
• Not to damage the Heat Exchanger in the process
• ??????????
• PILOT TESTING ??
• Jointly with IFP Axens at Solaize (France) ???IFP
  AXEN????
• Over one year period approximately. ?????????

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Alfa Laval PackinoxCleaning by Controlled
Combustion Packinox ??????????

• Cleaning Hardened Gums ??????
• Pilot Plant Coke Deposits from FCC Naphtha
• ?? ???FCC ??????
• Pilot result 100 coke removal, no damage to
  material
• ???? ??100??, ???????.

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Alfa Laval PackinoxCleaning by Controlled
Combustion Packinox ??????????
Steam to Sewer

• Decoking In-Situe

CO2/O2 Analyzer




N2
150 Steam


Heat Exch.


Plant Air

Preheating to 300F with N2 ( by Recircul. In
this Case)

Heater
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Alfa Laval PackinoxCleaning by Controlled
Combustion Packinox ??????????

• Commercial Scale Validation 1 (2002)
• ??????1

Heating with electric pads ?????
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Alfa Laval PackinoxCleaning by Controlled
Combustion Packinox??????????

• Commercial Scale Validation 2 (2003)
• ??????2

Heating with portable heater ???????
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Alfa Laval PackinoxCleaning by Controlled
Combustion Packinox??????????

• Commercial Scale Validation 2 (2003) ??2

Before ???? H/E Coked ??? After Decoke ???
HAT ???? 63F gt 100F 63F
Feed Side DP ????? 2 3 psi 40 psi 2 psi
COKED ???
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Alfa Laval PackinoxCleaning by Controlled
Combustion Packinox ??????????

• Commercial Scale Validation 2 (2003) ??2

70.0
1800
1600
60.0
1400
50.0
1200
40.0
1000
lbs TOTAL
lbs/hr
800
30.0
600
20.0
400
10.0
200
0.0
0
16/4/03 000
17/4/03 000
18/4/03 000
19/4/03 000
20/4/03 000
16/4/03 1200
17/4/03 1200
18/4/03 1200
19/4/03 1200
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Alfa Laval PackinoxCleaning by Controlled
Combustion Packinox ??????????

• Conclusion ??
• Proven Methods to Clean ?????????
• Foreseeable fouling forms in Catalytic
  Reforming, HDT, HDS,
• ????????, ??, ??????????????
• In situe procedure, ????
• Quick to Implement, ????
• At reasonable costs, ????

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