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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 aParticular 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 Refinery’s 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

H HE HEC
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 / hrFeed Into the HE

Texas Technology Showcase 2003 - 6

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

Texas Technology Showcase 2003 - 7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

Texas Technology Showcase 2003 - 8

PSHE as Best Equipment to Achieve Minimum Pinch
• •
Corrugated Surface Works as a Static Mixer Maintains highTurbulence 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
Texas TechnologyShowcase 2003 - 10

•

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 bpdUnits 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...