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Enhancing performance of tubular heat exchangers using hiTRAN Systems

Enhancing performance of tubular heat exchangers using hiTRAN Systems. INTHEAT Friday 8 th July 2011. Providing solutions to:. Increase plant capacity Reduce energy costs Increased equipment performance Reduce production costs Provide operational flexibility Increase plant profit !.

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Enhancing performance of tubular heat exchangers using hiTRAN Systems

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  1. Enhancing performance of tubular heat exchangers using hiTRAN Systems INTHEAT Friday 8th July 2011

  2. Providing solutions to: • Increase plant capacity • Reduce energy costs • Increased equipment performance • Reduce production costs • Provide operational flexibility • Increase plant profit !

  3. Direction of Flow • hiTRAN tube-side heat transfer enhancement system – • increases heat transfer up to 8 times • reducing fouling by increasing fluid sheer

  4. Blue dye: Red dye: B)turbulent flow A)Laminar flow How hiTRAN Wire Matrix Elements work • hiTRAN Matrix Elements remove the boundary layer and mix it with the bulk flow. • Fluid from the centre is displaced in the direction of the wall • Residence time of the fluid at the wall is considerably reduced. • Improved heat and mass transfer and reduced fouling hiTRAN Matrix Element

  5. hiTRAN video – how hiTRAN works

  6. Case study LUKOIL Refinery, Volgograd Feed Effluent Exchanger Problem Plant capacity limited by low heat exchanger performance (mal-distribution) Recovered heat was 19 MW but …… 23.1 MW needed to meet target temperature Fired Heater performance much too low! 4.1 MW not available from Fired Heater High on-going energy cost if upgraded Plant expansion now requires 28MW

  7. Case study Lukoil - refinery Volgograd Optimised Engineering Solution Study identified hiTRAN System would solve the problem Reduce maldistribution on tubeside - balance flow Increase tubeside heat transfer hiTRAN System retrofitted in just 2 weeks

  8. Case study Benefits to Lukoil hiTRAN System increased performance from 27.8MW to 32.4MW 4.6 MW energy load saving without requiring new fired heater Fuel saving of over US$500K per year (at full flow rate) Enables higher plant throughput Increased plant profit!

  9. Case study Rosneft - Novokuibyshevsk New Air Coolers with hiTRAN System enhancement Benefits: • Smaller units • Less bays • Increased efficiency • Reduced capital costs

  10. Case study Rosneft - Novokuibyshevsk

  11. Cal Gavin’s Deliverables Work Package 2: “Combined tube-side and shell-side heat exchanger enhancement” D2.1: Report on state of the art of heat transfer enhancement technologies and their benefits. (May 2011) D2.2: Report on tube side and shell side enhancement research (August 2011) D2.3: Mathematical models and the software implementation of tube- and shell side heat transfer enhancement ( May 2012)

  12. State-of-art of heat transfer enhancementtechnologies and their benefits • D2.1, 6 month • Heat Transfer Promoters - Twisted Tapes, Static mixers, Helically-coiled wires, Core Tubes and hiTRAN turbulators • Comparisons - Between hiTRAN, Twisted tapes and coiled wires • The Influence of the boundary layer and overcoming the limitations in the heat transfer.

  13. Report on tube side and shell side enhancement research • D2.2, 9 month Other deliverables Cal Gavin is involved in • WP1 ‘Analysis of intensified heat transfer under fouling’ ( 4 person months) • WP4 ‘Design, retrofit and control of intensified heat recovery networks’ (3 person months) • WP5 ‘Putting into practice’ (2 person months) • WP6 ‘Technology transfer’ (2 person months)

  14. Thank-you for listening Questions? www.calgavin.com

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