Enhancing performance of
tubular heat exchangers using
hiTRAN Systems
INTHEAT
Friday 8th July 2011
© Copyright Cal Gavin 2011
www.calgavin.com
Page 1
Providing solutions to:
•
•
•
•
•
•
Increase plant capacity
Reduce energy costs
Increased equipment performance
Reduce production costs
Provide operational flexibility
Increase plant profit !
© Copyright Cal Gavin 2011
www.calgavin.com
Page 2
• Identify equipment and control system limitations
• Review technology options to overcome limitations
• Incorporate selected retrofit technologies
• Simulate performance of new production plan
• Implement low cost retrofit solutions
© Copyright Cal Gavin 2011
www.calgavin.com
Page 3
hiTRAN tube-side heat transfer
enhancement system –
• increases heat transfer up to 8 times
• reducing fouling by increasing fluid sheer
Direction of Flow
© Copyright Cal Gavin 2011
www.calgavin.com
Page 4
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
Blue dye:
Red dye:
A) Laminar flow
© Copyright Cal Gavin 2011
B) turbulent flow
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Page 5
hiTRAN video – how hiTRAN works
© Copyright Cal Gavin 2011
www.calgavin.com
Page 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
© Copyright Cal Gavin 2011
www.calgavin.com
Page 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
© Copyright Cal Gavin 2011
www.calgavin.com
Page 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$500K
per year (at full flow rate)
• Enables higher plant throughput
• Increased plant profit!
© Copyright Cal Gavin 2011
www.calgavin.com
Page 9
Case study
Rosneft - Novokuibyshevsk
New Air Coolers with hiTRAN System enhancement
Benefits:
• Smaller units
• Less bays
• Increased efficiency
• Reduced capital costs
© Copyright Cal Gavin 2011
www.calgavin.com
Page 10
Case study
Rosneft - Novokuibyshevsk
Design Comparisons
No. of bays/bundles
No of passes
Flow length m
Tubeside htc W/m2OC
Overall htc (bare) W/m2OC
Total Surface Area m2
Plot space m2
Weight tonnes
Total Fan Power kW
Pressure Loss, Bar
Annual cost of electrical fan power
US$
© Copyright Cal Gavin 2011
Empty tube
design
5/10
12
108
44
35
18,100
123.3
84
165
0.71
105,000
www.calgavin.com
design
1/2
2
18
307
180
3,600
24.1
16
33
0.71
21,000
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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)
© Copyright Cal Gavin 2011
www.calgavin.com
Page 12
State-of-art of heat transfer enhancement
technologies 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.
© Copyright Cal Gavin 2011
www.calgavin.com
Page 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)
© Copyright Cal Gavin 2011
www.calgavin.com
Page 14
Thank-you for listening
Questions?
www.calgavin.com
© Copyright Cal Gavin 2011
www.calgavin.com
Page 15