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Corresponding author: [email protected]; Tel +1 (281) 437‐5906 Effective Fouling Control Methods for Improving CDU Performanc e and Economics Draft Manuscript for International Petroleum Refining, Jan 2012 by Jimmy D Kumana, Kumana & Associates, Houston, Texas [email protected], Phone +1 (281) 437‐5906 Abstract: Crude oil distillation accounts for a large fraction of the energy used in oil refining. Crude oil contains a variety of substances that tend to deposit as fouling layers in heat e xchangers, and which result in decreased energy recovery and increased fuel input to the furnace. CDU pre-heat train fouling is estimated to cost over $2 billion per annum in the USA. In addition, fossil fuel savings from fouling mitigation would result in significant reduction of CO 2 emissions. This paper proposes a broad strategy for fouling mitigation and control consisting of: crude oil storage under non-oxidizing conditions crude-oil blending to minimize fouling caused by asphaltene precipitation addition of chemicals to retard deposition of asphaltenes and other foulants revamping the HEN structure to keep tube wall temperatures such that fouling rates are kept to acceptable levels retrofitting the HX bundle and channels (eg. twisted tubes, “E-to-F” conversions) to increase velocities and shear rates replacement of Shell & Tube HX with alternative designs that lead to reduced fouling and easy to clean in place use of tube inserts to promote high shear rates “smart HX cleaning” strategy, based on fouling rate models Chemical analysis and visual observation of the deposits are key diagnostic tools that indicate the probable cause of fouling, and suggest the appropriate control/mitigation/cleaning strategy. Introduction Fundamentally, heat transfer efficiency is all about improving flux: (q/A) = U. T m . Pinch analysis seeks to improve the “system flux” by optimizing the global T m for the HEN. Fouling control effectively improves the first term, U, in the HX design equation. Fouling in the heat exchangers used for pre-heating crude oil prior to distillation incurs three kinds of costs: (a) increased energy consumption, (b) reduced throughput, and (c) increased emissions of greenhouse gases. Figure 1 shows the estimated costs of fouling without an effective mitigation program for an average-sized 200 MBD refinery, using typical operating parameters and assumpti ons as listed in Table 1. Avoidable lost production var ies by refinery, depending on type of crude, design of the existing CDU preheat train, and operating practices, but generally ranges from 4-10 days.

Fouling Mitigation Improves CDU Perfomance IPR Jan 2012 - Kumana _draft

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