Applications of Computational Fluid

Dynamics (CFD) in Oil and Gas

industries in Saudi Arabia and GCC

By:

Salamah S. Al-Anizi
May 14, 2011

Introduction:
Demand for oil and gas services in Saudi Arabia and the Gulf Area is one of the
strongest in the world because of huge new projects due to increasing demand
for oil and gas production and strict environmental regulations. Therefore,
advanced engineering analysis methodologies to help in understanding flowrelated issues and designs like engineering simulation and flow modeling, in
particular, are tools very well required in servicing those industries. It is well
understood in the region that computational fluid dynamics has a growing
demand throughout the production processes to lower internal engineering
services costs, increase equipment reliability, and reduce risk. The following are
some examples of CFD applications.
Examples of Applications:
Piping Flow Simulation
Saudi Arabia has one of the largest pipelines and piping systems in the world.
Most of the times pipes in hydrocarbon processing operations carry a combination
of liquid, gas, and/or solids. Therefore, CFD can be utilized to provide a good tool
of visualization to understand flow behavior and properties throughout the piping
systems that may be difficult and expensive to accomplish by experimental
means.
Example: Erosion of an eccentric reducer in a DGA flow in a gas plant.

Applications of CFD in Saudi Arabia

Steam Generation
Computational fluid dynamics (CFD) software can help in solving several
problems in the steam generation within utility plants in hydrocarbon processing
industries in terms of equipment monitoring, lower maintenance cost, and lower
retrofitting costs through simulation. Boilers, burners, heat recovery steam
generators (HRSG) are a few of the power sources and associated equipment and
processes that need the service of this technology.
Example:
Determination of a velocity profile in a HRSG duct within the first three rows of
evaporator tubes to encounter flow induced vibration.

Applications of CFD in Saudi Arabia

Sulfur Recovery Unit

Sulfur recovery units (SRU) in gas plants are composed of several equipment like
process heaters, high intensity burners, reaction furnaces, sulfur condensers, and
thermal oxidizers. Variety of processes take place in those equipment involving
different flow patterns. CFD analysis can be applied to solve many flow and/or
combustion related matters within SRU's in Saudi Arabia and the Gulf region.

Example: Sulfur converter vessel flow distribution redesign to have uniform

distribution of converter catalyst.

Applications of CFD in Saudi Arabia

Refinery Processes
Process fired heaters are major equipment in refineries and they have different
designs and configuration. In several instances they encounter flue gas flow
maldistribution that effect draft profile within a heater and reduce performance.
A comprehensive CFD simulation of process fired heaters helps a great deal in
knowing draft profiles, temperature profiles, and flue gas flow pattern within
heater for different configuration in petroleum refineries. In addition, CFD
simulation will help great deal in determining emission amounts to the
atmosphere and would determine optimal operational schemes decisions.
Example: A comprehensive process heater flow simulation including draft profile,
combustion, and emission analysis.

Applications of CFD in Saudi Arabia

Heat Transfer
Various heat transfer equipment are used in hydrocarbon processing plants to
exchange heat and optimize processes. Heat transfer equipment encounter many
flow related problems such as erosion/corrosion, flow maldistribution, and
component arrangement. CFD helps in determining root causes of many heat
transfer equipment problems and help in solving them.
Example: Flow visualization under a heat exchanger solid impingement baffle.

Applications of CFD in Saudi Arabia

Flue Gas Dispersion and Flare Systems

Hydrocarbon processing industries uses combustion to provide processes with
heat energy. Combustion products are always released to the atmospheres with
different levels of temperatures reaching high temperatures that need to be
dispersed away from plant facilities and working personnel. Dispersion of flue
gases through flues and stacks require proper design requirements that are not
always met. This necessitates the use of advances analysis tools such as CFD to
determine levels of temperatures and emission. Similarly, flare systems are
either over or under designed and require CFD to recommend the best operation
of them to have them operate within safe ranges.
Example: Flare or stack radiation level in a process plant.

Applications of CFD in Saudi Arabia