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
Slides
• Atmospheric Emissions from Use of • 3-4
Energy in the HPI
• Heat Integration • 5
• Thermal Pinch • 6
• PSHE as Best Equipment to Minimize • 7-11
the Pinch
• Case Story: Diesel Hydrotreater • 12-13
• Case Story: Catalytic Reforming • 14
• Case Story: Pygas Hydrotreater • 15-16
• Summary • 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 a Particular Diesel HDS
Unit
– Fired Heater 19 ¢ / bbl 6 lb. GHG / bbl
– Compressor 6 ¢ / bbl (*)
– Product Cooler 1 ¢ / 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 Cooling
Side of HE Side of HE

Fired Reactor
Heater Cooler

H
H

HE HE
HE
HE

C C
Feed In LESS Heat
Integration Product
MORE Heat Out
Integration

Texas Technology Showcase 2003 - 5

 Thermal Pinch Inside the HE

Minimize Delta T at hot end

to Minimize Charge Heater Duty Reactor Effluent
Into the HE
°F

Feed
g Out of the HE
olin and to the Heater
Co

g
atin
He

Effluent Out Heat Recovery is Limited

By Thermal Pinch Inside the HE

Feed MM BTU / hr
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 high
Turbulence and
Promotes Two-
phase 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 Technology Showcase 2003 - 10

 Plate-and-Shell HE as Best Equipment
to Achieve Minimum Pinch
Feed Outlet Effluent Inlet

• The Protection
of a Pressure
Vessel Allows
the Plate
Plate Bundle Bundle to
Operate at
High T and P
Pressure
Vessel

Effluent Spray Bars for

Outlet Liquid Feed

Recycle Gas inlet

Texas Technology Showcase 2003 - 11

 Case Story:
Charge Heater
Q (operating) = 5 MW
= 17 MM BTU/hr
Q (design) = 12 MW

Diesel Hydrotreater 744

680
8950

Quench gas
210 t/d
R1

Two 65.000 bpd Units at 776

Formosa Petrochemical 662
657
464

716 Q E3 = 7 MW

• Eliminated: 689 45

– 75% of Heater Duty

MP Steam
100 t/d

PACKINOX Wash Water

– 40% of Compressor HP 94 MW
320 MM BTU/hr
430 t/d
110°F
419
460

– 40% of Cooler Duty 131 217

Recycle Gas Comp.
= 2.20 MW
= 2950 hp
PACKINOX
Recycle Gas
783 624 39 MW
320 t/d
133 MM BTU/hr
Q (E4) = 23 MW
P1 Q (design) = 30 MW
0.9 MW 520 129
122 158

•
Q E9 = 4 MW

On line Since 12/2000 8640 Q (design) = 5 MW

120

• Savings per Unit: SOUR GASOIL FEED FRESH H2 Cold Gas Oil

– CAPEX > $5 Million

8 630 t /d = 65.000 bpd 70 t /d 8 190 t/d
122°F 110°F

– OPEX > $3 Million / yr

- Temp. (°F)
- Pressure(PSI)
- Flow (t/d)

Selected PFD with PACKINOX Exchangers

Texas Technology Showcase 2003 - 12

 Case Story:
Charge Heater
Q (operating) = 23 MW
= 78 MM BTU/hr
Q (design) = 25 MW

Diesel Hydrotreater 744

680
8950

Quench gas
210 t/d
R1

813

Two 65.000 bpd Units at 581

716 657
464

Formosa Petrochemical 649 Q E3 = 17 MW

583 45

MP Steam
100 t/d
Shell-&-Tubes
E2 A/E Wash Water

• 68 MW 430 t/d

Same Unit based on S&T: 232 MM BTU/hr

110°F
347
460

– Heater: 78 MM BTU/hr
Recycle Gas Comp.
3.73 MW Q (E5 A/B)
5000 hp 29 MW
336
99 MM BTU/hr
v. 17 MM BTU/hr Recycle Gas
320 t/d
850 586
129 246

– Compressor: 5000 hp v. 284 Q (E4) = 39 MW

Q E8 = 6 MW
Q (design) = 40 MW
P1 20 MM BTU/hr
0.9 MW (HDS Feed)
520
2950 hp 122

8640
Q E9 = 8 MW

– Cooler: 133 MM BTU/hr

171 Q (design) = 10 MW

to / from
E8
120

v. 78 MM BTU/hr SOUR GASOIL FEED FRESH H2 Cold Gas Oil

8 630 t /d = 65.000 bpd 70 t /d 8 190 t/d
122°F 110°F
- Temp. (°F)
- Pressure(PSI)
- Flow (t/d)

Planned PFD with Shell-&-Tube Exchangers

Texas Technology Showcase 2003 - 13

 Case Story: Catalytic Reforming

1000 More than 50 Units

900 Retrofitted Around the
800 World
Temperature, Degrees F

700
600
500
Feed
Effluent • Two Reduction Samples in
400
North America:
300
200 – 59.000 tons CO2 Equiv.
100 / yr on a 40.000 bpd
0
0 100.00 200.00 300.00 400.00 500.00
Reformer
Heat Duty, MM BTU/hr – 16.500 tons / yr on a
26.000 bpd Reformer

Texas Technology Showcase 2003 - 14

 Case Story: Pygas Hydrotreater
(Mitsui, Japan)
BFW

• Unit with S&T H2 Heater

before Revamp 300°C

with PSHE
– Heater 28 Reactor
Fuel gas
consumption
13.9 tonnes/day
Off Gas
MM BTU/hr
Recycle H2 Comp.

• Operation
Shell-&-Tube Exchangers
Restricted by 330 °C 130 °C
Limits on Air H2 Pre-heater - II
AG Feed Pre-heater
H2 Pre-heater - I HP
Stabilizer

Pollution
Effluent
SW Cooler

AG

Re-boiler

HPG

Texas Technology Showcase 2003 - 15

 Case Story: Pygas Hydrotreater
(Mitsui, Japan)
• Eliminated: BFW

– 100% of H2 Heater
- normally Off-line
Heater Duty
after Warm- 300°C

Up Fuel gas
consumption
0 tonnes/day
Reactor Off Gas

Recycle H 2 Comp.

• On line since Combined

Feed
1995 330 °C
Packinox
Exchanger
(AG + H 80 °C
Stabilizer
2 )

•
HP

Allows to SW
Effluent
Cooler

Operate during
Air Emissions AG 12 Bar.g Steam

Restriction Re-boiler

HPG

Texas Technology Showcase 2003 - 16

 Summary

High Efficiency
Shell & Plate = +
Heat Exchangers

Texas Technology Showcase 2003 - 17