Thermo‐hydraulic analysis of refinery heat exchangers undergoing fouling

Díaz-Bejarano, Emilio; Coletti, Francesco; Macchietto, Sandro

doi:10.1002/aic.15457

Cited by 27 publications

(66 citation statements)

References 37 publications

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“…A framework and methodology for plant data analysis 26 was applied to an industrial case study of a heat exchanger located in between the desalter and the flash dram of a refinery preheat train. The framework was extended to include various relative deposition rate models.…”

Section: Discussionmentioning

confidence: 99%

“…This assumption, however, relies on the common belief that chemical reaction fouling is the main deposition mechanism. A methodology that uses pressure drop predictions as a soft-sensor to narrow down the range of feasible conductivities was proposed 26 . Whilst this method allows establishing a maximum feasible deposit conductivity, it has limited capabilities in determining the conductivity with some precision, especially if the thermal impact of fouling is not severe.…”

Section: Preliminary Study: Uniform Deposit With Assumed Deposit's Comentioning

confidence: 99%

“…This paper presents an industrial application of the second stage of the methodology suggested previously 26 , in particular the analysis of fouling rate, in the same PDPF heat exchanger studied by Diaz-Bejarano et al 7 . Such analysis aims at characterising the deposition rates and is performed in two sequential steps 26 :…”

Section: Introductionmentioning

confidence: 99%

“…24 highlighted how this approach may be not just inaccurate in predicting both fouling state and pressure drops, but also misleading (see also discussions in refs. 24-26 ).A more comprehensive method for fouling analysis based on plant data was presented by Diaz-Bejarano et al 26 which includes two main stages: i) analysis of fouling state; ii) analysis of fouling rate. The analysis is based on applying advanced deterministic models of shell-and-tube heat exchangers undergoing fouling in combination with thermo-hydraulic measurements.…”

mentioning

confidence: 99%

“…These two aspects convey considerable additional useful information compared to those derived from traditional fouling resistance-based analyses (see reviews in refs. 24,26,27 ) which…”

mentioning

confidence: 99%

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Organic and Inorganic Fouling in Heat Exchangers: Industrial Case Study Analysis of Fouling Rate

Díaz-Bejarano

Behranvand

Coletti

et al. 2018

Ind. Eng. Chem. Res.

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Fouling rates in refinery heat exchangers with mixed organic/inorganic deposits (frequent in practice) are estimated using a comprehensive model-based thermo-hydraulic methodology combining data-driven measurements analysis with advanced models. An industrial case study for a heat exchanger over 4-years demonstrates the method. Following an analysis of the fouling state, the dynamic analysis here estimates organic and inorganic fouling rates using constant or time-varying proportionality ratios. Base-line organics deposition rate is described by a typical correlation, inorganics deposition as a perturbation with constant or time-varying proportionality ratios.Deposition rate parameters are estimated from measured pressure drops and validated against temperatures. Results show that: the deposition rate ratio varied substantially over time, revealing acute inorganic deposition periods; accounting for inorganics explains well both thermal and hydraulic performances; the time-varying ratio provided a good fit of the data; this is a highly promising new method for predictive monitoring, detection and diagnosis of fouling. 10 ). With respect to the fouling rate, most past works focused on development and fitting of semiempirical models for chemical reaction fouling that relate dRf/dt to process conditions (e.g. 6,9,[11][12][13][14][15][16] ).Extensive reviews on the subject can be found in the literature 10,[17][18][19] . This mechanism, traditionally considered to be dominant in crude oil fouling, assumes the build-up of organic deposits over long periods of time (months, years). The thermal conductivity of such deposit has therefore been assumed to be within the range recommended for organic hydrocarbon deposits (e.g. 20,21 ), based on which, in a few modelling studies investigating the hydraulic impact of crude oil fouling (e.g. 14,22,23 ), the Rf was used to estimate the deposit thickness and its impact on the pressure drop. As discussed later in this section, ref. 24 highlighted how this approach may be not just inaccurate in predicting both fouling state and pressure drops, but also misleading (see also discussions in refs. 24-26 ).A more comprehensive method for fouling analysis based on plant data was presented by Diaz-Bejarano et al. 26 which includes two main stages: i) analysis of fouling state; ii) analysis of fouling rate. The analysis is based on applying advanced deterministic models of shell-and-tube heat exchangers undergoing fouling in combination with thermo-hydraulic measurements. The application presented is to crude oil refining, however the method is generally applicable to fouling in heat exchangers. presented an application of stage i), analysis of fouling state, to a comprehensive industrial case study involving a pre-flash, post-desalter (PDPF) heat exchanger, over a four year period, showing that extent, characteristics and transformations of fouling deposit over time could be well characterised. The combined use of temperature, flowrate and tube-side pressure drop measurements, together wi...

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Section: Discussionmentioning

confidence: 99%

Section: Preliminary Study: Uniform Deposit With Assumed Deposit's Comentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

mentioning

confidence: 99%

“…These two aspects convey considerable additional useful information compared to those derived from traditional fouling resistance-based analyses (see reviews in refs. 24,26,27 ) which…”

mentioning

confidence: 99%

See 3 more Smart Citations

Organic and Inorganic Fouling in Heat Exchangers: Industrial Case Study Analysis of Fouling Rate

Díaz-Bejarano

Behranvand

Coletti

et al. 2018

Ind. Eng. Chem. Res.

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A new dynamic model of crude oil fouling deposits and its application to the simulation of fouling‐cleaning cycles

2015

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Modelling of crude oil fouling in heat exchangers has been traditionally limited to a description of the deposit as a thermal resistance. However, consideration of the local change in thickness and the evolution of the properties of the deposit due to ageing or changes in foulant composition is important to capture the thermal and hydraulic impact of fouling. A dynamic, distributed, first-principles model of the deposit is

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An energy‐efficiency evaluation method for high‐sulfur natural gas purification system using artificial neural networks and particle swarm optimization

Qiu

2021

Intl J of Energy Research

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Natural gas purification, especially with high sulfur content, is an energyintensive chemical production process, for which there are considerable differences in the energy consumption patterns of different purification plants. Therefore, these purification plants are required to establish a universal evaluation standard for energy consumption performance. This article proposed a novel approach to evaluate the energy efficiency of the natural gas purification process from the systems engineering perspective. An evaluation system is established for the hierarchical indicators of energy consumption using this technique providing the detailed definition of evaluation indicators for process, unit, and device. At the same time, a technical route is proposed for intelligent algorithm optimization and artificial neural network modeling based on historical operation data of the plant to discover the energy consumption benchmarks under various raw gas flow rates. Using this proposed method, the energy consumption efficiency can be evaluated while analyzing the energysavings potential of these natural gas purification plants with various process types or raw gas characteristics. Furthermore, the model based on historical operating data can objectively and truly reflect the plant's energy consumption features; therefore, the plant's energy consumption can be decreased to benchmark by adjusting the corresponding operation parameters. Ultimately, the computational process of the energy consumption benchmark is described thoroughly for a high-sulfur natural gas purification plant.

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Thermo‐hydraulic analysis of refinery heat exchangers undergoing fouling

Cited by 27 publications

References 37 publications

Organic and Inorganic Fouling in Heat Exchangers: Industrial Case Study Analysis of Fouling Rate

Organic and Inorganic Fouling in Heat Exchangers: Industrial Case Study Analysis of Fouling Rate

A new dynamic model of crude oil fouling deposits and its application to the simulation of fouling‐cleaning cycles

An energy‐efficiency evaluation method for high‐sulfur natural gas purification system using artificial neural networks and particle swarm optimization

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