Crude Preheat Train Fouling

Monitoring

September 14, 2012

2010 Aspen Technology, Inc. All rights reserved

Fouling of Preheat Train: Main Concerns

Heat exchanger Fouling leads to:

to:
- Decrease of the furnace inlet temperature
increase of
the amount of combustible (100$/ton of fuel oil)
- Once furnace bottlenecked
decrease of the crude feed
flow rate
- Possible heat exchanger on-line cleaning to keep the feed
flow rate as high as possible
- Shutdown for preheat train cleaning (45 to 90 k$ / train)

Preheat train on every unit: CDU, VDU, HDT, HDS, FCC

High financial losses
2010 Aspen Technology, Inc. All rights reserved

Fouling Monitoring: Principal

M2, T2in, density

M1, T1in, density

T2out

T1out

Measured parameters: Flows and Temperatures

Rigorous calculation of properties Cp , , = f(T, P fluid type )
Thermal Balance

UF =

MCp T

Rf =

S DTLM

1
1

U F UC

Uc calculation = f(heat exchanger geometry, flow rates, fluid

properties)

2010 Aspen Technology, Inc. All rights reserved

Fouling Monitoring: Performance Monitoring

Data Import to ASW
DCS Data

DCS data is imported to

ASW interface

ASW Interface

Heat Shell &

Tube Utility
(Maximum
Fouling Mode)

Repository

DCS data is averaged

and validated
(hourly/daily)

HYSYS Shell &

Tube Exchangers
(Simulation Mode)

2010 Aspen Technology, Inc. All rights reserved

Fouling Monitoring: Performance Monitoring

DCS Data

ASW Interface

Heat Shell &

Tube Utility
(Maximum
Fouling Mode)

Repository

HYSYS Shell &

Tube Heat
Exchangers
(Simulation Mode)

2010 Aspen Technology, Inc. All rights reserved

Fouling Monitoring: Performance Monitoring

300

DCS Data

y = 1.9105x - 70294
R2 = 0.9192

fouling resistance (10 4Chm2/kcal)

250

HX-114
HX-118
HX-112

200

ASW Interface

Repository

y = 0.8647x - 31829
R2 = 0.9126

150

Heat Shell &

Tube Utility
(Maximum
Fouling Mode)

HYSYS Shell &

Tube Heat
Exchangers
(Simulation Mode)

y = 0.4735x - 17405
R2 = 0.917

100

50

0
01/10/09

20/11/09

2010 Aspen Technology, Inc. All rights reserved

09/01/10

28/02/10

19/04/10

08/06/10

28/07/10

Fouling Monitoring: Performance Monitoring

DCS Data

ASW Interface

Heat Shell &

Tube Utility
(Maximum
Fouling Mode)

Repository

HYSYS Shell &

Tube Heat
Exchangers
(Simulation Mode)

2010 Aspen Technology, Inc. All rights reserved

Demo
 Show ASW and HYSYS case
 Not so robust but the concept can be understood.

2010 Aspen Technology, Inc. All rights reserved

Summary
 A frame-work is presented, where
HYSYS Shell & Tube Utility is used for fouling factor estimation
ASW is used for data transfer and data storage
HYSYS Shell & Tube HXs are used for rigorous calculations

 ASW framework can also be used for evaluating various

opportunities such as heat exchanger cleaning
 This interface can be applied easily to any refinery
configurations (please look at the word document)

2010 Aspen Technology, Inc. All rights reserved