Best Practise for Kochi BIP

Energy Management
Furnace & heat exchange various
20 March 2007
Confidential
ENERGY BEST PRACTISE furnace & heat
exchange
Air preheater corrosion
Heat exchange train cleaning
optimisation
Furnace control
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Air preheaters - why
Higher efficiencies
- Can raise by 5 to 10%
Higher flame temperature
- Better combustion quality
- But potential for increased NOx emissions
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Furnace efficiency as a function of stack exit temperature
Assuming 0% radiation losses, and 20C outside temperature
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
0 2 4 6 8 10 12 14
Measured stack oxygen - vol% or mol%
F
u
r
n
a
c
e

e
f
f
i
c
i
e
n
c
y
150 200 350 450 550 650 750 850 950 1050
Stack exit temperature (C)
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Air preheaters - constraints
Flue gas exit temperature too low
- Dewpoint corrosion
- Keep cold corner metal wall temps > dewpoint + 15C
- Consider LPS preheat preheater
Air to furnace too hot
- Nox formation
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Simplified schematic
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50
Fuel Oil
C/H ratio : 6 kg / kg
(10% H
2
O in Flue Gas)
Fuel Gas
MW = 20 kg / kmole
C/H ratio : 3,4 kg / kg
(15% H
2
O in Flue Gas)
1000 10 1
% mass S in Fuel Oil
ppm (vol) H
2
S in Fuel Gas
75
50
100
125
150
1 5 10 0,5
0,1
100
125
150
100
50
5 500
1 5 10 0,5
175
A
c
i
d

D
e
w
p
o
i
n
t
,

C
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Heat exchanger fouling
Heat exchanger fouling
Due to fouling, Heat Exchangers (HX) suffer from efficiency loss over time
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Heat exchanger cleaning
Heat exchanger cleaning
Clean-out dates are clearly visible in a HX OHTC curve
Goal: find the optimal clean-out schedule for a HX with respect to cost
Clean-out dates
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VOEDING
F-201 A/
B/C
P-202
A/B
E-204
LGO
E-203
KERO
E-205
HGO
KERO
E-209AB
LGO
DAMP
NAAR C-201
V-
201
P-201A/B
E-211B E-210B
E-211A E-210A
OCR
LONG
RESIDU
C-202
E-211C
E-210C
E-206A
MCR C-201
E-206B
V-101-
A
E-207AB
LONG RES.
E-207CD
E-202A
E-202B
E-201A
TCR C-202
E-201B
TCR C-201
E-
213AB
LONG RES.
E-213CD
E-
212A
OCR C-201
E-212B
N.C. N.C.
N.
C.
N.C.
E-208AB
N.C.
MIXE
R
PROCESWAT
ER
EX V-
801
PROCESWATER
NAAR C-801
V-101-
B
NAAR V-101-A
MIXE
R
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Heat exchanger network
Heat exchanger network
Optimisation for a single HX is straightforward
The interaction between heat exchangers in a heat exchanger network,
however, requires the use of advanced optimisation techniques.
HX_A HX_B
FhotA
ThotA_out ThotB_out
Tcold_in
Fcold
TcoldA_out TcoldB_out
FhotB
ThotA_in ThotB_in
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HEAT4N Optimisation
HEAT for Networks (HEAT4N) is designed to:
Determine an optimal clean-out strategy for a train of heat exchangers
by minimising the overall averaged costs ($/day).
Overall costs are defined as:
Efficiency loss costs
Throughput loss costs +
Product quality loss costs +
Clean-out costs +
_____________________________________
Overall Costs
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HEAT4N Software
HEAT4N is a user-friendly flow
sheeting software package.
HEAT4N provides predictive fouling
models for heat exchangers in a
network
The fouling models, combined with
economical parameters, determine
the optimal clean-out scheme for a
train of heat exchangers
Heat for Networks graphical user interface.
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HEAT4N Output Optimal clean-out scenario
The clean-out scenario provides:
- Most cost-effective clean-out frequency with corresponding costs
- Average overall costs
- Regret costs for postponing cleaning of a HX. This identifies bad actors
in the train.
0 92 6.2 HX21
..
95,610 1,306 0.6 HX3
0 184 4.4 HX2
27,330 140 0.8 HX1
Cumulative Regret Costs,
postponing one year [$]
Average Overall
Costs [$/day]
Optimal Clean-
Out period [y]
Name
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HEAT4N Output User specified clean-out scenarios
The optimal clean-out scenario might be difficult to implement. Therefore, in
cooperation with technologists, different clean-out scenarios are compared to find
the most cost-effective applicable clean-out scheme; i.e. comparison of costs for
different (user-specified) clean-out scenarios.
The output from the user-defined scenarios can provide decision support for
maintenance optimisation
2889 4 10.3 222.6 Scenario 3
3653 2 3.8 216.1 Scenario 2
3880 1 1.6 213.9 Scenario 1
4077 - 212.3 Base case
Av overall
costs [$/d]
Extra bundles to
be cleaned
Increase in FIT
[C]
FIT [C] Scenario
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HEAT4N Benefits
As a decision support tool HEAT4N will
Cut operational & maintenance costs
Increase profits
Require absolutely no capital investment or significant changes to
your existing operational structure
Allow you to establish an optimal heat exchanger cleaning schedule
for future years
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Advanced furnace controls why ?
Safety
- Consistency with protective functions
Reliability
- Control scheme to avoid loss/trip of furnace
Cost
- Drive oxygen down consistently to best practise =>
fuel savings
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Advanced Air/Fuel Ratio Control of
Heaters/Boilers
Dual Fuels
Double ratio cross limiting to Shell DEP Standard
Minimum air/fuel ratio
Fuel gas compensation (density/composition)
Oxygen trimming control
Protective controllers
Integration with safeguarding and protective
controls
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Typical Design Inadequacies Encountered
Safeguarding implemented not in accordance with Shell standards
Critical I/O not redundant
No mechanical stops on heater/boiler air blower dampers
Air/fuel ratio control system air leading, with no limits on increase
of air in case fuel flow does not follow
No compensation for fuel gas composition
No low air/fuel ratio protection provided
Instrumentation problems
Burner turndown
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Advanced Air/Fuel Ratio Control of Heaters/Boilers
D-1050
Fuel Gas
Advanced A/F Ratio Control
(Fuel Oil and Fuel Gas)
PI
xx
To Pilots
From Air Flow FT
To Air Flow FC SP
To FG CV
via signal
selector
To FO CV
via signal
selector
Y3
AI
xx
FT
xx
Y2
Y6
Y7
Y9
Y17
Hsel
Y10
Y8
Y16
Lsel
QC
Oxygen
Fuel Oil Supply
Fuel Oil Return
XSLL
xx L
LL
Min Air
Max fuel
A/F Ratio
arwu
LOAD
To Burners
FC
xx
I
Y5
FI
FC
Y4
I
Y1
Y22
FT FT
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Important Messages
Advanced air/fuel ratio control can produce
significant benefits, but care needs to be taken to
integrate control with safeguarding and ensure
instrumentation is working well.
ATTENTION TO DETAIL