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A REPORT

ON
CDU: HEAT EXCHANGE & INTEGRATION



BY

Mudit 2010A1PS349P
Amanpreet Singh 2010B4A1356P
Rishu Gupta 2010A1PS401P





AT
IOCL REFINERY, GUWAHATI

A Practice School-I station of
BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI
July, 2012
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We feel immense pleasure in presenting before you this final report on our PS-1
program IOCL Guwahati refinery. This report encompasses a comprehensive
discussion of what we learnt on this program.
The report starts with a brief introduction about the organization i.e. IOCL Guwahati
refinery. We have kept discussion in this section brief to focus more on our Project
Heat exchange and integration in CDU .
The main report is divided into 4 sections. To start with, the first Section is a basic
introduction to Crude distillation unit, its process and products.
Heat exchange is among the most important activity for crude distillation units. The
2nd part of the report focuses on this heat exchange process occurring in the crude
distillation unit of Guwahati refinery. Necessary data regarding all the heat
exchangers has been provided in a tabular manner to make understanding easier. The
concept of critical heat exchanger is introduced subsequently in the 3
rd
section along
with the case study of some important heat exchangers of the process. Heat duty
&other calculations presented in this section for heat exchangers are clearly explained
in step by step manner along with formulas used. Through these calculations we have
tried to analyze whether these exchangers are working efficiently.
In the Last part of the report we have given an introduction to heat integration one
of the most important tool for increasing energy efficiency of a process. Points
discussed about heat integration in this section are: Meaning, Importance, its need in
CDU, Tools. We have concluded this part with an example of heat integration done in
2010 in pre-heat train of CDU, showing how it helped saving energy & increasing
efficiency.
A final conclusion and glossary are provided to sum up the report. We hope you have
a good time reading this report and find it informative and useful.

Mudit, Amanpreet & Rishu
PREFACE
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A comprehensive report always requires the goodwill, encouragement, guidance and
support of many people so we would like to start by thanking our college BITS pilani
for initiating program like ps-1 thereby giving us the opportunities to visit real time
industries and learn by working on hand in organizations as big as IOCL.
Our sincere thanks to Mr. B K Das, CPNM and Mr. P S Sonowal for assigning us this
important project on heat integration in refinery and getting us in contact with the
required person in each unit. Without their help this whole program would not have
been possible.
We are indebted by the constant support and mentoring provided by Mr. Vijay
Kumar, TS for the preparation of this report.
Also, we take this opportunity to thank all the chief engineers, and workers we have
met in different units who have received us with open hearts and helped us in
learning the vast array of knowledge that a refinery holds. Mr. E Edmund of CDU, Mr.
A. Bairagi of OM&S are just the few of these names with whom we shared numerous
informative talks which finally went into the preparation of this report.
We also express our deep sense of gratitude to IOCL administration for providing us
with necessary data and making our stay a pleasant one.
Thanks to our families & friends for their constant support and encouragement
throughout the period of preparation of this report.
It goes without saying that we are sincerely grateful to our instructor, Mr. Prasantha
G for coordinating this ps-1 program and giving us opportunity to present before him
this report.

Thank you all






ACKOWLEDGEMENT
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S No. Topic Page No.


Preface 2

Acknowledgement 3

List of Illustrations 5

Abstract

6
1.1 Introduction 7
1.2 IOCL Guwahati refinery 8
1.3 Production Units of Guwahati refinery 9

Crude Distillation Unit
2.1 CDU : Process Description 11

CDU Pre-heat Train (Heat exchange Process)
3.1 Introduction 15
3.2 Shell & tube Heat exchanger 16
3.3 Pre-heat train : Description 17

Heat Exchanger Performance Calculation
4.1 Critical heat exchangers 22
4.2 Performance analysis: Examples 23
S-25A/B 23
S-11C 25
S-23A/B 27

Heat Integration
5.1 Heat Integration : Introduction 30
5.2 Heat Integration in CDU 32

Need for heat integration in CDU 32

Heat integration in Guwahati Refinery 32

Example from pre-heat train 33



Conclusions 35

References 36

Bibliography 37

Glossary 38
TABLE OF CONTENTS
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ILLUSTRATION NO. DESCRIPTION

1.2.1 IOCL Indian market share
1.3.1 Table showing Production units

2.1.1 CDU flow diagram
2.1.2 Table Showing CDU product
properties

3.2.1 Types of Shell Tube heat exchanger
3.3.1 Pre-heat train flow diagram
3.3.2 Table Showing cold section heat
exchangers
3.3.3 Table Showing mid section heat
exchangers
3.3.4 Table Showing hot section heat
exchangers

4.2.1 4.2.3 Properties, Design data, Practical data
of S-25A/B
4.2.4 4.2.6 Properties, Design data, Practical data
of S-11C
4.2.7 4.2.7 Properties, Design data, Practical data
of S-23A/B

5.1.1 Steps of Heat Integration
5.2.1 Heat integration in Pre-heat train
5.2.2 S-11/c before & after heat integration







LIST OF ILLUSTRATIONS
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Title of the Project: CDU: HEAT EXCHANGE & INTEGRATION
Key Words: Crude distillation, Heat exchange, Heat integration, CDU-Pre heat train
Project Areas: Heat exchange, Process design & optimization, Energy
Abstract: In this work is on Crude distillation unit in a refinery & discusses the heat
exchange process in it and introduction of the concept of heat integration which is of
wide importance in CDU.CDU is used for crude fractionation and requires a
temperature of 354
o
C. To increase the temperature of crude 2 step process is used;
heat exchange with product streams & furnace. In the shell & tube type heat
exchangers of Guwahati refinery Low temperature crude exchanges heat with high
temperature streams of SRGO, RCO etc. in 3 stages(cold , mid, hot). The
performance of some of these heat exchangers have a major impact on production
and are classified as 'Critical' on the basis of different criteria like frequent fouling,
Large surface area. Calculation of heat duty, LMTD of some of these heat
exchangers(s/15, S/23a-b,s-24) is done using design & practical data to check
whether they are working efficiently as compared to design.
Heat integration is an important concept to increase energy efficiency of process
through heat recovery. Tools like pinch analysis are used in high energy demanding
units like CDU to optimize the Heat Exchanger Network for maximum efficiency.
Analysis of past heat integration done in Pre heat train of CDU is taken as an example
for analysis.



Signature(s) of Students(s) Signature of PS Faculty
Date Date


ABSTRACT
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This Report is an analysis of the one of the most key elements of any crude
distillation unit i.e. Heat Exchange & Heat integration. The report is based on Work
in CDU of Guwahati refinery.
Crude distillation units are used for the fractionation of crude into more valuable
products using their difference in boiling points. Increase in temp for distillation us
achieved in 2 steps; first step is the heat exchange of crude with product streams at
high temperatures. In the next step a furnace is used to further elevate the
temperature.
Our main point of discussion in this report is the first step of heat exchange called the
Pre-heat train. The pre-heat train consists of 3 sections: Cold, Mid & hot. The purpose
of each section is to recover heat from hot product stream of RCO, SRGO etc and
supply it to crude through a shell-tube type heat exchanger. The details about various
heat exchanger used in process are presented in the report.
Performance of some heat exchanger is more critical on overall heat exchange than
others; these heat exchangers are classified as 'Critical heat exchangers'. Constant
monitoring of efficiency of these heat exchangers needs to be done. As Example
calculations like heat duty, LMTD is done in this report for some of these critical heat
exchangers (S-11C, S-23A/B) to check their efficiency.
Crude distillation is an energy intensive process. With increasing oil costs, the focus is
to maximize energy recovery. One way to do this is 'heat integration' which is a
technique to design a process to minimise energy consumption. Tools like pinch
analysis are used for obtain an optimized heat exchanger network for heat
integration in CDU.
The retrofitting of the HEN in CDU is taken as case study in report to realize
importance of heat integration. Meaning of all the key terms used in the report can
be found in the Glossary. Necessary data used in the report has been obtained
through manuals & officials of Guwahati refinery.


1.1 INTRODUCTION
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IOCL
Indian Oil Corporation limited is largest state owned company in terms of revenue
having Maharatna status. It is ranked 98th in the Fortune global 500 listing. Its
biggest player in Indian downstream oil & Gas sector and operates10 of India's 21
refineries with refining capacity of 65.7 MMTPA. Major ones are Panipat, Mathura,
Guwahati, Gujrat, Haldia etc. Its products are Petrol, Diesel, LPG (Indane), ATF,
lubricants, Naphtha, Kerosene etc. (1.2.1)








Guwahati Refinery
Guwahati refinery is the first public sector refinery of India commissioned in 1962.It
had an initial capacity of 0.75 MMTPA which was extended to 1 MMTPA in 1986.
Guwahati Refinery receives the raw crude from Oil India Limited & has a product line
to Siliguri. Final products of Guwahati -Refinery are Motor spirit (MS), ATF,
Kerosene, LPG, Diesels, Petroleum Coke &Elemental Sulphur. Its an
environmentally Conscious refinery with modern effluent treatment facilities, Stack
gas monitoring, Products with strict environmental specifications like BS-3 & BS-4.






Sector (India) IOCL Share
Petroleum products 49%
Refining capacity 37%
Downstream pipelines 67%
1.2 IOCL GUWAHATI REFINERY
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Shown below in the table are the various production units of Guwahati refinery
along with their use, feed & products(1.3.1):

Unit Purpose Feed Output
CDU
Separation of Crude into useful
products by distillation.
Raw Crude
LPG , Naphtha, RCO, Kero-1
& 2
DCU
Thermal Cracking to obtain
useful products from higher ends
RCO
CK, CGO, CFO, RFO and
RPC
HGU Production of hydrogen
Light Naphtha
(LN)
Hydrogen
INDMAX
FCC unit for maximizing LPG
production from residual stocks.
CFO, CK, RCO LPG & Gasoline
HDT
Quality improvement of Diesel,
ATF by removing sulphur.
SRGO, KERO 1
& 2
BS 3 Diesel, ATF, SKO

MSQU
Improving Octane No. of MS by
Hydrotreating & Isomerization

LN Isomerate (MS)
SRU
Recovering Sulphur

HDT off gases Elemental Sulphur
OM&S
Crude & product storage,
Pumping & blending
_ _
ETP
Treatment of waste water to
remove oil and suspended solids

Waste water Effluent free water
1.3 PRODUCTION UNITS
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CRUDE DISTILLATION
UNIT
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INTRODUCTION
Crude distillation unit or CDU in short is first & most important unit for any refinery. Its
called the Mother unit as its products forms the feed of other units. CDU receives its
crude from OM&S (oil movement and supply section) where it is supplied by Oil India
Ltd from upper Assam oil fields. Incoming crude has following properties (2.1.1):
Property Value
Density at 15
o
C 0.8735
Water content 2.05%
Salt content(ppm) 8.7
Sulphur content(ppm) 0.29

CDU then stripes the crude into various products like kero1, kero2, reduced crude oil,
LPG, heavy gasoline and light gasoline using the distillation principle of difference in
boiling points.
KEY FACTS
Installed in 1962. Revamped and modernized in 1986 & 2000.
Capacity of 1MMTPA but currently processing 1.3 MMTPA
Its an Atmospheric distillation unit (ATU)
PROCESS DESCRIPTION
A brief description of the different processes taking place in CDU is given on next page
(2.1.2):
1. Pre heating train before Desalter: Crude is pumped by pumps P1/1A at a pressure of
15 kg/cm
2
through a series of heat exchangers where its temperature is elevated to
130
o
C. Crude is gaining heat in these exchangers from pre fractionated overhead
vapours(in s-26), RCO( in s-29), SR Kero1 etc.
2 CDU: Process Description
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2. Desalter: Demulsifier mixed crude is fed at 130
o
C to Desalter (v-101) where it is
mixed with water through a mixing valve. The salt in crude dissolves in water and
separated from the oil. Salt free crude on the other hand is pumped to Pre-topping
column (CL-1) though 2 safety valves.
3. Pre-topping Column (CL-1): The average temperature of crude before entering pre-
topping column is 238
o
C (achieved through heat exchange). The purpose of this column
is to remove the straight run (SR) light gasoline and LPG from overhead and reduce the
load on the main fractionating column. Shown below is the Flow diagram of CDU(2.1.1):

4. Atmospheric furnace (C 1 A): the crude coming from CL-1 bottom at 246
o
C is fed
to furnace. Furnace is fired by fuel oil (FO), Fuel gas (FG) or a mix of both supplied by
DCU. The crude coming out of the furnace has a temperature of around 354
o
C and
goes to the flash zone of main fractionators column.
5. Main Fractionators column (CL-2): Its the most important part of CDU. Cl-2 is
where the actual distillation is taking place crude is separated into different products
of different cut. Stripping stream enters at the bottom. The various subsystems of
CL-1 are:
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a) Overhead system: The overhead of the column of the water and the Straight
rum Heavy Gasoline (SRHG) are separated.
b) Stripper column: A stripping column (CL-3) is attached to the main
fractionating column .Its function is to strip apart (separate) kero1, kero 2 and
straight run gas oil coming from main fractionating column.
c) CL-2 Bottom Section: The remaining crude oil called as the reduced crude oil
(RCO) comes out of the bottom of CL-2. RCO forms the feed of DCU
6. Light Gasoline /Heavy Gasoline Processing System: Un-stabilized light gasoline
from CDU pre-toping column is stabilized in the stabilizer where LPG is recovered
from it while heavy gasoline is split in the two naphtha splitter to separate LN (Light
Naphtha), RN (Reformer Naphtha) and HN (Heavy Naphtha).The table below shows
properties of the Products formed in the CDU(2.1.2):


LN HN Kero 1 Kero 2 SRGO RCO
TBP cut
range
65-135 135-165 165-190 190-300 300-370 370+
Yield (% of
crude)
11.27 4.90 8.16 12.11 22.16
39.7
Density
0.731 0.786 0.806 0.866 0.866 0.9542






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CDU PRE-HEAT TRAIN
(HEAT EXCHANGE IN CDU)






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As we have seen the temperature of the Crude oil needs to increase to 354
o
C in CDU.
This section is a discussion on how this is achieved.
Why Crude needs to be heated in CDU?
The various components of crude oil have different sizes, weights and boiling
temperatures. Crude Distillation Unit is used to strip this crude into various products
using the difference in their boiling points. Therefore for distillation to take place the
temperature of the Crude has to be elevated to around 354
o
C so that all the
fractions of crude oil can vaporize and get separated.
How Temperature of Crude is increased in CDU?
The Temperature increase of Crude oil consists of 2 major steps:
1. A 3 Stage Heat exchange (called CDU pre-heat train) of crude with product streams at
high temperatures using shell & tube type heat exchangers. This step results in crude
being supplied at 246
o
C (elevated from ambient) to the next step The atmospheric
Furnace.
2. The atmospheric furnace (C-1A) is then used to further elevate the temperature.
Modes of heat transfer in furnace are both convective and radiative the crude
coming out of the furnace has a temperature of around 354
o
C and goes to the flash
zone of main distillation column (CL-2).
Furnace alone is not used because it would to too expensive and Energy consuming.
By exchanging heat with products, the pre-heat train is serving twin purpose; The
Crude is being heated at the same the temperatures of product streams of SRGO,
RCO, KERO is brought down which was needed for their storage. This heat would
have otherwise been wasted.
Our point of discussion in this report is the First step i.e. The Heat exchanger
Network which we will now study in detail.


3.1 INTRODUCTION

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The Pre heat train uses shell & tube type heat exchager for heat transfer.


The principle of operation: Two fluids of different temperatures are brought into
close contact but they are not mixing with each other. One fluid runs through the
tubes, and another fluid flows over the tubes (through the shell) to transfer heat
between the two fluids. The temperature of the two fluids will tend to equalize.
The heat is simply exchanged from one fluid to the other and vice versa. No
energy is added or removed.

Common types of shell and tube exchangers:




3.2 SHELL & TUBE HEAT EXCHANGER
It consist of two main things as its
name implies Shell & Tubes
The shell is a large vessel with a
number of tubes inside it.

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Our point of discussion in this report is first step of the 2 stages used for raising the
temperature of crude i.e. the Heat exchanger network in which heat transfer occurs
between crude and product streams of RCO, SRGO, and Kero 1. This network is also
called the CDU pre-heat train.
In this process the temperature of the crude is elevated form ambient conditions at
which it is supplied from OM&S to 246
o
C. The heat needed for this is coming from
the product streams which are at high temperatures. Dual purpose is served in this
way: heating of crude as well as the cooling of product streams (needed for their
storage).
The pre-heat train is divided into three sections on the basis of temperature of crude
flowing through them:
1. COLD section
2. MID section
3. HOT Section
Shown below is the flow diagram of the CDU pre heat train (3.3.1):

3.3 PRE-HEAT TRAIN: Description
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1. Cold Section (before Desalter):
The crude from battery limit is pumped by pumps P-1/1A at about 15.8 Kg/cm
2

through a preheat train where it is heated to a temperature of 130 C before
entering the Desalter (V-101).The following table shows the shell side & tube side
streams of all exchanger in this section along with their inlet-outlet temperatures
(3.3.2):-
Exchanger Service Total
Surface
area

Heat
Duty
Temperature
Shell Tube shell tube
I O I O
S-26 Gasoline Crude 300 x 1 2.11 107 90 40 65
S-29 RCO Crude 171 x 1 0.47 116 100 54 60.3
S-12A Crude Kero 2 148 x 1 0.92 60.3 72.6 130 82
S-27A/B Crude SRGO 183 x 2 1.39 72.5 90.3 173 85
S-7 Kero 2 Crude 93 x1 1.48 199 130 90.3 109
S-11A/B RCO Crude 134 x 3 1.49 165 115 109 122

2. Mid Section (Between Desalter and pre-topping column):
The crude from the Desalter is pumped by pump P-21 A/B and divided equally into 2
streams (Train A & B) for further heating before entering the Pre-topping column.

P-21A/B CL-1


The crude in train A is preheated by hot-streams of SR Gas Oil (in S-24), RCO (in S-9A,
S-23A/B), SR Gas Oil (in S-9B/C), RCO (in S-22) to about 236 C. While the crude in
Train A: S-24, S-9A,
S-23A/B, S-9B/C, S-22
Train B: S-4A/B,
S-12B, S-25A/B
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train B is preheated by SR kero circulating Reflux (CR) (in S-4A/B, S-12B) and RCO (in
S-25A/B) to about 240 C.
Desalted crude from both Train A and Train B streams are combined before entering
the pre-topping column. Mixed preheat temperature achievable is around 238 C at
which it is fed to pre-topping Column. Below is the table showing heat exchangers of
mid section (3.3.3)



3. Hot Section (At CL-1 Bottom):
The topped crude from CL-1 bottoms is pumped by pumps P-2/2A to exchangers S-
16/S-9D in series, where it is heated by SR Gas Oil Circulatory reflux. It then passes to
exchanger number S-11C and further to S-21 where it is heated by Reduced Crude Oil
(RCO) to about 246C. At this Temperature pre topped crude enters Atmospheric
furnace (C-1A). The table on next page gives details about every heat exchanger in
this section (3.3.4).

Exchanger Service Total Surface
area

Heat
Duty

Temperature
o
C
Shell Tube Shell Tube
I O I O
S-24 Desalted
Crude
SRGO - 0.70 122 138 214 173
S-9A RCO Desalted
Crude
149 x 1 0.61 184 195 138 152
S-23A/B RCO Desalted
Crude
148 x 2 1.93 241 184 153 195
S-9B/C SRGO Desalted
Crude
82 x 2 0.54 272 214 195 218
S-22 RCO Desalted
Crude
149 x 1 0.91 320 296 218 236
S-4A/B Desalted
Crude
Kero CR 148 x 2 1.67 122 161 190 164
S-12B Desalted
Crude
Kero CR 148 x 2 1.8 161 198 216 190
S-25A/B RCO Desalted
Crude
113.15 x 2 2.0 297 283 228 223
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Exchanger Service Total Surface
area

Heat
Duty

Temperature
o
C
Shell Tube Shell Tube
I O I O
S-16/9D SRGO CR Skimmed
crude
186 x 2 2.16 291 250 197 257
S-21 RCO Skimmed
crude
175 x 1 0.61 336 320 239 246
S-11C RCO Skimmed
crude
134 x 3 1.49 336 320 239 246




















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HEAT EXCHANGER
PERFORMANCE
CALCULATION
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The critical heat exchangers are identified as the ones whose performance has a
major impact on heat exchange rate, Production rate, product quality or
environmental and health issues. Problem or inefficiency in any of the critical
exchanger has a severe effect on overall heat exchange process occurring in the
crude distillation unit. The engineers need to see that these exchangers are working
efficiently for smooth running of the process (Though efficiency monitoring is
important for every exchanger but the most attention has to be paid for Critical heat
exchangers).
Criteria for Classification:
1. Fouling: is accumulation of unwanted material of heat exchanger surface is called
fouling. Fouling is inevitable in heat exchanger but certain heat exchangers are more
prone to fouling than others. These exchangers foul in short intervals and need to be
cleaned frequently. Their regular maintenance is very necessary for the heat
exchange process. E.g. is S-11/C in hot section is prone to frequent fouling.
2. Large surface area: Some heat exchanger have a very large heat transfer area
which means they have a large contribution in total heat exchange taking place.
Their inefficiency or by-passing them would have a vital effect of final crude
temperature. For example S-23 A/B in the mid section of heat exchanger trains.
3. Single heat exchanger in line: If a heat exchanger is single heat exchanger in the
line like the one used in circulating reflux then it cannot be stopped or by-passed. For
any maintenance work on them the whole unit has to shut down. Example is S-
16/9D.
In next section the basic performance measurement calculations like heat, Duty,
LMTD, Heat transfer coefficient is done for some of these critical heat exchangers.



4.1 CRITICAL HEAT EXCHANGER
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This section analyzes the performances of some main heat exchangers of pre-heat
train through calculation of simple performance measurement tools like Heat duty,
LMTD & Heat transfer coefficient. The definitions & formulas for these tools can be
found in glossary at the end of the report.
1) S-25 A/B
Type: Shell & tube
Section: Mid
Properties:
(4.2.1)
Design Data:
Shell Tube
Total flow (Kg/h) 54554 55454 77586 77586
Operating temperature (C) 296
(I)
241
(O)
197.7
(I)
240.5
(O)
LMTD (C) 49.1(uncorrected) 47.1 (corrected)
(4.2.2)
Practical data:
Mass flow rate (RCO) = 59187.5 Kg/hr
Exchanger
No.
Service Temperature, C
Shell Tube Shell side Tube side
I O I O
S-25A/B RCO crude Post M&I 297.5 283.7 231.9 245
Nov 11 263 253 198 203
(4.2.3)
Calculations:
1. Heat Duty (design): M*C
p
*(T
i
T
o
) = 2002813.7 Kcal/hr
Exchanger
no.
Service No. of passes Total Surface area
Sq.M x no. of
element
Heat
Duty
Shell Tube Shell Tube
S-25A/B RCO Desalted
Crude
1 2 113.15 x 2 2.0
4.2 PERFORMANCE ANALYSIS: Examples
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2. Heat Duty (practical): 559336 Kcal/hr
3. Correction factor for LMTD (practical): 1.01

4. LMTD (practical): 52.12 (uncorrected), 51.57(corrected)


Observation
The practical heat transfer of 559336 Kcal/hr is much lower than the design heat duty
of 2002813.7 Kcal/hr.
Conclusions
1. The exchanger is not working efficiently
2. Due to fouling the temperature difference across the crude side is low which is
reducing the total heat exchange in the exchanger.



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2) S-11/C
Type: Shell & tube
Section: Hot
Properties: Its a critical heat exchanger because of the frequent fouling
(4.2.4)
Design data:
Shell Tube
Total flow (Kg/h) 54554 55454 155171 1551
71
Operating temperature (C) 336
(I)
320
(O)
239
(I)
246
(O)
LMTD (C) _ _
(4.2.5)
Practical data:
Mass flow rate: 59871.5

Exchanger No. Service Temperature, C
Shell Tube Shell side Tube side
I O I O
S-11C RCO Skimmed
Crude
Post
M&I
327 315 257.8 263
Nov 11 330.2 275 231 255
(4.2.6)



Exchanger
no.
Service No. of passes Total Surface area
Sq.m x no. of
element
Heat Duty Shell Tube Shell Tube
S-11C RCO Pre-
Desalter
1 2 134 x 3 1.49
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Calculations:
1. Heat Duty (design): M*C
p
*(T
i
T
o
) = 6295320 Kcal/hr
2. Heat Duty (practical): 597382.7 Kcal/hr
3. Correction factor for LMTD(practical) = 0.975

4. LMTD (practical): 82.84 (uncorrected), 80.79(corrected)

Observations:
Heat transfer at present is 597382.7 Kcal/hr which is satisfactory as compared to
design heat transfer of 6295320.

Conclusions:
The present performance of the heat exchanger is satisfactory as compared to design.
This little variation in the design heat duty and practical heat duty is due to variation in
value of C
p
of RCO with temperature.












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3) S-23A/B
Type : Shell & Tube
Section: Mid (Train A)
Properties: It is an critical heat exchager becase of its large heat transfer area

Service No. of passes Total Surface area
(Sq.m x no. of element)
Heat Duty
Shell Tube Shell Tube
RCO Desalted
Crude
1 2 148 x 2 1.93
(4.2.7)
Design Data:
Property Shell Tube
I O I O
Total Flow (Kg/h) 54554 54554 77585 77585
Temperature (C) 241.0 184.0 152.70 195.0
Specific Heat (Kcal/kg-C) 0.646 0.597 0.566 0.617
LMTD (C) 38.21 35.6
(4.2.8)
Practical data:
Mass flow rate (RCO) = 59187.5 Kg/hr
Service Temperature C
Shell Tube Shell side Tube side
I O I O
RCO crude Post M&I 260.2 230 145.7 178.8
Nov 11 253 230 142 160
(4.2.9)


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Calculations:
1. Heat Duty (design): M*C
p
*(T
i
T
o
) = 1932602.7 Kcal/hr
2. Heat Duty (practical): 1161000.7 Kcal/hr
3. Correction factor:
4. LMTD (practical): (uncorrected), (corrected)


Observations
The practical heat transfer of 1161000.7 Kcal/hr is much lower than the design heat
duty of 1932602.7. The value of LMTD on the other hand is actually higher in case of
practical situation
Conclusions
The heat exchanger is not working efficiently. Due to fouling the temperature
difference across the crude side is low which is reducing the total heat exchange in the
exchanger even after having a high LMTD value.













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HEAT
INTEGRATION
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In Todays process industries like Guwahati refinery increasing energy efficiency is of
prime importance. With the rising costs of input like crude, power the process has to
be designed to have maximum energy recovery so as to reduce the costs. Heat
integration is one of the ways to achieve this.
1. MEANING
Heat integration is technique for designing a process to minimise energy
consumption and maximise heat recovery. Its part of the broader term Process
integration which is a holistic approach to process design which emphasizes the
unity of the process and considers the interactions between different unit
operations from the outset, rather than optimising them separately.
2. NEED FOR HEAT INTEGRATION
Heat integration can lead to substantial reduction in the energy requirements of a
process thus saving costs. Its the answer to following questions:
Are the existing processes as energy efficient as they should be?
What changes can be made to increase energy efficiency without incurring any
costs? What is the most important utility mix for the process?
What investments can be made to increase energy efficiency?
How to put energy efficiency & other targets like emission reduction,
increasing plant capacity into one coherent strategic plan?

3. TOOLS FOR HEAT INTEGRATION
Pinch Analysis
The term pinch technology was introduced by Linnhoff to represent a set of
thermodynamics based tools that that guarantee minimum energy levels in design of
heat exchanger networks. Pinch Technology provides a systematic methodology for
energy saving in processes & total sites. Its prime objective is to provide energy
saving by better process heat integration. Here are some of its key features:
4.1 HEAT INTEGRATION: Introduction

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1. Based on the first and second law of thermodynamics.
2. Pinch analysis is applicable for both new design as well as the retrofit systems.
3. It was developed for crude distillation systems but is now applicable to large
number of process industries.
4. In addition to energy conservation Pinch technology provides general
improvements
5. Some famous Pinch softwares are Pinch Express
TM
, Aspen Pinch
TM
&
SuperTarget
TM


Retrofit analysis

Retrofit analysis is done to in old process processes to see what modifications
suggested by pinch analysis are most suitable for the project. It looks into the
optimization of the process through energy capital trade off.
In oil refining, retrofit designs are far more common than grass root applications.
The retrofit targets are preferably achieved by re-using existing equipment more
efficiently rather than installing new equipments and incurring new costs.

4. STEPS IN HEAT INTEGRATION
Shown below are the different steps of heat integration (5.1.1)





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1. IMPORTANCE OF HEAT INTEGRATION IN CDU
Distillation is the largest single energy consumer in the Refinery. Large section of oil is
spent in fuelling the CDU itself.
It is energy intensive process as the temperature of the crude has to be elevated to a
high temperature of 354
o
C. This increase in temperature is achieved by exchanging
heat in various heat exchangers between crude and streams of RCO, SR Gasoline,
Kero 2 etc which are at high temperature. Heat integration focuses on achieving
maximum energy recovery from these streams through an optimized HEN so that
the crude can be supplied at highest possible temperature to the furnace, thus
saving energy.
A recent development in distillation technology has shown potential savings of up to
15-40 % through the heatintegrated exchanger network (pre-heat train) &
distillation column.

2. HEAT INTEGRATION AT CDU GUWAHTI REFINEY
What has been done?
1. The basis of heat integration in heat exchange process is putting process hot
streams in thermal contact with process cold streams. We have already seen how
product hot streams of RCO, SRGO etc at high temperature are used to exchange
heat with the crude oil at low temperature.
2. Designing of an Optimized Heat Exchanger Network in pre-heat train using heat
integration tools like pinch analysis & retrofit analysis in July 2010. This design allows
maximum energy heat recovery.
What can be done?
1. Using heat integrated distillation columns. HIDC can save energy by recovering
excess heat from the rectifying section for usage in the stripping section.
5.2 HEAT INTEGRATION IN CDU
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2. Seeing the interactions of HEN and distillation column and applying combined
heat integration for whole unit.



3. EXAMPLE FROM CDU PRE-HEAT TRAIN
Reallocation of heat exchangers was done in CDU pre-heat train in July 10 for heat
integration in Guwahati refinery. The whole process is summarized below (5.2.1):










The 3 Step pre-heat train of CDU
Low temperature difference across the
heat exchangers like S-11/C was
reducing overall heat transfer.
Pinch analysis was performed and
Retrofitting of the exchanger network
was done.
S-11/C was moved from cold section to
hot section along with shell side tube
side fluid interchange of S-24, S-12A.
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The figure (5.2.2) on the next Page shows the Position of S-11C before and after the
heat integration process:




RESULTS
1. Increase in temperature difference & heat exchange across 11/C
2. Increase of 10
o
C in temperature of crude being supplied to the furnace.
3. Savings of 1120 SRTF/Yr energy




S-11C Old
Position
S-11C new
Position
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These are our Conclusions based on the project:
1. The Importance of Crude distillation Unit in a refinery as the mother unit
2. We learnt the need of Need of heat exchange process in CDU. The 3 step heat
exchanger network of CDU is used to heat crude through energy exchange with
hot products streams.
3. Performance & Efficiency of critical heat exchanger is very necessary for
efficient heat transfer. These heat exchangers need to be properly maintained.
4. We have seen how simple Concepts like heat Duty, LMTD can be used to
monitor Heat exchanger efficiency.
5. Through Calculations we saw that heat exchanger no S-11/c is working
efficiently while there is less heat transfer as compared to design in S-23A/B
and S-25.The reason for inefficiency was found to be Fouling.
6. With rising costs of inputs like oil Heat integration has became an essential
step in Process industry like Guwahati refinery for maximizing heat recovery
and reducing costs. Pinch Analysis is an excellent tool for heat integrated
exchanger network.
Through our 2 months stay at Guwahati refinery as our first industrial exposure we
have understood how the gap between the Books & industry is bridged. We
familiarized ourselves with the various production activities taking place in the
refinery. Role of Economics, Environmental constraints etc. for an industry were
seen. We now have a clear image of oil industry in India and role of its biggest
player, IOCL in it. ALL in all this training has helped us in gaining confidence to take on
the challenges of the industry in an efficient way in the future.
CONCLUSIONS
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Smith R, Jobson M, Chen L & Farrokh P S (2010), Heat integrated distillation
system design, Chemical Engineering Transactions, volume 21.
Al-Mutairi E M, Mirgani A, Daajani B.F.& Qureshi BA ( 2011), Energy
optimization of crude oil separation plant. IPCBEE, volume 14.
Gadalla M, Jobson M & Smith R (2003), Optimisation of existing heat-
integrated refinery distillation system, Chemical Engineering Research and
Design, 81(1):147-152.
Feng X, Pu J, Yang J & Chu K H (2011), Energy recovery in petrochemical
complexes through heat integration retrofits analysis, Applied Energy Volume
88
Chegini S, Dargahi R & Mahdavi A (2008), Modification of preheating heat
exchanger network in crude distillation unit of arak refinery based on pinch
technology, Proceedings of the World Congress on Engineering and Computer
Science, 02.
Sahdev M (2010), Pinch Technology: Basics for Beginners, The Chemical
Engineers Resources Page.












REFERENCES
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Operation Manual Crude Distillation Unit, Guwahati Refinery, Indian Oil
Corporation Ltd., 2009
Heat Exchangers Manual, Guwahati Refinery, Indian Oil Corporation Ltd., 1997
Smith R, Chemical Process Design and Integration. West Sussex: McGraw Hill,
2005.
Kevin D. Rafferty. Heat Exchangers. Oregon: Geo-Heat Centre, 2012.
Bejan A and Allan D Kraus, Heat Transfer Handbook, New Jersey: John Wiley &
Sons, 2003.
Kutz M, Heat-Transfer Calculations, Oshawa: McGraw-Hill, 2006.
March Linnhoff, Introduction to Pinch Technology, Cheshire: Linnhoff March
Ltd., 1998.
















BIBLIOGRAPHY
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1. CDU : Crude Distillation Unit
2. Heat Exchanger : A instrument for exchanging energy within two mediums
3. HEN: Heat Exchanger Network
4. Heat Duty : Amount of heat exchanged per hour
Q= m*C
p
*t
5. LMTD : Logarithmic mean temperature Difference
LMTD=
(Ti ti)(Toto)
ln(
Ti ti

)


6. Heat Integration: Method for maximising heat recovery
7. Pinch Analysis: Tool for heat integration


GLOSSARY

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