NEW DEVELOPMENTS

IN HEAT TRANSFER
2015
Special Supplement to

CORPORATE PROFILES
Multi-faceted
approach on energy CB&I H89
efficiency methods
H85 COVER PHOTO
Photo courtesy of
Heat transfer news
Sandvik Materials Technology.
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 NEW DEVELOPMENTS IN HEAT TRANSFER
MULTI-FACETED APPROACH
ON ENERGY EFFICIENCY METHODS
HP STAFF
The hydrocarbon processing industry (HPI) is a high-energy-
consuming business. After cost for feedstocks, energy is the next
largest operating expense for an HPI facility. Since the first oil em-
bargo in the 1970s, HPI companies have endeavored to control
and improve energy efficiency for processing facilities (FIG. 1).
Energy efficiency is a multi-faceted program. Many factors can
be followed to control energy consumption and optimize energy
recovery (conservation) from process and product streams. The
HPI uses chemical reactions to manufacture transportation fuels,
petrochemicals and other refined products. Such operations enlist
many processing steps and pretreatment to bring feedstocks to
the desired temperatures, thus promoting the desired chemical
reactions. Likewise, unit operations will use differences in boiling
points to separate end products from the reactant mixture. Better
application of heat-transfer methods/processes is continuously
reviewed to conserve energy and control operating costs.
UPDATES
More energy-efficient operation is a long-standing goal for
HPI facilities. Improving the energy costs of existing process
operation is a high priority when product margins are thin. Sev-
eral case histories demonstrate new developments for better en-
ergy management and heat transfer operations for HPI facilities.
Revamps of crude units. Debottlenecking of crude distilla-
tion units (CDUs) is a high priority as refiners seek more flex-
ibility in the types of crude oil feedstocks refined. The CDU is
the first process operation in which boiling points are used to
separate crude oil into primary distilled products, including fuel
gas, LPG, gasoline, kerosine/jet fuel, diesel cuts and heavy oil.
Extensive heat exchanger networks (HENs) are used to man-
FIG. 1. HPI unit operations are high-energy consumers.
HYDROCARBON PROCESSING|FEBRUARY 2015|NEW DEVELOPMENTS IN HEAT TRANSFER
age product temperatures and to recover process heat. Space
is limited in existing CDUs; thus, revamping the HEN of the
CDU becomes a balance between the capital costs to modify the
present heat exchangers vs. the value of recovered heat (energy).
Alfa Lavals Compabloc technology is emerging as a potential
solution to enhance heat transfer capability in the space-limited
area of the CDU (FIG. 2).
The Compabloc heat exchanger is a game-changing develop-
ment. It can add more heat transfer surface area (FIG. 3) and pro-
vides three to five times higher heat transfer efficiency, accord-
ing to Eva Andersson, Alfa Lavals market manager for refining.
This exchanger can provide 4,000 m2 of surface area that can
fit into a 2.9 m2 plot space. Equally important is the low fouling
tendency of the Compabloc heat exchanger, which can offer a
service run that is three times longer between cleanings.
CASE HISTORY
Heat transfer efficiency is difficult when refining heavy
naphthenic crudes. In the revamp of a bitumen refinery in
Southeast Asia, the main project goal was to increase capacity
of the CDU/vacuum distillation unit (VDU) from 25 Mbpd to
FIG. 2. Alfa Lavals Compabloc technology provides flexibility
in revamping existing HENs where plot space is limited.
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 NEW DEVELOPMENTS IN HEAT TRANSFER
30 Mbpd. The refinery processed a heavy, naphthalenic crude
to yield virgin naphtha, gasoil (GO) and fuel oil products. In ad-
dition to expanding capacity, the refinery also wanted to mini-
mize modifications of the existing equipment and remove unit
bottlenecks in the columns. Based on pinch analysis, three of
the CDUs existing heat exchangers needed to be rebuilt, along
with the installation of a new exchanger to support the higher
capacity. This plan would involve significant changes in the ex-
isting piping and service of the exchangers.
In another approach, new Compabloc exchangers would
replace the three exchangers that needed to be rebuilt and be
Upper head
Heat transfer
plate pack
Panel
Baffle Girder
Gasket
Lower head
Support
FIG. 3. The unique and compact arrangement of plates for the
Compabloc exchanger can add 35 times the heat transfer efficiency
and offer low fouling tendencies in dirty service operations.
FIG. 4. Duplex SS is being used not only in new equipment
construction but also for retubing of existing heat exchangers.
H86 NEW DEVELOPMENTS IN HEAT TRANSFER|FEBRUARY 2015|HydrocarbonProcessing.com
used as the units additional exchanger. Using the Compabloc
exchangers, this refinery found the added benefits of increased
throughput and greater energy recovery, as well as reduced fuel
costs. The project enabled a return on investment within four
months. For more information, visit www.alfalaval.com.
NEW ALLOY FOR REFORMER TUBES GAINS MOMENTUM
In the production of syngas, methanol, ammonia or hy-
drogen, one of the strategic process equipment is the steam
reformer furnace. The reformer tubes inside the furnace are
designed to withstand a minimum of 100,000 hours at approxi-
mately 950C and under 30 bars of pressure without impact-
ing output. The key concern in the operation of furnaces is the
creep resistance of the reformer tubes at higher temperatures
and their capability to withstand thermal cycles.
Over the years, creep property improvements have been
achieved by using alloying elements (macro or micro) that,
combined with the carbon present in the tube metallurgy, form
carbides. The carbides act as strengtheners to limit creep defor-
mation. However, creep deformation will inevitably occur, lead-
ing to the formation of creep voids dispersed in the material.
Background. As early as in the 1950s, the first widely used
alloy for reformer tube application was HK40, which was basi-
cally an iron (Fe)-based alloy composed of 25% chromium
(Cr) to ensure creep and oxidation resistance, 20% nickel (Ni)
to maintain an austenitic structure, and 0.4% carbon (C). This
high C contentas compared to a similarly wrought alloy
coupled with a high quantity of available Cr, leads to the forma-
tion of Cr carbides.
HP alloy is the mother alloy of the 25Cr/35Ni family. The
evolution of 25/35 steels has never stopped. Manoir Indus-
tries introduced Niobium (Nb) as an alloying element to in-
crease the operating temperature of HP alloys by improving
the resistance of carbides to coarsening and coalescence.
The use of micro alloying (MA) has governed the last
two generations, namely 25-35 Nb-MA and 25-35 Nb-MA R
grades, to become respectively a standard for one and a very
interesting potential for improvement for the second, sanc-
tioned by several prestigious references. The benefit of these
improved properties include improved robustness, longer life-
time, cheaper tubes and increased production. For more infor-
mation, visit www.manoir-industries.com.
DUPLEX STAINLESS STEEL PROVIDES BENEFITS
FOR HEAT EXCHANGERS
The severe environment (high temperatures and pressures)
of refining processes creates corrosive conditions for plant
equipment. Research has shown that carbon steel (CS) and
austenitic stainless steel (SS) are extremely vulnerable to cor-
rosion. These construction materials are widely used in heat
exchanger tubing, so the tubes become susceptible to stress
corrosion cracking (SCC).
Recognizing this problem, the HPI is switching to more du-
rable materials, such as duplex SS, that offer a combination of
corrosion resistance, mechanical properties and excellent fab-
rication capabilities (FIG. 4). Duplex SS is being used not only
in new equipment construction but also for the retubing of
existing heat exchangers replacing CS and even austenitic SS.
 NEW DEVELOPMENTS IN HEAT TRANSFER
Sandviks SAF 2304 offers high strength with a yield
strength twice that of ASTM 316L, along with low thermal
expansion, very good weldability, physical properties that pro-
vide design advantages, ease of fabrication and toughness. For
more information, visit www www.sandvik.com.
NEW EXCHANGER DESIGN AND RATING TOOL
OPTIMIZES MODELING
Conventional workflow for the design of heat exchangers
required manual data transfer from process engineers to ther-
mal and mechanical heat exchanger experts to a cost estima-
tor. The design cycle involved several iterations and was prone
to data transcription errors. This approach also excluded the
process engineers visibility into problem details, making it dif-
ficult to investigate multiple process scenarios and arrive at a
fully optimized design. As a solution, AspenTech developed
the Aspen Exchanger Design & Rating (EDR) tool.
Available within Aspen Plus and Aspen HYSYS, the EDR
tool makes it easier than ever for process engineers to design
rigorous heat exchangers that are optimized for CAPEX and
OPEX while still considering process constraints (FIG. 5). This
is possible because the Aspen EDR product family offers pro-
cess engineers access to the most comprehensive range of heat
exchanger design and rating software from within Aspen Plus
and Aspen HYSYS. The Aspen EDR suite of programs was
built using over 40 years of Aspen HTFS proprietary research
work on heat exchanger design.
Aspens EDR is a unique solution because it enables pro-
cess engineers to optimize and troubleshoot exchanger perfor-
mance without ever leaving the simulation environment. With
HEAT TRANSFER NEWS
ALFA LAVAL TO SUPPLY HEAT EXCHANGERS
FOR KOREAN PETROCHEMICAL PROJECT
Alfa Laval has won an order to supply its Alfa Laval Pack-
inox heat exchangers to a petrochemical plant in South Korea.
The order, booked in the companys energy and process seg-
ment, has a value of approximately SEK 85 million, and deliv-
ery is scheduled for 2015.
The Alfa Laval Packinox heat exchangers will be used in the
production of mixed xylenes, ingredients in the manufactur-
ing of synthetic nylons and PET bottles.
CLEANTECH WINS $13-M EQUIPMENT ORDER
FOR CHINESE ETHYLENE GLYCOL PROJECT
Cleantech Solutions, a manufacturer of metal components
and assemblies used in various manufacturing industries
including clean technology, textile dyeing and finishing ma-
chineshas received a $13 million order from a large state-
owned enterprise based in Xinjiang, China.
The purchase order covers parts and equipment includ-
ing washing, distillation, purifying, dehydration, refining and
other columns, along with storage containers, heat exchang-
ers and carbonation reactors that will be used in a large-scale
project that transforms glycol calcium carbide furnace tail gas
into ethylene glycol.
HYDROCARBON PROCESSING|FEBRUARY 2015|NEW DEVELOPMENTS IN HEAT TRANSFER
FIG. 5. Apsens EDR tool makes it easier than ever for process engineers
to design rigorous heat exchangers.
the use of rigorous simulation models, users can increase the
fidelity of their process simulation models while rapidly and ac-
curately sizing heat exchangers directly from the process flow-
sheet. With Aspen EDR, heat exchanger operational risks are
clearly flagged on the process flowsheet, thereby enabling users
to identify potential operational problems early in the design
cycle. Users have reported great benefits including optimized
equipment designs resulting in savings of 10%30% on capital
costs; the ability to identify areas to reduce energy, capital and
operational costs, with potential savings from the integration
with Aspen Plus and Aspen HYSYS; and increased engineer-
ing efficiency with emphasis on fast-track, front-end engineer-
ing through fully integrated tools for process design. For more
information, visit www.aspentech.com.
Cleantech received an advance payment of approximately
$1.3 million, or 10% of the purchase price. It will receive an
additional 80% of the purchase price upon delivery, and will
receive the remaining 10% within six months of delivery pro-
vided there are no technical problems with the equipment.
The company expects to begin delivering the equipment in
April 2015.
MANOIR INDUSTRIES INCREASES MANAURITE
HIGH-ALLOY CAPACITY IN YANTAI, CHINA
The Petrochem and Nuclear business unit of Manoir Indus-
tries has announced a 50% increase in its production capacity
of Manaurite high-alloy petrochemical tubes and equipment at
its Yantai, China, facility. The addition of a 7,000-m2 surface
area has allowed Manoir to enlarge its Yantai static production
line, as well as its assembling line and welding shop floor. This
ramp-up will be gradually effective in the first semester of 2015.
Manoir Yantai is the only high-alloy manufacturing plant
in China with international production standards for tubes,
collectors and ancillary equipment for hydrogen and ethylene
furnaces. Manoir Industries has been producing its Manaurite
high alloys in Yantai for more than 15 years. Today, more than
90% of production in Yantai is exported worldwide to major
petrochemical end users and engineering companies.
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