Enhancing performance of tubular heat exchangers using hiTRAN Systems

Page 1© Copyright Cal Gavin 2011 www.calgavin.com

Enhancing performance of

tubular heat exchangers

using hiTRAN Systems

INTHEAT

Friday 8th July 2011


Providing solutions to:

• Increase plant capacity• Reduce energy costs• Increased equipment

performance• Reduce production costs• Provide operational flexibility• Increase plant profit !



hiTRAN tube-side heat transfer enhancement

system –

•increases heat transfer up to 8 times•reducing fouling by increasing fluid sheer

Direction of Flow


How hiTRAN Wire Matrix Elements work

• hiTRAN Matrix Elements remove the boundary layer and mix it with the bulk flow.

• Fluid from the centre is displaced in the direction of the wall

• Residence time of the fluid at the wall is considerably reduced.

• Improved heat and mass transfer and reduced fouling

Red dye:

A) Laminar flow B) turbulent flow

Blue dye:hiTRAN Matrix Element


hiTRAN video – how hiTRAN works


Case study LUKOIL Refinery, Volgograd Feed Effluent Exchanger

Problem

Plant capacity limited by low heat

exchanger performance (mal-distribution)

Recovered heat was 19 MW but ……

23.1 MW needed to meet target

temperature

Fired Heater performance much too low!

4.1 MW not available from Fired Heater

High on-going energy cost if upgraded

Plant expansion now requires 28MW


Case study Lukoil - refinery Volgograd

Optimised Engineering Solution

• Study identified hiTRAN System would solve the problem

• Reduce maldistribution on tubeside - balance flow

• Increase tubeside heat transfer

• hiTRAN System retrofitted in just 2 weeks


Case study Benefits to Lukoil

• hiTRAN System increased performance from 27.8MW to 32.4MW

• 4.6 MW energy load saving without requiring new fired heater

• Fuel saving of over US$500K per year (at full flow rate)

• Enables higher plant throughput

• Increased plant profit!


Benefits: • Smaller units • Less bays• Increased efficiency• Reduced capital costs

Case study Rosneft - Novokuibyshevsk

New Air Coolers with hiTRAN System enhancement


Design Comparisons Empty tube design

design

No. of bays/bundles 5/10 1/2No of passes 12 2Flow length m 108 18

Tubeside htc W/m2OC 44 307Overall htc (bare) W/m2OC 35 180

Total Surface Area m2 18,100 3,600Plot space m2 123.3 24.1Weight tonnes 84 16

Total Fan Power kW 165 33Pressure Loss, Bar 0.71 0.71

Annual cost of electrical fan power US$

105,000 21,000

Case study Rosneft - Novokuibyshevsk


Cal Gavin’s Deliverables

Work Package 2: “Combined tube-side and shell-side heat exchanger enhancement”

•D2.1: Report on state of the art of heat transfer enhancement technologies and their benefits. (May 2011)

•D2.2: Report on tube side and shell side enhancement research(August 2011)

•D2.3: Mathematical models and the software implementation of tube- and shell side heat transfer enhancement ( May 2012)


State-of-art of heat transfer enhancement

technologies and their benefits• D2.1, 6 month• Heat Transfer Promoters

- Twisted Tapes, Static mixers, Helically-coiled

wires, Core Tubes and hiTRAN turbulators

• Comparisons- Between hiTRAN, Twisted tapes

and coiled wires

• The Influence of the boundary layer and overcoming the limitations in the heat transfer.


Report on tube side and shell side enhancement research

• D2.2, 9 month

Other deliverables Cal Gavin is involved in • WP1 ‘Analysis of intensified heat transfer

under fouling’ ( 4 person months)• WP4 ‘Design, retrofit and control of intensified

heat recovery networks’ (3 person months)• WP5 ‘Putting into practice’ (2 person months)• WP6 ‘Technology transfer’ (2 person months)


Thank-you for listening

Questions?

www.calgavin.com

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Enhancing performance of tubular heat exchangers using hiTRAN Systems