efficiency & savings through on-line chemical cleaning · on-line dry chemical cleaning of air...
TRANSCRIPT
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Efficiency & Savings throughOn-Line Chemical Cleaning
USA | UK | Germany | Russia | Turkey | India | Brazil | Indonesia SENTRO Technologieswww.sentro-technologies.com
SENTRO Technologies provides innovative cleaning services to the Refining, Petrochemical & Pipeline industries
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▸ Introduction
▸ Online Chemical Cleaning Solutions for
▸ Furnaces, Heaters & Steam Boilers
▸ Air Cooled Heat Exchangers (Fin Fans)
▸ Case Study @ SAPREF
▸ Credentials
▸ Q&A
Agenda
![Page 3: Efficiency & Savings through On-Line Chemical Cleaning · On-line Dry Chemical Cleaning of Air Cooled Heat Exchangers (Fin Fans) - Low heat transfer efficiency - High pressure drop](https://reader030.vdocuments.us/reader030/viewer/2022040914/5e8ab665f266405973070a57/html5/thumbnails/3.jpg)
Introduction:Online Cleaning for sustainable efficiency
Efficiency
Time
Offline
Cleaning
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Introduction:Online Cleaning for sustainable efficiency
Efficiency
Time
Offline
Cleaning
Online
Cleaning
![Page 5: Efficiency & Savings through On-Line Chemical Cleaning · On-line Dry Chemical Cleaning of Air Cooled Heat Exchangers (Fin Fans) - Low heat transfer efficiency - High pressure drop](https://reader030.vdocuments.us/reader030/viewer/2022040914/5e8ab665f266405973070a57/html5/thumbnails/5.jpg)
SENTRO Technologies provides innovative cleaning services to the Refining, Petrochemical & Pipeline industries
USA | UK | Germany | Turkey | India | Brazil SENTRO Technologieswww.sentro-technologies.com
SENTROMAXOn-line Chemical Cleaning of
Furnaces, Heaters & Steam Boilers
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Radiation & Convection sections become fouled during normal production
The fouling of the external tube surfaces with
dust, dirt & refractory materials leads to:
▸ Reduced flue gas flow
▸ Increased flue gas temperature
▸ Reduced production
▸ Increased fuel consumption
▸ Increased emissions/pollution
▸ Increased corrosion
And results in:
▸ Plugging & the requirement to shut-downTypical plugged convection fins
Typical fouled radiation tubes
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Traditional cleaning methods have significant disadvantages
Off-Line CleaningUses mechanical means such as high
pressure water jet, sand blasting or manual
labor using steel brushes.
▸ Lost production during shutdown
▸ Damage to refractory/insulation
▸ Safety risks from entry to confined areas
▸ Partial cleaning due to limited access to
bundles in convection sections
On-Line Cleaning by “Dry Ice” Uses a spray of “dry ice” (CO2)
▸ Effective only on the upper surface of fin
bundles (does not penetrate between the
bundles)
▸ Significant risk of thermal shock to fins and
tube supports (made of cast iron) causing
stress cracks, metal deformation &
accelerated corrosion
On-Line Cleaning by hazardous
chemicalsUses spraying of toxic chemicals containing
ammonia or low pH acids.
▸ Non-environmental friendly method.
▸ Creation of air pollution with hazardous
gases during the cleaning.
▸ In humid conditions hazardous gases in the
atmosphere can condense and accumulate
on the ground and into water resources.
Methods Disadvantages
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Increase efficiency
Increase production
Save energy
Reduce emission/pollution
Reduced temperature profile
Avoid shutting-down/start-up problems
Save maintenance activities
Future rights for carbon credits (Kyoto Protocol)
Reduced and inhibited tube corrosion
SENTROMAX On-line Furnace Cleaning
Removal of scale and deposits from the external tube walls during normal operating conditions
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SENTROMAX cleaning procedure
Dry chemical granules are sprayed by compressed air into the radiation and convection sections
High Return on Investment
Innovative Chemistry
Safe Process
Environmentally Friendly
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A process of chemistry & physics
Erosion impact through heat and flames
Chemical neutralization reaction with acidic deposits
Decomposition after reaction
Simultaneous combination of mechanical & chemical effect
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Chemistry & physics cont.
Developed over years of R&D and field
experience
Non-toxic, non-hazardous, non-corrosive,non-poisonous, non-flammable, non-explosive, non-transport regulated
Complete decomposition in high temperature
Compatible with furnace metallurgy
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On-Line Process
Using existing openings, windows, or flanges
No need for extra scaffolding
No entry into confined spaces
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Radiation section before and after results
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Radiation section application
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Convection section: Applied through standard OR specialOR soot-blower openings
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Plugged convection section before, during, and after
Before
During During: SENTROMAX draws out dirt
After
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SENTROMAX cleaning delivers Corrosion Resistance
Challenge:
Fuel impurities including sulphur and
vanadium cause tube surface
corrosion and thereby reduces tube
life span and increases maintenance
costs.
Solution:
SENTROMAX chemical granules are
coated with nano-sized Alpha-Fe2O3
Ecotrans R-1 (Magnetite).
Once the tubes are cleaned of fouling
the Magnetite forms a mono-molecular
passivation film on the tubes that:
1. Acts as a barrier against corrosion
2. Passivates the metal tubes
3. Inhibits further corrosion
4. Extends the tube life
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REGAP Refinery, BRASIL
Before cleaning531°C 758°C 868°C
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After cleaning
REGAP Refinery, BRASIL, July 2012
461°C 615°C 721°C
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Final results :
C B A
531°C868 °C758°CBEFORE
461°C11°C7615°CAFTER
(70°C)(147°C)((143°Cdelta T
13%17 %18%%
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Milazzo Refinery, ITALY
Before cleaning 900°C 948°C 973°C
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After cleaning
Milazzo Refinery, ITALY, May 2012
726°C 753°C 784°C
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Cell temp trends :
Cell C
Cell B
Cell A
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Final results:
Cell C Cell B Cell A
973°C949 °C900°CBEFORE
784°C753 °C726°CAFTER
(189°C)(196°C)(174°C)delta T
19%20%19%%
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AXION Refinery, Argentina
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Safety Benefits
Personnel hazards avoided No personnel inside the furnace
Proper Personal Protective Equipment
Professional personnel and attitude
Maintenance & operational benefits No shut down or start up time needed
No scaffold assembly
No damage to refractory or insulation
No damage to instrumentation
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Environmental Benefits
Environmentally friendly process
NO creation of waste Chemicals burned / dissolved inside the furnace No creation of acidic waste water (like in off-line cleaning)
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SENTROMAX Cost Benefit
Production increased
Fuel consumption reduced
Temperature profile (cell, bridge wall, stack) decreased
TOTAL EFFICIENCY of the furnace can be increased by 4-12%
Typical Return On Investment 2-12 weeks
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Applicable for all furnaces, heaters and steam boilers that have negative pressure and cleaning access (at least 1.5" flanges)
Delayed coker unitsFlexi coker unitsFCC unitsPlatformersReformersHydrocrackers
HydrotreatersTopping unitsVisbreakersVacuum unit Atmospheric distillationProcess furnaces
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▸ Introduction
▸ Online Chemical Cleaning Solutions for
▸ Furnaces, Heaters & Steam Boilers
▸ Air Cooled Heat Exchangers (Fin Fans)
▸ Case Study @ SAPREF
▸ Credentials
▸ Q&A
Agenda
![Page 33: Efficiency & Savings through On-Line Chemical Cleaning · On-line Dry Chemical Cleaning of Air Cooled Heat Exchangers (Fin Fans) - Low heat transfer efficiency - High pressure drop](https://reader030.vdocuments.us/reader030/viewer/2022040914/5e8ab665f266405973070a57/html5/thumbnails/33.jpg)
SENTRO Technologies provides innovative cleaning services to the Refining, Petrochemical & Pipeline industries
USA | UK | Germany | Russia | Turkey | India | Brazil | Indonesia SENTRO Technologieswww.sentro-technologies.com
SENTROFINOn-line Dry Chemical Cleaning of
Air Cooled Heat Exchangers (Fin Fans)
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- Low heat transfer efficiency
- High pressure drop
- High outlet temperature
- High energy consumption (fan power)
- Low throughput
- Low total efficiency
Fouled Air Cooled Heat Exchangers lead to the following problems:
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Traditional cleaning methods have disadvantages SENTRO guarantees no damage to the fins
No cleaning means low efficiency High pressure water & walking on fins causes
fin damage
Foam/Soap evaporates before penetrating
all the way through the bundles
Acid causes damage to fins
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SENTROFIN cleaning solution is:
EFFICIENT
SAFE
ENVIRONMENTALLY FRIENDLY
COST EFFECTIVE
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SENTROFIN dry-chemical cleaning method
Spray dry chemical,from bottom-to-top,with compressed air.
Each fan is temporarily switched off for 45 minutes for cleaning
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SENTROFIN Air Coolers cleaning film-clip
Air Cooler Cleaning - Video
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SENTROFIN chemical powder
SENTROFIN is a fine powder that does not damage the fins.
It penetrates all the way through the bundle, and disperses like steam.
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SENTROFIN removes 100% of the fouling(both organic & inorganic) from the bundles
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• Cleaning during normal operation
• Removes all types of fouling from bundles
• No damage to fins
• No need for scaffolding
• No need to enter into the housing
• No need to remove the safety net
SENTROFIN Advantages
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Visible Cleaning Results !!
Half-clean, Half-dirty fins
Before Cleaning
After Cleaning
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Inlet/Outlet temperatures
Airflow
Power of the fan
Parameters to monitor effectiveness:
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Visual Inspection
Dirty (light blocked)
Clean (light visible)
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Before Treatment: T in = 47.9C
T out = 40.8C
After Treatment: T in = 47.2C
T out = 37.5C
Delta T = 3.3 C (8.1%)
Throughput benefit: 1,180 $/day
Energy consumption benefit: 243 $/day
Example of increased Air Cooler efficiency
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Environment:SENTROFIN cleaning is environmentally friendly
• NO creation of waste water
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Safety: SENTROFIN is SAFE
• Temporarily turn-off each fan for only 45min• No Scaffolding needed
Chemicals are non-corrosive and compatible with all types of metallurgy, non-hazardous, non-explosive, and non-toxic
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▸ Introduction
▸ Online Chemical Cleaning Solutions for
▸ Furnaces, Heaters & Steam Boilers
▸ Air Cooled Heat Exchangers (Fin Fans)
▸ Shell Case Study @ SAPREF
▸ Credentials
▸ Q&A
Agenda
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Case Study: SENTROMAX and SENTROFIN forSAPREF, Shell BP JV Refinery, Durban, South Africa
To whom it may concern,
The furnace on line cleaning (F7101 A/B/C) of both the radiant and convection bank of Crude
Distiller 2 and the fin fan bank (E7209) was successfully done from Monday 8th April 2013 until
Saturday 13th April 2013.
SENTRO performed this activity with the highest degree of competency and safety. In addition the
housekeeping was excellent.
The final benefit with regards to BWT (bridge wall temperature) is 80 degrees and 25 degrees
benefit with regards to stack temperature. The benefit would have been higher if there were more
accesses to the convection bank.
The fin fan bank of E7209’s were cleaned. Prior to the cleaning the fan pitch was at 100%, the feed
rate was at 260 t/d and we were flaring. Soon after the cleaning the fan pitch was at 20%, the unit
feed rate increased to 340t/d and there was no flaring,
Kindest regards
Baker Moodley
Cross Zonal and Combustion Engineer
Shell and BP South African Petroleum Refineries (Pty) LTD
+27314801657 , +27(0)836482300
email: [email protected]
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▸ Introduction
▸ Online Chemical Cleaning Solutions for
▸ Furnaces, Heaters & Steam Boilers
▸ Air Cooled Heat Exchangers (Fin Fans)
▸ Case Study @ SAPREF
▸ Credentials
▸ Q&A
Agenda
![Page 51: Efficiency & Savings through On-Line Chemical Cleaning · On-line Dry Chemical Cleaning of Air Cooled Heat Exchangers (Fin Fans) - Low heat transfer efficiency - High pressure drop](https://reader030.vdocuments.us/reader030/viewer/2022040914/5e8ab665f266405973070a57/html5/thumbnails/51.jpg)
Track record of On-Line Chemical Cleaning success across the Americas, Europe, the Middle East & Asia
Eni
Italy
AXION,
Argentina
SAPREF
South Africa
Essar
India
Tupras
Turkey
Dow Chemicals
Canada
Petrobas
Brazil
YPF
Argentina
MOL
Italy
References & recommendations available
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▸ Introduction
▸ Online Chemical Cleaning Solutions for
▸ Furnaces, Heaters & Steam Boilers
▸ Air Cooled Heat Exchangers (Fin Fans)
▸ Case Study @ SAPREF
▸ Credentials
▸ Q&A
Agenda
![Page 53: Efficiency & Savings through On-Line Chemical Cleaning · On-line Dry Chemical Cleaning of Air Cooled Heat Exchangers (Fin Fans) - Low heat transfer efficiency - High pressure drop](https://reader030.vdocuments.us/reader030/viewer/2022040914/5e8ab665f266405973070a57/html5/thumbnails/53.jpg)
To discuss your cleaning requirements please contact:
Email: [email protected]
USA | UK | Germany | Russia | Turkey | India | Brazil | Indonesia SENTRO Technologieswww.sentro-technologies.com
SENTRO Technologies is an international services
company specializing in on-line dry chemical cleaning
solutions for the petroleum, petrochemical, and power
industries.