page 1 © copyright cal gavin 5/2006 cal gavin ltd process intensification engineering
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Page 1© Copyright Cal Gavin 5/2006 www.calgavin.com
Cal Gavin LTD
Process Intensification Engineering
www.calgavin.com
Page 2© Copyright Cal Gavin 5/2006 www.calgavin.com
Cal Gavin Limited
Established as an engineering company in 1980 to research, develop and provide process enhancement technology.
Today, Cal Gavin’s design, research and manufacturing facility is located in the picturesque Roman town of Alcester.
- 8 miles (13km) West of Stratford-upon-Avon- 20 miles (30km) South East of Birmingham- 100 miles (160km) North West of London
Located in Alcester, Warwickshire, England.
Page 3© Copyright Cal Gavin 5/2006 www.calgavin.com
Scope of Activities Include:
• Debottlenecking – engineering solutions to overcome plant and process limitations
• Designing new enhanced exchangers
• Simulating performance and upgrading existing exchangers (Aspentech & HTRI Software available)
Page 4© Copyright Cal Gavin 5/2006 www.calgavin.com
Red dye:
A) Laminar flow B) Pseudo turbulent flow
Blue dye:
Heat transfer• Up to 20 times heat transfer compared to plain
tube(up to 10 times at the same pressure drop when designing heat exchangers)
• Proportional heat transfer to flow rate (no transition region)
• Suitable for single & two phase flowfouling reduction through:• Increased wall shear rate / Reduced wall residence
time / changed wall temperatures
hiTRAN technology / principles
Page 5© Copyright Cal Gavin 5/2006 www.calgavin.com
Wide range of process applications
Power GenerationDouble-enhanced fuel gas heaters, hiTRAN® and low-finned tubes used to create compact single-pass design (less than ½ size of conventional unit) through a US fabricator.
Speciality Chemicals ProductionDebottleneck of three column condensers handling highly toxic product (avoiding exchanger replacement). Stade, Germany.
Bulk Chemicals ProductionRe-use of existing exchanger for condensate/DI water energy recovery (project payback <6 months). Wilton, UK.
Bulk Chemicals ProductionDebottleneck of large overhead condenser on vacuum distillation process (30% throughput gain. Alberta, Canada.
Bulk Chemicals ProductionDebottleneck of ammonia waste heat boiler (15% throughput gain).France.
Page 6© Copyright Cal Gavin 5/2006 www.calgavin.com
Application Highlights….
Batch Chemicals ProductionBatch time reduction through improved separation in reflux condenser. Stepan, USA.
Speciality Chemicals ProductionDebottleneck of forced flow reboiler (3 x duty increase). Bergen Op Zoom, Holland.
RefineryEnhanced design of air-cooled exchanger subject to waxy fouling.Baytown, Texas.
RefineryDebottleneck of large air-cooled Sulfinol® cooler. Deer Park, Texas.
Syngas PlantAdaptation of second-hand heat exchangers to new Selexol® chilling duty. Coffeyville, Kansas.
Page 7© Copyright Cal Gavin 5/2006 www.calgavin.com
INHEAT Consortium
Basis for co-operation with Manchester University Department of Process Integration and PIL Limited
Goal of this consortium
• To develop a software capability to address the needs of the process industries to model exchanger network systems for optimum production and minimum energy consumption by way of enhanced heat transfer.
Page 8© Copyright Cal Gavin 5/2006 www.calgavin.com
INHEAT Consortium
Aim of the funded project
• bringing together existing knowledge of exchanger design, (component tubes, enhanced surfaces, fouling mitigation experience etc.
• extend current knowledge, where possible, to fill in the technology gaps
• facilitating a broad applicability of the resulting technology combinations.
The results of the project will allow engineers to provide realistic upgradecapability with enhanced heat exchangers for existing process plants.
Page 9© Copyright Cal Gavin 5/2006 www.calgavin.com
Cal Gavin Role in the Project
• Responsible for Work Package 2 (WP2)
Combined tube-side and shell-side heat exchanger enhancement
• Report on state-of-art heat transfer enhancement technologies
• Report on tube-side and shell-side enhancement research (with focus on tube-side)
• Mathematical modelling and software implementation of tube and shell side enhancement
Page 10© Copyright Cal Gavin 5/2006 www.calgavin.com
Cal Gavin Role in the Project
• Responsible for Work Package 2 (WP2)
Combined tube-side and shell-side heat exchanger enhancement
• Report on state-of-art heat transfer enhancement technologies
• Report on tube-side and shell-side enhancement research (with focus on tube-side)
• Mathematical modelling and software implementation of tube and shell side enhancement
Page 11© Copyright Cal Gavin 5/2006 www.calgavin.com
Participation in other work packages:
WP1: Analysis of intensified heat transfer under fouling
• Cal Gavin ltd: Support for CFD research on heat transfer and shear stress, when applying tube inserts. WP5: Putting into practice
Demonstration activities with different subtasks:e.g.:
• Validation of practicality of the improved methods in oil/petrochemical sectors
• Demonstration of the benefits of the improved methods in terms of energy and emissions savings
Page 12© Copyright Cal Gavin 5/2006 www.calgavin.com
Requirements to achieve this goal
• Cooperation with Companies providing shell side enhancement technology(EMBaffle B.V. ….)
• Access to Organisations with experimental test equipment to develop models for enhanced two-phase heat transfer(Universities, HTRI…)- Funding of those activities ?
Page 13© Copyright Cal Gavin 5/2006 www.calgavin.com
Technical Manager
Martin Gough MD of Cal Gavin LTD has been chosen as Technical Manager of the project.
Main Tasks:
•Coordination of technical activities and communication between partners within work packages
•Review and management of project progress against objectives