ABSTRACT

Heat exchanger fouling is a persistent problem contributing to process economics, plant capacity, environmental concerns, and safety. Advances in research on hydrocarbon fouling have changed the impact of fouling in crude refinery operations, through the use of rigorous performance monitoring and process optimization methods, use of fouling predictive models, use of fouling mitigation technologies (e.g., use of tube inserts), etc. This work presents case studies from two TOTAL refineries preheat trains where the exchangers are subject to fouling. TOTAL has implemented performance monitoring and predictive maintenance software (HTRI SmartPM™) throughout their refineries to improve existing fouling management practice. The software performs advanced data reconciliation, including simulation of detailed exchanger operational data using HTRI shell-and-tube heat exchanger calculation methods and inferring fouling resistance for individual shells for shells-in-series based on dynamic fouling behavior. Dynamic fouling models are used to assess the impact of fouling on the overall network performance. Several heat exchangers in the network have tube inserts (Turbotal® and Spirelf^® inserts from Petroval), and their performances are monitored and predicted. The case studies demonstrate successful implementation of SmartPM software in TOTAL Normandy and Grandpuits refineries, enabling economically feasible, technically viable, and environmentally desirable decision-making for refinery operation.

摘要

热交换器结垢是一个长期存在的问题，会影响工艺经济性、工厂产能、环境问题和安全性。通过使用严格的性能监控和工艺优化方法、使用污垢预测模型、使用污垢缓解技术（例如，使用管插入件）等，碳氢化合物污垢研究的进展已经改变了原油炼油厂操作中污垢的影响. 这项工作介绍了来自两个 TOTAL 炼油厂预热系统的案例研究，其中交换器容易结垢。道达尔在其炼油厂实施了性能监控和预测性维护软件 (HTRI SmartPM™)，以改进现有的结垢管理实践。该软件执行高级数据核对，包括使用 HTRI 管壳式换热器计算方法模拟详细的换热器运行数据，以及基于动态结垢行为推断串联壳的单个壳的结垢阻力。动态污染模型用于评估污染对整体网络性能的影响。网络中的几个热交换器具有管插件（Turbotal® 和 Spirelf^®来自 Petroval 的插入件），并对其性能进行监控和预测。案例研究表明，在 TOTAL Normandy 和 Grandpuits 炼油厂成功实施 SmartPM 软件，为炼油厂运营提供经济可行、技术可行和环保的决策。