a systematic approach to improving heater absorbed...
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A Systematic Approach to Improving Heater Absorbed Duty Texas Industrial Energy Management Forum S. Chatterjee March 1, 2012
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Company Profile
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LyondellBasell is…
One of the world’s largest olefins, polyolefins, chemicals and refining companies with revenues of $41billion (2010) The global leader in polyolefins technology, production
and marketing A pioneer in propylene oxide and derivatives A producer of fuels and refined products, including biofuels Dedicated to ongoing research and development programs
that meet the ever-changing requirements of our customers, including the creation of new catalysts, processes and products Listed on the New York Stock Exchange (NYSE) as a publicly
traded company. Ticker symbol: LYB
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Fast facts
•Third-largest independent chemical company in the world
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• Olefins and Polyolefins – Europe, Asia and International
• Olefins and Polyolefins – Americas
• Broad product portfolio
• Manufacturing flexibility
• Superior technology base
• Operational excellence
• Vertically integrated facilities
• Intermediates and Derivatives
• Technology
Five business segments
Delivers exceptional customer value across
the petrochemical chain
• Refining and Oxyfuels
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Global reach
•58 plants in 18 countries
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•More than 14,000 employees
worldwide
•Sales in more than
100 countries
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Diversified and vertically integrated portfolio
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Technology Intermediates & Derivatives
Olefins & Polyolefins Europe Asia & International
Olefins & Polyolefins Americas
Refining & OxyFuels
Wellhead
Refining
Olefins
Olefin Derivatives
2nd Level Derivatives
Capturing value along the chain
Styrene
Glycols Glycol Ethers
Butanediol
PP Compounding
Ethylene Oxide Acetyls Propylene
Oxide Polybutene-1 Oxy Fuels
Aromatics Fuels
Crude Natural Gas Liquids
Olefins
Glycols Glycol Ethers
Refining
Technology
Catalloy Process Resins
Polypropylene Polyethylene
Olefins Crackers
Technology
PP Compounding
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Our product lines and the end markets we serve…
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Technology Intermediates & Derivatives
Olefins & Polyolefins Americas Europe, Asia & Int’l
Process Licensing Catalyst Sales Technology Services New Ventures
Ethylene Propylene Polyethylene Polypropylene Catalloy process resins PP Compounds Polybutene-1
Propylene Oxide Styrene Monomer PG and PGE Acetyls C4 Chemicals Ethylene Oxide EG and EOD
End Uses • Insulation • Home Furnishings • Adhesives • Consumer Products • Coatings
End Uses • Polyolefin
and Chemical Manufacturers
End Uses • Food Packaging • Textiles • Automotive • Appliances • Films • Flexible Piping
Refining & Oxyfuels
Gasoline Diesel Olefins Feed Oxyfuels
End Uses • Automotive Fuels • Aviation Fuels • Heating Oil • Industrial Engine
Lube Oils
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A Systematic Approach to Improving Heater Absorbed Duty Texas Industrial Energy Management Forum S. Chatterjee March 1, 2012
lyondellbasell.com lyondellbasell.co
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- Houston Refinery
Improving Process Absorbed Duty
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Houston Refinery- Strong Energy Focus
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5
10
15
20
25
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2005 2006 2007 2008 2009 2010
Mill
ion
Dol
lars
02004006008001000120014001600
Mill
ion
Btu
per
Hou
r
Annual Reduction ($MM) Act Cumul MMBtuH Goal Cumul MMBtuH
Equivalent to: •Annual power consumption of over 110,000 homes •Carbon dioxide reduction of over 500,000 Metric tons
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Energy Footprint
The Refinery energy source is predominantly fuel gas
Consider steam from a FG/NG fired source FG/ NG footprint is ~ 65%
Total firing duty ~ 1,800 Million Btu/ Hr
Maintaining desired level of heater efficiency is critical
Heater evaluation beyond basic operating practices
Can improve efficiency without costly Capital
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Focus Area: Process Absorbed Duty
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Overall Heater Efficiency Components
Combustion Efficiency
Process Absorbed Efficiency
• Excess air • Burner Design/ Oper • Stack temp • Heater tuning • Air PreHeaters
Focus Area
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Refinery Heater – Heat Balance
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Heat Balance
Q Absorbed Duty
= Q Firing- Q Stack Loss - Q Radiation Loss
OR
(Q Convection + Q Radiation )
= (Q FG + Q Stoich.Air + Q Excess Air )
- Q Stack Flue Gas – Q Radiation
First Step : Validate Heater performance data
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Methodology – 5 Steps 1. Perform Heat balance
Convection section
Radiant Section
2. Complete design vs actual analysis for top 15 heaters Normalize data for actual feed rate and
composition
3. Rationalize, validate the gap
and develop corrective scope
4. Identify funding source
5. Include in execution planning
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Radiant Section Convection Section TotalHeat Absorption MMBTU / hrPercent Heat AbsorptionFluidMass Flow Rate Lb / hrVolumetric Flow bbl / hr
Radiant Section Convection Section TotalTemperature °FPressure psigLiquid Flow Lb / hrVapor Flow bbl / hrWeight Percent VaporMolecular Weight Lb / LbmoleVapor Viscosity cp
Specific Heat BTU / lb °FThermal Conductivity BTU / hr ft °F
Radiant Section Convection Section TotalTemperature °FPressure psigLiquid Flow Lb / hrVapor Flow bbl / hrWeight Percent VaporMolecular Weight Lb / LbmoleVapor Viscosity cp
Specific Heat BTU / lb °FThermal Conductivity BTU / hr ft °F
Heater Radiant Section Convection Section TotalExcess Air %Calculated Heat Release MMBTU / hr Guaranteed Efficiency HR%Calculated Efficiency HR%Radiation Loss HR%Flue Gas Temperature °FRadiation Loss MMBTU / hr Flue Gas Loss MMBTU / hr
Actual / Calculated
Process
Combustion Design Conditions
Inlet Conditions
Outlet Conditions
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Heater Process Data Collection
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Tin
H vap
Tin
Tout
Tout C int
C out
C in Flow MBPH
H vap
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Heater Combustion Data Collection
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Combustion Air Temp Tin
Tout
FG Flow MSCFH
Draft and O2
Draft and O2 FG Comp
FG Btu/SCF
Radiation Loss
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Actual vs. Design Heater Performance – Pareto Chart
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Absorbed Duty Gap (Design – Actual)
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Convection deficiencies
Radiation deficiencies
Under performing
Over performing
Systematically develop Flow and Temp trends for each suspect heater pass
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Examples of Process Variables Impacting Absorbed Duty
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BPH/FG RatioNote data separationfor passes
FG Flow maldistribution - Heater passes
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Coil Outlet temp variations at
Heater passes
Coil Outlet temp deviation trend
Examples of Process Variables Impacting Absorbed Duty
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Charge Flow rate variations at
Heater passes
Charge Flow deviation trend
Examples of Process Variables Impacting Absorbed Duty
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Other Reasons for Deficiency Further engineering analysis & heater examination reveals other gaps due to following : • Radiant :
– Instrument accuracy and calibration – Control system design – FG currents in fire box – Flame impingement causing coking – Improper flame pattern with poor heat flux – Net loss in performance due to underperforming convection
• Convection:
– Lower feed temp and different composition characteristics – FG Channeling, not using effective convection surface area – High Burner flame height, Internal coke deposit – External coil fouling, high DP
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Funding Options
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• Non Capital Funding dedicated to improve energy efficiency such as , IR scans, Refractory, etc.
• Permanent asset upgrades , additions such as redesign burners, add convection modules, etc.
• Items that will require shut down and be incorporated into TA planning , such as pigging, cleaning convection coils etc
• Simple remediation done with routine maintenance , such as Instr. Calibration, Analyzer verification
Maintenance Turnaround
Energy Program Capital
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Execution Planning
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Capital LRP
3-5 yrs TA Planning
2 yrs Energy Program
3-6 mos Maintenance
1 mo
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Conclusion
Comparison against Design provides a benchmark for acceptable performance Systematic analysis of Design versus Actual heat balance
provides deeper learnings about gaps Further improvements can be applied to new findings that
otherwise may have been overlooked
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Disclaimer and trademarks
•Catalloy, Spheripol, Spherizone, Hostalen and Lupotech are trademarks owned and/or used by the LyondellBasell family of companies. Spheripol, Spherizone and Hostalen are registered in the United States Patent and Trademark Office. •All information (“Information”) contained herein is provided without compensation and is intended to be general in nature. You should not rely on it in making any decision. LyondellBasell accepts no responsibility for results obtained by the application of this Information, and disclaims liability for all damages, including without limitation, direct, indirect, incidental, consequential, special, exemplary or punitive damages, alleged to have been caused by or in connection with the use of this Information. LyondellBasell disclaims all warranties, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose, that might arise in connection with this information. •LyondellBasell does not sell PB-1 for use in pipe applications intended for use in North America, and requires its customers not to sell products made from PB-1 into pipe applications for North America. •
•© LyondellBasell Industries Holdings, B.V. 2011
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