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Efficiency & Savings through On-Line Chemical Cleaning
2372 Morse Ave, Suite 200, Irvine CA 92614, USA SENTRO Technologies USA, LLC www.sentro-tech.com
SENTRO Technologies provides innovative cleaning services to the Refining, Petrochemical & Pipeline industries
SENTRO TECHNOLOGIES USA, LLC Tel: +1 888 239 3132 Email: [email protected]
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SENTRO Technologies USA, LLC a California based company, is a leader for SAFETY and QUALITY
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▸ Introduction
▸ Online Chemical Cleaning Solutions for
▸ Furnaces and Heaters
▸ Air Cooled Heat Exchangers (Fin Fans)
▸ Credentials and Q&A
Agenda
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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
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2372 Morse Ave, Suite 200, Irvine CA 92614, USA SENTRO Technologies USA, LLC www.sentro-tech.com
SENTRO Technologies provides innovative cleaning services to the Refining, Petrochemical & Pipeline industries
SENTRO TECHNOLOGIES USA, LLC Tel: +1 888 239 3132 Email: [email protected]
SENTROMAX On-line Chemical Cleaning of
Furnaces and Heaters
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Radiation & Convection sections become fouled during normal production
The fouling of the external tube
surfaces with scale (Iron Sulfide, Iron
oxide, vanadium, polymers, dust,
dirt, refractory materials, etc..) leads
to:
▸ Reduced throughput (production)
▸ Increased fuel consumption
▸ Increased flue gas temperature
▸ Increased emissions/pollution
▸ Increased corrosion rate
Typical plugged convection fins
Typical fouled radiation tubes
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Traditional Off-Line cleaning method is carried out mechanically mainly by: - Steel brushing
- Sand blasting
- Water blasting
With the following disadvantages:
- Lost production during shutdown
- Maintenance costs: scaffolding, labor, mechanical work,
etc..
- Time consuming procedures: scaffolding, permits
(confined space), etc..
- Aggressive cleaning due to hard scale: Damage to
refractory/insulation, and damage to wall thickness if
using sand blasting
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Immediate increased thermal efficiency
Immediate increased production
Immediate save energy
Immediate reduced emission/pollution
Immediate reduced temperature profile
Saved maintenance activities
Reduced and inhibited tube corrosion
SENTROMAX On-line Furnace Cleaning
Non-Aggressive method which removes 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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On Line chemical cleaning of radiant section
in a furnace
Cleaning during normal operating conditions
hyoTpGs5https://www.youtube.com/watch?v=mtt
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On Line chemical cleaning of convection section
in a furnace
Cleaning during normal operating conditions
R_JVhqbA0www.youtube.com/watch?v=oihttps://
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A process of chemistry & physics
Erosion/Abrasion 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-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 scaffolding needed
No confined spaces entry
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Radiation section before and after results
Fouled radiant tubes
Tubes during cleaning
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Radiation section application
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Convection section cleaning: Applied through standard OR special OR soot-blower openings
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Plugged convection section
Before
During During: SENTROMAX draws out dirt
After
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SENTROMAX cleaning delivers Corrosion Resistance:
SENTROMAX chemical granules are coated with a very thin layer of IRON OXIDE (in more details: 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: Acts as a barrier against corrosion
Inhibits further corrosion
Extends the tube life
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Recent example: Before / After Pictures
Before cleaning – hot spots, scale,
pieces of refractory
On-Line chemical cleaning of 50-H-3 heater at DELEK Refinery (Tyler, Texas), JUNE 2015
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Recent example: Before / After Pictures
After cleaning – tubes are clean
On-Line chemical cleaning of 50-H-3 heater at DELEK Refinery (Tyler, Texas), JUNE 2015
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Recent testimonials (original email)
DELEK Refinery (Texas USA, June 2015)
(-),
Here is what I see on the fuel gas system…
1. About 1 psig reduction in fuel gas pressure.
2. Fuel gas control valve opening dropped about a 3%
3. All the skin temperatures increased which may suggest the heat transfer improved.
4. Fuel gas consumption dropped about 2000 scfh
When inspection does an IR scan of the tubes in July it will be interesting if they see a signal on tube
temperatures with the IR scan.
Stephen Pawelkowski
Delek Refining, Ltd.
Tyler Refinery
425 McMurrey Drive
Tyler, TX 75702
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Recent testimonials (original email)
SASOL Secunda Refinery (South Africa, October 2014)
Results:
1) Reformer heater HT101, a gas-fired furnace currently working in just 60% load. After cleaning
convection only - reduced stack temp by 82F (28C).
(…..)
Hi (-),
Regarding your visit to Sasol Secunda complex and the work that you guys performed for us, I would like to extent my
gratitude for the manner in which you performed your tasks!
· Safety
o I really appreciated it that you were so safety conscious. Seeing that this is completely new to the Sasol environment,
your guidance in the safety measures that needed to be put in place was highly appreciated and respected. The task was
done safely and even when we had a small hiccup, you quickly made a plan to work more safely.
o You also respected our safety and governance processes and adhered to them.
· Technical
o The tasks were done with a high level of professionalism. We could see that you really believe in your cleaning method
and that you take your job seriously.
o The good results on the heater parameters also indicated the success of the project.
o Your enthusiasm to add value on other units within Sasol was also evident.
· Overall
o Even though it took a while to get you badged and into the plant, you guys always remained friendly and
professional. The job was done safely and to a high technical standard. It was a joy to work with you.
All the best and thanks,
Gerhard du Plooy
Area Manager Production – Refining East (North Units)
Sasol Synfuels
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Recent testimonials (original email)
SHELL & BP (SAPREF) Refinery (South Africa, 2013)
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
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Before cleaning 900°C 1,652 F
Milazzo Refinery, ITALY (oil fired heater)
948°C 1,738 F
973°C 1,783 F
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After cleaning
Milazzo Refinery, ITALY
726°C 1,339 F
753°C 1,387 F
784°C 1,443 F
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Cell temp trends :
Cell C
Cell B
Cell A
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Cleaning results:
Cell C Cell B Cell A
BEFORE
AFTER
delta T
900°C 1,652 F
948°C 1,738 F
973°C 1,783 F
726°C 1,339 F
753°C 1,387 F
784°C 1,443 F
189°C 340 F
174°C 313 F
195°C 351 F
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REGAP Refinery, BRASIL (oil fired heater)
Before cleaning 631° C 1,168 F
808.9°C 1,488 F
808.0°C 1,486 F
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After cleaning
REGAP Refinery, BRASIL
461° C 862 F
615.1°C 1,139 F
620.7°C 1,149 F
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Cleaning results :
Cell C Cell B Cell A
BEFORE
AFTER
delta T
631° C 1,168 F
808.9°C 1,488 F
808.0°C 1,486 F
461° C 862 F
615.1°C 1,139 F
620.7°C 1,149 F
170° C 338 F
194°C 381 F
187°C 369 F
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Immediate results at AXION Refinery, Argentina (gas fired heater)
Before cleaning
During cleaning
After cleaning
Reduced BW temperature
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SENTRO Benefits - Summary
We anticipate that the SENTROMAX On-Line chemical cleaning of furnaces or heaters will deliver the following benefits and results: Removal of the fouling from the fire side of the tubes, thereby
increasing heat transfer, reducing temperature profile and minimising operating energy consumption.
No Scaffolding No water or liquids No dry-Ice (thermal shock) No foam No cleanup or disposal requirements No harmful chemicals (no environmental impact) No damage to the tubes
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SENTROMAX Cost Benefit
Production increased
Fuel consumption reduced
Temperature profile (cell, bridge wall, stack) decreased
TOTAL THEMAL EFFICIENCY of the furnace
can be increased by 4-12%
Typical Return On Investment: 2-12 weeks
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SENTRO treatment is applicable for all furnaces and heaters that have: A)Negative draft, and B)Cleaning access (at least 1.5" flanges)
For example: CRUDE Atmospheric, CRUDE Vacuum, Platformer, Reformer, Isomerization, BTX, Ethylene, Polypropylene, Etc..
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▸ Introduction
▸ Online Chemical Cleaning Solutions for
▸ Furnaces and Heaters
▸ Air Cooled Heat Exchangers (Fin Fans)
▸ Credentials and Q&A
Agenda
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2372 Morse Ave, Suite 200, Irvine CA 92614, USA SENTRO Technologies USA, LLC www.sentro-tech.com
SENTRO Technologies provides innovative cleaning services to the Refining, Petrochemical & Pipeline industries
SENTRO TECHNOLOGIES USA, LLC Tel: +1 888 239 3132 Email: [email protected]
SENTROFIN On-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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Air Coolers Cleaning Methods Comparison SENTRO
On-Line
Chemical
Cleaning
“Dry Ice”
(Solid CO2)
Foam or
Soap
High
Pressure
Water Wash
Weak Citric
Acids
Effectiven
ess
Very
effective,
removes
both
organics
and
inorganics
deep
through the
whole
bundle
Cleans only
the surface,
not deep into
the bundle
Limited
effectiveness,
cleans only the
top layers
effectively as
Soap evaporates
from hot surfaces
before
penetrating
Cleans only the
surface, not
deep into the
bundle
Very effective,
removes both
organics and
inorganics
deep through
the whole
bundle
Damage
to fins
No damage
to fins
Damage to fins
and tubes due
to thermal
shock. Causes
stress
cracking to
both fins and
tubes
Damage to fins
and tubes if
caustic soap is
used (causes
caustic stress
corrosion
cracking)
Mechanical
damage to fins
due to high
pressure.
Chemical
damage to fins
if water
contains
calcium
carbonate or
chlorine
Damage to fins
if acid time
spent is too
long, or if acid
is too strong
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Air Coolers Cleaning Methods Comparison (Con.) SENTRO
On-Line
Chemical
Cleaning
“Dry Ice”
(Solid CO2)
Foam or
Soap
High
Pressure
Water Wash
Weak Citric
Acids
Scaffolding No
Scaffolding
Needs
Scaffolding
Needs Scaffolding Needs
Scaffolding
Needs
Scaffolding
Clean-up
and
disposal
No clean-up
or disposal
requirements
No clean-up or
disposal
requirements
Need to clean-up
foam and soapy
effluent
Need to clean-
up or treat dirty
water
Need to clean-
up acidic
effluent
Environme
ntal impact
No
Environment
al impact
No
Environmental
impact
High pH effluent No
Environmental
impact
Low pH effluent
Confined
Space entry
No Confine
Space entry
Needs Confine
Space permit
No Confined
Space entry
No Confine
Space entry
No Confine
Space entry
Foot Print
and
Mobility
Minimal
footprint,
high mobility
between
units, needs
a small
forklift
Large footprint,
needs a crane
to move heavy
equipment
Minimal footprint,
high mobility
between units,
needs a small
forklift
Minimal
footprint, high
mobility
between units
Minimal
footprint, high
mobility
between units,
needs a small
forklift
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Traditional cleaning methods have significant disadvantages: SENTRO guarantees no damage to fins or tubes
No cleaning means low efficiency High pressure water & walking on fins causes
serious fin damage
Foam/Soap causes caustic stress corrosion,
and does not penetrate all the way through
the whole bundle
Acid causes damage to fins
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Damages involved with water wash:
Chemical damage low pH water Mechanical damage water pressure
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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 30-40 minutes for cleaning
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On Line chemical cleaning of fin fan air coolers (top view)
Chemical penetrate through the bundle from bottom to top
https://www.youtube.com/watch?v=aqWIxC61O30
https://www.youtube.com/watch?v=T6VaKVRROKk
On Line chemical cleaning of fin fan air coolers (bottom view)
Spraying bottom-to-top, no scaffolding and no confined space entry
https://www.youtube.com/watch?v=C97s8aSmxxQ
https://www.youtube.com/watch?v=MYKwgcAgsI0
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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 bundle
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We anticipate that the SENTROFIN On-Line chemical cleaning will deliver the following benefits and results: Removal of the fouling from the entire air cooler bundles, thereby
increasing heat transfer, output temperature and minimising operating energy consumption.
No Scaffolding No water No dry-Ice (thermal shock) No foam No cleanup or disposal requirements No harmful chemicals (no environmental impact) No damage to the fins No confined space entry
Anticipated Results
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Visible Cleaning Results
Half-clean, Half-dirty fins
Before Cleaning
After Cleaning
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Production rate - Increased
Outlet process temperature – reduced
Power of the fan (RPM for variable speed motors) - Reduced
Parameters to monitor effectiveness:
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Visual Inspection and ISO 9001 Quality Control
Dirty (day light blocked)
Clean (day light visible)
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Recent testimonials (original email)
LION OIL Refinery, El Dorado AR (USA, May 2015)
(-),
Sorry for taking some long to give you this information. Here are the functional location of the fin
fans.#4 AVGO- SouthWest-004-0042-BB, North west 004-0043-AB, (S)East 004-0042-BA,
(N)east 004-0042-AB. LVGO- (N)west 004-40-1A, 004-0040-1B, HVGO-(S)west-004-0041-1A,
(S)East 004-0041-1B. #8 unit Diesel Product 113BB, 113AB, 113BA,113AA. HHPS
114BB,114AB,114BA,114AA
You all done an excellent job on all of the fin fans. It was done safety and in a timely manner.
Temp. drop on all of the fin fans. Appreciate all of you all work.
Thanks
TBoyd
CROSS OIL Refinery, Smackover LA, (USA, January 2015)
“….. Everything has went well. They'll be finishing up shortly. If we want Al and the crew back
tomorrow to hit a couple of more fans…”
Brian Ricker, Maintenance Manager
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Recent testimonials (original email)
NEXEN Energy, Fort McMurray (Canada, June 2014)
Hello (-)
The test with the fin fans here at Nexen Long lake was a success and we would like to schedule
you in to clean another 70 Fans.
Can you provide myself and John a quote for this work and we can set a date please?
Thanks
Danny Johnson
Area 3 AGU planner
Nexen Energy ULC
Oil Sands
P.O. Box 6010
Fort McMurray, AB T9H 4V9
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Recent testimonials (original email)
SASOL Secunda Refinery (South Africa, October 2014)
Results:
(…..)
2) 3 fin fan air coolers: After the cleaning - outlet temperature reduced by 77-86F (25-30C) and vacuum
significantly increased.
Hi (-),
Regarding your visit to Sasol Secunda complex and the work that you guys performed for us, I would like to extent my
gratitude for the manner in which you performed your tasks!
· Safety
o I really appreciated it that you were so safety conscious. Seeing that this is completely new to the Sasol environment,
your guidance in the safety measures that needed to be put in place was highly appreciated and respected. The task was
done safely and even when we had a small hiccup, you quickly made a plan to work more safely.
o You also respected our safety and governance processes and adhered to them.
· Technical
o The tasks were done with a high level of professionalism. We could see that you really believe in your cleaning method
and that you take your job seriously.
o The good results on the heater parameters also indicated the success of the project.
o Your enthusiasm to add value on other units within Sasol was also evident.
· Overall
o Even though it took a while to get you badged and into the plant, you guys always remained friendly and
professional. The job was done safely and to a high technical standard. It was a joy to work with you.
All the best and thanks,
Gerhard du Plooy
Area Manager Production – Refining East (North Units)
Sasol Synfuels
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Recent testimonials (original email)
SHELL & BP (SAPREF) Refinery (South Africa, 2013)
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
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A process of chemistry & physics
Erosion/Abrasion impact through the whole bundle
Chemical and mechanical effects simultaneously
Chemicals behave like steam, fly away, do not settle
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-flammable, non-explosive, non-transport regulated Compatible with bundle metallurgy – tubes and fins (usually made of aluminum or copper)
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▸ Introduction
▸ Online Chemical Cleaning Solutions for
▸ Furnaces and Heaters
▸ Air Cooled Heat Exchangers (Fin Fans)
▸ Credentials and Q&A
Agenda
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Track record of On-Line Chemical Cleaning success across USA, Canada, South America, Europe, the Middle East, India, South Africa
ENI
Italy
AXION,
Argentina
SAPREF
South Africa
ESSAR
India
TUPRAS
Turkey
DOW
Canada
PETROBRAS
Brazil YPF
Argentina
MOL
Italy
References & recommendations available
CITGO
TX, USA
DELEK
Texas USA
ERGON
WV, USA
LION OIL
AR, USA
NEXEN
Canada
SUNCOR
Canada
CROSS OIL
AR, USA
CHEVRON
Canada
SASOL
LA, USA
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To discuss your cleaning requirements please contact:
SENTRO TECHNOLOGIES USA Tel: +1 888 239 3132
Email: [email protected]
USA | UK | Germany | Russia | Turkey | India | Brazil | Indonesia SENTRO Technologies www.sentro-tech.com
SENTRO Technologies is an international services
company specializing in on-line dry chemical cleaning
solutions for the petroleum, petrochemical, and power
industries.