refining summit 2015
TRANSCRIPT
Optimizing plant efficiency
Heat recovery and saving energy
Hans van Essen
Den Haag – April 22 2015
Content
• Introduction Bronswerk
•Radiax®
– Case 1: Mechanical vapour recompression
• Whizz-wheel®
– Case 2: Debottlenecking – ACHE offshore
– Case 3: Debottlenecking – ACHE refinery
• Site survey
History:
1940
1988 – Privately owned
2015
What we do:
• Process design
• Thermal design
• Mechanical design
• Manufacturing
• Supply
• Installation & Commissioning
• After market
Radiax®
:
Developing the Radiax® started from the beginning, a fully
new principle compressor / turbine / pump was designed.
Radiax®
:
Key features:
• Compact (up to factor 10)
• Fully integrated drive and seal system
• Oil free system behavior
• Flexible in extended ranges
• No surge and No stall
• Flat pressure vs flow curves (no specific work point)
• High pressure ratio
• High efficiencies over extended ranges
Radiax®
:
Applicatoins
- Wet compression & wet expansion
- Well gas conditioning for gas turbines
- Waste Heat Recovery (ORC & RC)
- Vapour recompression
CASE 1: Steam Recompression
Case description :
Stripper
flash drum
Steam ejector
4 bara
7000 kg/h
144°C / 4 bara
Water: 312352 kg/h
HP steam
2500 kg/h
3,29 bara
4500 kg/h
3,29 bara
Operating cost: €537.000,- / year
Solution :
Stripper
Flash drum
4 bara
7000 kg/h
144°C / 4 bara
Water: 312352 kg/h
2,85 bara
7000 kg/h
Radiax
2,85 bara
E-power: 200kW
Operating cost: €137.600,- / year
• OPEX reduction:
€400.000,-/year
• ROI: <2 year
Whizz-wheel®
:
Develop ultra low noise fans to meet the stricter client
requirements.
Conventional :
Whizz-wheel®
:
Main features
•Rim
•Small hub
•Blades are fully curved
Whizz-wheel®
:
Developed for low noise: 6 – 20 dB lower noise
Benefits:
• 45 - 60% lower absorbed power
• Up to 40% more cooling air flow with same absorbed power
• Or a combination
• Minimal vibrations
• Rigid construction
• Less sensitive to wind
Whizz-wheel®
:
Trends:
• Upgrading existing facilities
• Decreasing OPEX
– absorbed motor power
– Maintenance
• More strict noise requirements
CASE 2: Debottlenecking
2 new gas compression modules – Mexico
Litoral-A
Case description :
Plant
• Existing platform
• Two new gas compression trains (modules)
Challenges:
1. Plot space
2. Maximal absorbed power
3. Maximum noise level
Solutions :
Conventional Whizz-wheel®
Plot space area 582m2 412m2
Installed motor power 390 kW 308 kW
Sound pressure level 90 dB(a) @ 1m <85 dB(a) @ 1m
Total height 7,6m 7m
Total weight of units 141 ton 126 ton
Results:
• 40% reduced plot space
• 24% lower absorbed power
• 8% reduced height
• 12% less weight
• No noise issues
Quote PM: “without the whizz-wheel we could not have
executed this project.”
CASE 3: Debottlenecking
Air Cooled Coolers – Germany
Case description:
Plant
• 120.000 barrels/day
• Located in a populated area
• More then 60 fans
• Different services
Challenge:
• Reduce high noise
emissions
Solutions :
Option 1: Standard low noise fans
• Noise level of 72 dB(a)
• 12,6 kW absorbed power
Option 2: Whizz-wheel ® system
• noise level of 66 dB(a)
• 5,6 kW absorbed power
Results:
• 20 dB(A) proven lower noise
• 56% lower absorbed power
• 5% more airflow
• Installation during operation
Site Survey
What is your specific challenge? Or where can you safe
energy
With a Site Survey the problem can be identified and a
solution is within reach!
Thank you for your attention.
Questions?
Let’s talk more in our booth (No. 12)
How to contact us:
Hans van Essen
+31-33-24-72-562
www.bronswerk.com