2016 SENTRO-Tech Online Chemical Cleaning_5-2016

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]

SENTRO Technologies USA, LLC a California based company, is a leader for SAFETY and QUALITY

▸ Introduction

▸ Online Chemical Cleaning Solutions for

▸ Furnaces and Heaters

▸ Air Cooled Heat Exchangers (Fin Fans)

▸ Credentials and Q&A

Agenda

Introduction: Online Cleaning for sustainable efficiency

Efficiency

Time

Offline

Cleaning

Introduction: Online Cleaning for sustainable efficiency

Efficiency

Time

Offline

Cleaning

Online

Cleaning




SENTROMAX On-line Chemical Cleaning of

Furnaces and Heaters

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

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

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

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

On Line chemical cleaning of radiant section

in a furnace

Cleaning during normal operating conditions

hyoTpGs5https://www.youtube.com/watch?v=mtt

https://www.youtube.com/watch?v=mtt5hyoTpGs



https://www.youtube.com/watch?v=OIcldNKz2zk

On Line chemical cleaning of convection section

in a furnace

Cleaning during normal operating conditions

R_JVhqbA0www.youtube.com/watch?v=oihttps://

https://www.youtube.com/watch?v=oi0R_JVhqbA




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

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

On-Line Process

Using existing openings, windows, or flanges

No scaffolding needed

No confined spaces entry

Radiation section before and after results

Fouled radiant tubes

Tubes during cleaning

Radiation section application

Convection section cleaning: Applied through standard OR special OR soot-blower openings

Plugged convection section

Before

During During: SENTROMAX draws out dirt

After

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

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

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

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


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


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

Before cleaning 900°C 1,652 F

Milazzo Refinery, ITALY (oil fired heater)

948°C 1,738 F

973°C 1,783 F

After cleaning

Milazzo Refinery, ITALY

726°C 1,339 F

753°C 1,387 F

784°C 1,443 F

Cell temp trends :

Cell C

Cell B

Cell A

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

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

After cleaning

REGAP Refinery, BRASIL

461° C 862 F

615.1°C 1,139 F

620.7°C 1,149 F

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

Immediate results at AXION Refinery, Argentina (gas fired heater)

Before cleaning

During cleaning

After cleaning

Reduced BW temperature

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

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

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..

▸ Introduction





Agenda




SENTROFIN On-line Dry Chemical Cleaning of

Air Cooled Heat Exchangers (“Fin Fans”)

▸ 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:

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

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

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

Damages involved with water wash:

Chemical damage low pH water Mechanical damage water pressure

SENTROFIN cleaning solution is:

EFFICIENT

SAFE

ENVIRONMENTALLY FRIENDLY

COST EFFECTIVE

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

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
















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

SENTROFIN removes 100% of the fouling (both organic & inorganic) from the bundle

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

Visible Cleaning Results

Half-clean, Half-dirty fins

Before Cleaning

After Cleaning

Production rate - Increased

Outlet process temperature – reduced

Power of the fan (RPM for variable speed motors) - Reduced

Parameters to monitor effectiveness:

Visual Inspection and ISO 9001 Quality Control

Dirty (day light blocked)

Clean (day light visible)


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

[email protected]

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

[email protected]


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


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


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

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

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)

▸ Introduction





Agenda

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

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.

Documents

2016 SENTRO-Tech Online Chemical Cleaning_5-2016