258988 alfa Refinery PPI00091EN...AlfaLavalrefinerysolutions5 Lowermaintenancecosts Becauseoftheirmuchgreater reliability,AlfaLavalall-welded plate-typeheatexchangersrequire lessserviceandmaintenance,witha

Boost your refinery benefits

All-welded plate-type heat exchanger solutions

In refinery operations, all-welded plate-type heat exchangersare the most cost-effective way to conserve energy andreduce emissions. This can result in major reductions in theenvironmental impact of the many processes used in oilrefineries.

All-welded plate-type heat exchanger designs from Alfa Lavalare easy to integrate into demanding refinery environments.They have a proven record of boosting processing efficiencyand product value, as well as reducing installation andoperating costs.

Alfa Laval refinery solutions 3

Refined solutionsApplied technology accelerates achievement

Making processes run moreefficientlyThe all-welded plate-type heatexchanger technologies pioneeredby Alfa Laval can exploit energy inputsmuch more effectively than traditionalsolutions in association with superiorhydraulic characteristics.

Alfa Laval Packinox exchangers, forexample, provide opportunities formore effective heat recovery with alower pressure drop. Because thereaction loop is at lower pressure,the catalytic reforming process canoperate at a higher production rate.This means better reaction efficiency,improved yield and increasedhydrogen production.

Global supplierAlfa Laval is the world leader insupplying the all-welded plate-typeheat exchangers used in countless oilrefining processes, and the only globalprovider of such solutions. Almost athousand heat exchangers of this typeare already installed throughout theworld to help optimize a wide range ofprocesses in oil refineries.

Energy conservation – the key tocutting costsEnergy is essential for many refineryoperations and can account for asmuch as 50% of total operating costs.This energy is not only expensive –its production also has a vastenvironmental impact.

Soaring energy costs and globalenvironmental concerns aboutemissions of greenhouse gases, alongwith the highly competitive market forrefinery feedstocks and products, allput constant pressure on refineries tooperate more efficiently and moreeconomically.

Recovering thermal energy that hasalready been used once and thenusing it again therefore plays a keyrole in optimizing refinery operations.

And energy recovery is also one ofthe few major upgrade measures thatprovides a rapid return on investment.

Excellence in heat recoveryDifferent types of Alfa Laval all-weldedplate-type heat exchangers extractand re-use energy with unparalleledefficiency. This significantly reducesboth fuel costs and the life cyclecosts of refinery process units.

All-welded plate-type heat exchangersare therefore rapidly becomingstandard equipment in many refineryprocesses and installations, replacingtraditional technologies such as bulkyshell-and-tube units and energy-wasting air coolers. They providenumerous significant end-user benefitsthat include� greater production throughput� energy conservation via heatrecovery

� reduced emissions� lower CAPEX and OPEX� less downtime and reducedmaintenance

� improved operating costs.

Reducing processing costsOil refineries are capital-intensiveinstallations with high operating costs.And because heating and coolingare important parts of most refiningoperations, energy costs are normallythe largest single expense in arefinery’s operating budget.

Advanced plate heat exchangertechnology therefore makes it possibleto make dramatic improvements in thebasic cost parameters. Even smallimprovements in heat exchangerperformance mean considerablesavings that add up to newmilestones in cost-effectiveness.4 Alfa Laval refinery solutions

Keen to cut down on energy andemissions?Energy-efficient heat exchanger solutions

Cutting back on emissions with efficient heat transferThermal NOX� Amount produced is primarily a function of flame temperature� Estimated reduction in emissions: 3 tons per process MW per year

Fuel NOX� Amount produced depends on nitrogen content in the specific fuel (N% wt.)� Emission = 36*N tons per process MW per year� Estimated reduction in emissions: N = 0.25% = 9 tons per processMW per year

Total NOX = thermal NOX + fuel NOX� Estimated reduction in emissions = 12 tons per process MW per year�Monetary value = USD 1,000 per ton = USD 12,000 per MW per year

SOX� Functions of sulphur in heater fuel (S% wt.)� Emission = 27*S tons per process MW per year� Estimated reduction in emissions: S = 0.6% = 16 tons per processMW per year

�Monetary value = USD 1,000 per ton = USD 16,000 per MW per year

Greenhouse gases�Carbon in fuel transformed into CO2 during combustion� Average carbon content in fuel: 71% by weight� Emissions = 2,500 tons per process MW per year�Monetary value = USD 20 per ton = USD 50,000 per MW per year

SummaryMonetary value (per year) of 1 MW duty gain using plate-type heat exchanger� Fuel cost savings USD 462,000�Reductions in NOX and SOX emissions USD 28,000�Reductions in greenhouse gas emissions USD 50,000

Assumptions�USD 50 per BOE local fuel cost� 65% heater efficiency� 0.6% sulphur in fuel� 0.25% nitrogen in fuel


Lower maintenance costsBecause of their much greaterreliability, Alfa Laval all-weldedplate-type heat exchangers requireless service and maintenance, with asignificant impact on costs.

Alfa Laval heat exchangers aremuch more easily accessible for anyservice and maintenance that mightbe required. They are also easy toclean with standard CIP procedures,high-pressure cleaning equipment orusing patented decoking by controlledcombustion.

Lower emissions costsMore efficient heat transfer meansthat Alfa Laval all-welded plate-typeheat exchangers make an importantcontribution to reducing the use offossil fuels, thus cutting back onCO2, SOX and NOX emissions.

Lower capital and installation costsThe compactness of Alfa Laval plate-type heat exchangers means they aresignificantly cheaper to install. Theytake up much less space and requirefewer alterations to buildings andother structures, as well as lessextensive foundations andinfrastructure.

Small size also means that it isrelatively inexpensive to specify exoticmetals for use in corrosive operatingenvironments.

Lower energy costsThe thermal efficiency of Alfa Lavalall-welded plate-type heat exchangersmakes them models of good practicein energy conservation. This cutsdown on energy costs, which arean increasingly important part ofoverall operating costs.

Recovering energy in atmospheric distillationTwo Compabloc heat exchangers are installed in a refinery in the UK for coolingatmospheric residue using boiler feed water to ensure that the heat is recovered intothe refinery’s steam generation system.

The Compablocs have been in operation for three years with no need for service, andare now included in the refinery’s 10-year maintenance scheme.

6 Alfa Laval refinery solutions

The efficiency with which a heatexchanger extracts thermal energyfrom one medium and passes it on toanother can result in important savingsas well as significant improvements inhow specific refining processes areundertaken.

Exceptional heat recoveryDesign and process engineers focusincreasingly on small pinch,temperature cross and the exploitationof even the tiniest temperaturedifferences. When it comes tothermal performance, Alfa Lavaltechnology is 2–4 times more efficientthan any comparable shell-and-tubeunit, even under difficult processconditions. Alfa Laval all-weldedplate-type heat exchangers canexploit temperature differences assmall as 3°C, and provide maximumbenefit from pinch techniques.

As an example, Alfa Laval Packinoxfeed/effluent heat exchangers reducecharge heater duties by achievingmuch closer pinch temperatures thanis possible with traditional tubulartypes of heat exchangers. As theheat release curves show, this alsomeans lower hot and cold approachtemperatures (HAT and CAT). Theinlet temperature of the charge heateris higher and its heat duty is lower,so less fuel is burned.

Effluent

Dew point = 137°C

Pinch = 35°C

Feed mix

Dry point 156°C

Liquid feed (in tons/day/10)

Liquid effluent (in tons/day/10)

HAT = 48°C

CAT = 38°C

Heat exchanger = 81.8 MW

Heater = 12.1 MW

Cooler = 11.6 MW

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Feed rate = 3000 tons/day Reactor outlet pressure = 12 barg Recycle gas = 1100 tons/day

Reformer type: fixed bedFeed/effluent heat exchanger: shell-and-tube

Temperature, degrees C

Heat release curves, MW

Interested in getting processes to runmore efficiently?Performance improvements via advanced heat transfer

600

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00 20 40 60 80 100 120

Feed rate = 3000 tons/day Reactor outlet pressure = 12 bargRecycle gas = 1100 tons/day

Reformer type: fixed bed Feed/effluent heat exchanger: Packinox

,

Temperature, degrees C

Heat release curves, MW

Effluent

Dew point = 137°C

Pinch = 10°C

Feed mix

Dry point 156°C

Liquid feed (in tons/day/10)

Liquid effluent (in tons/day/10)

HAT = 12°C

CAT = 11°C

Heat exchanger = 88.7 MW

Heater = 5.1 MW

Cooler = 4.6 MW

Figure 2 Catalytic reformer, using Packinox

Figure 1 Catalytic reformer, using shell-and-tube

Catalytic reforming revampShell installed one of the very first Alfa Laval Packinox heat exchangers in thecatalytic reforming unit at its Berre refinery in France to deal with problems withlow heat recovery and high pressure drop. These problems were largely solvedby replacing 12 bulky horizontal shell-and-tube units, which not only improvedperformance and increased naptha throughput by 33%, but also reduced energyconsumption.

At the same time, the small footprint of the Packinox solution meant this majorrevamp was possible despite space restrictions, while weight reductions enabledShell to achieve significant savings on installation costs.


Process optimizationRefineries can achieve substantialboosts in processing efficiency usingall-welded plate-type heat exchangers.

Installing a Packinox unit in thecatalytic reformer results in lowerpressure drop and better heat transferperformance. This makes it possible toramp up production by as much as40% with no other changes.

The thermal efficiency of Compablocunits guarantees higher energyconservation. As a result, more heatcan be recovered into the boiler feedwater system or the crude oil pre-heattrain, as just two examples.

Spiral heat exchangers are ideal forextracting maximum heat energy frombottom residues, and their resistanceto fouling ensures less downtime forcleaning.

Saving energy countsTo boost the reliability of its production,Shell replaced the shell-and-tubecondensers at its Sarnia refinery inCanada with Alfa Laval Compabloccondensers. These units have nowbeen in continuous operation eversince commissioning in 2002.

The main motivation was to saveenergy. Compabloc condensersprovided the only feasible solutionfor using advanced alloys to avoidcorrosion and to achieve the degreeof heat recovery Shell was looking for.


Quantum leapAlfa Laval all-welded plate-type heat exchanger

solutions pave the way for big improvements

Atmospheric and vacuumcrude unitsCompabloc units are often installed inthe crude oil pre-heat train to pre-heatthe undesalted and desalted crude oilusing fractions from the distillationcolumn, including overhead vapour,gas oil, atmospheric residue, etc.

In refining operations, one of thekeys to success and profitability isto move beyond mere incrementalimprovements to ensure a significantcompetitive edge. All-welded plate-typeheat exchangers from Alfa Lavalprovide groundbreaking new levels ofperformance, reliability and profitability.

Packinox heat exchangers are normallyused as feed/effluent exchangers incatalytic reforming units, and also inHDT and HDS units.

Compabloc heat exchangers arenormally used as heaters, coolers,condensers and reboilers in virtuallyall the process units in the refinery.

Spiral heat exchangers are normallyused to cool fouling bottom fractionsas well as in top condensers whereextremely low pressure drops arerequired, such as the vacuum tower.

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Spiral heat exchanger units arenormally used as the main condenserin the vacuum column.

The best all-welded heat exchanger technology in the right place.

Compabloc in operation since 1996 ata refinery in Sweden for condensingvapour after the vacuum tower. Whencondensed to below the dew point forwater, the vapour becomes corrosive,and the Compabloc is therefore madeof titanium.


Solving the cleaning problemSevere fouling problems were experienced in 12 large shell-and-tube heatexchangers used for cooling the residue in the visbreaker unit at a majorEuropean refinery. Due to coke formation, these units had to be opened up tosix times per year for cleaning, at great cost.

The units were therefore replaced by 8 Alfa Laval spiral heat exchangers that canbe operated continuously with no unscheduled stops. These only need cleaningduring the planned general shutdowns of the visbreaker unit, which takes placeevery five years.

Catalytic and thermal conversionprocessesThese include fluid catalytic cracking(FCC), hydrocracking, continuouscatalytic reforming, isomerization,HDT, HDS, alkylation, cokers andvisbreakers, lube oil and asphalt plants.

Packinox heat exchangers areoften used as reactors and stripperfeed/effluent interchangers in catalyticreforming, HDT and HDS installations.

Compabloc units are often used inall these process installations inconjunction with the fractionationstages, as condensers, coolers,pump-around coolers, feed/effluentinterchangers and reboilers.

One instead of twelveA combined feed/effluent heat exchanger is used in a refinery in the Middle East.The refinery aimed to increase the capacity of its catalytic reforming process by50%. This was achieved using a single Packinox heat exchanger that replaced nofewer than 12 shell-and-tube units.

High-performance heat recovery and hydraulics increased throughput by 50%,while retaining all the existing ancillary equipment, such as heaters andcompressors. The investment was paid off within months.

In lube oil and asphalt plants,Compablocs are used in conjunctionwith extract and raffinate duties as wellas for pre-heating vacuum residue andcooling bitumen.

Spiral heat exchanger units are oftenused for cooling fouling residues suchas FCC bottoms and visbrokenresidue.

Treatment processesThese include amine plants, sulphurrecovery units (SRU), tail gas treatment(TGT), sour water strippers (SWS) anddesalter plants.

Compabloc heat exchangers areoften used as condensers, reboilers,interchangers and final coolers inamine, SRU, TGT and SWS plants.In TGT plants, Compablocs are alsoused for quench water cooling.

In desalter plants, Compabloc unitsare used as desalted water/feed waterinterchangers as well as for the finalcooling of the desalted water.


Alfa Laval Packinox heat exchangersare among the largest in the world,often as high as a six-storey building.Their enormous size is due to the hugetemperature difference from start toend – normally up to several hundreddegrees centigrade.

Nevertheless, the Packinox design isactually very compact in relation tothe heat transfer surface area. Theyare tiny compared with any shell-and-tube alternative, resulting in majorsavings in both infrastructure andinstallation costs.

Alfa Laval Packinox heat exchangersHigh-temperature, high-pressure performance

Performance payoffA US refinery was experiencing heavy fouling on its Alfa Laval Packinox heatexchangers due to improperly hydrotreated naphtha and oxygenated olefins.The heat exchanger was then completely cleaned by in situ steam-air decokingsupplied by Alfa Laval Packinox.

This controlled combustion (decoke) made it possible to rapidly return to theoriginal process performance.


Alfa Laval Packinox heat exchangersfeature a unique design that combinesthe high-temperature and high-pressure performance of shell-and-tubes with the thermal and hydraulicefficiency of plate heat exchangertechnology – all within a compact,large-capacity design. The result ishighly efficient heat recovery with anextremely low pressure drop.

Bundle inside pressure vesselThe Alfa Laval Packinox designconsists of a fully welded plate heatexchanger placed within a pressurevessel. This vessel contains a higher-pressure fluid that keeps the plateblock under compression while thecounter-current heat transfer processtakes place within. This makes itpossible to operate at temperaturesand pressures inconceivable for otherall-welded plate heat exchangers.

The design ensures both highefficiency and high operating safety,with near-minimal risk of fire, leaks orharmful emissions. This is an importantconsideration in refineries.

Alfa Laval Packinox advantages� High thermal and hydraulicefficiency

� Very large heat transfer surface in acompact space

� Single unit can replace multiplelarger shell-and-tube installations

� High-temperature and high-pressureoperation

� Simplified installation, lessinfrastructure required

� Minimal maintenance requirements.

Mechanical dataDesign pressure120 barg (1700 psig).Maximum pressure differencebetween media 30 bar (430 psi)

Design temperature650°C (1200°F)

Alfa Laval CompablocCompact, high-efficiency all-welded plate heat exchangers

The Alfa Laval Compabloc all-weldedheat exchanger design completelydoes away with gaskets betweenthe plates, making it ideal for manyprocess duties in refineries.

ConstructionThe heat transfer area of Compablocunits consists of a stack of corrugatedplates, laser-welded alternately toform channels. The high thermalefficiency of the design permits theuse of stainless steel, titanium andother exotic materials for the heattransfer area, at an affordable cost.

Compabloc is available with heattransfer areas ranging from 0.7 to320 m2 (7 to 3,450 ft2) per unit.


The Compabloc frame consists offour corner girders, top and bottomheads and four side panels with nozzleconnections. These are bolted togetherand can be quickly taken apart forinspection, service and cleaning.The nozzle size is variable and can beselected independently for each side.

Flexible flow arrangementThe overall flow arrangement iscounter-current for a multipass unit,though co-current operation is alsopossible. Each pass is separatedfrom the adjacent passes by a bafflethat forces the fluid to turn betweenthe plate pack and the panel.

The different nozzle sizes andflexible pass arrangements makethe Compabloc design suitable forliquid-to-liquid duties with dissimilarflow rates as well as for condensingand reboiling duties.

Alfa Laval Compabloc advantages� All-welded construction

� Large heat transfer surface in acompact space

� Manufactured in corrosion-resistantmaterials

� High degree of heat recoverypossible

� Heat transfer surface easilyaccessible for mechanical cleaning.

Low-maintenance efficiencyA Compabloc unit is in operation ata major refinery in Japan for coolingclarified slurry oil from the bottom ofthe main fractionator in the FCC.The heat exchangers previously usedfailed due to corrosion caused bythe high chloride content in thecooling water.

The high thermal efficiency of theCompabloc design made iteconomical to use corrosion-resistanttitanium. As a result, this Compablochas been in continuous service since2001, with no service or maintenancerequired.

Mechanical dataDesign pressure

Full vacuum to 35 barg (507 psig)

Design temperatureMax. 350°C (572°F), min. -29°C(-20°F) ASME, -40°C (-40°F)PED/CE

Unique shape, unique propertiesSpiral heat exchangers are particularlyuseful with media that cause fouling,because of the unique self-cleaningeffect of the spiral flow pattern.

A spiral heat exchanger is preciselywhat it says – a circular heatexchanger with two concentricspiral channels, one for each fluid.The curved fluid channels provideoptimum heat transfer and flowconditions for a wide variety of fluids,while keeping the overall size of theunit to a minimum.

This allows fully counter-current flowin which one of the fluids enters at thecentre of the spiral body and flowstowards the periphery. The other fluidenters at the periphery and movestowards the centre.


This results in maximum heat transferefficiency and makes it possible tooperate with temperature cross, whileonly taking up a minimum of space.

Alfa Laval spiral heat exchangersare ideal for liquid-to-liquid dutieswith dissimilar flow rates as well asfor condensing and for certainreboiling duties.

What goes in must come outIn a spiral heat exchanger, both fluidsin the heat transfer process occupya single channel. There is therefore norisk of a fluid diverting to other parallelchannels in case of fouling. Anyrestriction in the channel created byfouling increases the shear stress atthat exact point, creating a scrubbingaction that removes the blockage.This makes Alfa Laval spiral heatexchangers effectively self-cleaning.

Alfa Laval spiral heat exchangersFrom dirty fluids to high-vacuum condensation

Alfa Laval spiral heat exchangeradvantages� Self-cleaning effect ensurescontinuous operation

� Easy access to heat transfersurface, resulting in lowmaintenance cost

� Compact design results in lowinstallation cost.

Reduced maintenance slices payback timeA significant feature of spiral heat exchangers is their ability to handle mediathat contain suspended solids, without getting clogged up. TOTAL RaffinerieMitteldeutschland GmbH in Germany took advantage of this feature when thecompany installed Alfa Laval spiral heat exchangers in its fluid catalytic cracking(FCC) unit, thus drastically reducing both downtime and maintenance costs.

The savings in service costs during the first year of operation alone amountedto the capital cost for the spiral exchangers, representing excellent payback time.

Mechanical dataDesign pressure

Full vacuum to 30 bargunbalanced pressure,50 barg balanced pressure

Design temperature-100°C (-150°F) to 400°C (750°F)


With ten manufacturing centres forall-welded heat exchangers locatedthroughout the world, and backedby forty specialist service centres,Alfa Laval is a global provider of all-welded plate-type heat exchangersolutions – with expertise alwayson the spot when needed.

Global certificationAlfa Laval all-welded plate-type heatexchangers meet the requirementsof the European Pressure EquipmentDirective (PED) and are manufacturedin accordance with pressure vesselcodes that include AD2000,ASME VIII (including U-stamp),PD5500 and AS1210.

Production facilities are certified inaccordance with the ISO 9001 qualityassurance standard and the ISO14001 environmental managementstandard, and have also been awardedRussian GOST approval.

Reliability countsIn refinery operations, downtime isalmost always extremely expensive.Compared with traditional equipment,Alfa Laval all-welded solutions requirevastly less service and maintenance.And when any maintenance is actuallydone, it is a significantly quickeroperation than with conventional heatexchangers.

The basic design of Alfa Laval all-welded heat exchangers completelydoes away with gaskets, eliminatingall the time and labour-consumingproblems associated with gasketmonitoring, maintenance andreplacement.

Determined to reduce downtime?Global supplier of low-maintenance solutions


All-welded – and therefore gasket-free– designs also mean that Alfa Lavalheat exchanger solutions operatemuch more reliably with aggressivemedia and at higher temperaturesand pressures.

Easier to cleanThese heat exchanger designs areeasily accessible for any service andmaintenance that may be required.There is no need for all the spacerequired for extracting and cleaningthe tube bundle in comparable shell-and-tube units.

Both service time and manpowerrequirements are also minimal. Theentire heat transfer area is easy toclean using standard CIP procedures,high-pressure cleaning equipmentor decoking by patented controlledcombustion. Due to the corrosion-resistant materials, a wide selectionof cleaning chemicals can be used.

Safety boostOne single compact Alfa Laval all-welded plate-type heat exchanger canoften be used to replace several muchlarger shell-and-tube units, reducingthe amount of piping and the numberof valves and flanges required.

In addition to resulting in lessmaintenance, this greatly reducesthe risk of leaks of combustible vapouror other undesirable emissions as wellas the risk of fire or explosion that canresult from these. This represents amajor step forward in plant safetyand in the reduction of environmentalimpacts.

Alfa Laval automatic strainerInstalling an Alfa Laval back-washing strainer on the cooling water circuit protectsagainst debris entering into heat exchangers. This strainer unit is available in sizesthat can deal with up to 5000 m3/hr of water, with hole or wire-rod mesh availablefrom 0.5 to 2.5 mm. The strainers can be used for all types of cooling water,including cooling tower water, and water from the sea, lakes and rivers.

The automatic back-washing function is controlled either pneumatically orelectrically, to explosion-proof standard. The back-washing sequence takes placewithout interrupting the process operation. The strainer is installed as an integralpart of the pipework and only takes up a minimum of space.

Downtime drastically reducedA Compabloc heat exchanger replaced a shell-and-tube unit that wasexperiencing heavy fouling problems in the sour water treatment plant at Eni’sGela refinery in Italy, where part of the sour water derives from the coker.

With the Compabloc, the cleaning frequency was reduced to less than 10% ofthe previous requirement. In addition, the downtime caused by cleaning is nowonly half a day compared with two whole days for the shell-and-tube heatexchanger.

Alfa Laval in briefAlfa Laval is a leading global provider ofspecialized products and engineeredsolutions.

Our equipment, systems and servicesare dedicated to helping customers tooptimize the performance of theirprocesses. Time and time again.

We help our customers to heat, cool,separate and transport products suchas oil, water, chemicals, beverages,foodstuffs, starch and pharmaceuticals.Our worldwide organization worksclosely with customers in almost 100countries to help them stay ahead.

How to contact Alfa LavalUp-to-date Alfa Laval contact details forall countries are always available on ourwebsite atwww.alfalaval.com

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258988 alfa Refinery PPI00091EN...AlfaLavalrefinerysolutions5 Lowermaintenancecosts Becauseoftheirmuchgreater reliability,AlfaLavalall-welded plate-typeheatexchangersrequire lessserviceandmaintenance,witha