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Alfa Laval

Alfa Laval. Group Presentation 2006. Presented by Bernard FONTAINE. Markets 市场. Energy & Utilities 能源及工业设施. Oil & Gas, Power, Water, Environment, … 石油天然气，电力，水处理，环境 …. Process Industry 流程工业. Refinery, Chemical, Petrochemicals, Life Science, Starch, Natural Resources, ..

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Alfa Laval

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  1. Alfa Laval Group Presentation 2006 Presented by Bernard FONTAINE

  2. Markets 市场 Energy & Utilities能源及工业设施 Oil & Gas, Power, Water, Environment, … 石油天然气，电力，水处理，环境…. Process Industry流程工业 Refinery, Chemical, Petrochemicals, Life Science, Starch, Natural Resources, .. 炼油， 化工，石化，生命科学，淀粉，自然资源….. Food & Food related食品及相关工业 Brewery & Beverages, Vegetable oil, Proteins, Concentrates, 啤酒及饮料，植物油， 蛋白质，浓缩物... Hydrocarbon China Beijing 25-26 April 2006

  3. Key technologies关键技术 Separators & Decanters分离器及沉降式离心机 Heat Exchangers换热器 Flow Equipment & Membranes流体设备及膜 Other Equipment其他设备 Hydrocarbon China Beijing 25-26 April 2006

  4. Alfa Laval Heat Exchangers换热器

  5. Heat Exchangers换热器 • Plate Heat Exchanger板式换热器 • Spiral Heat Exchanger螺旋板式换热器 • Welded Heat Exchanger – Compabloc焊接板式换热器 • Welded Heat Exchanger – AlfaRex焊接型板式换热器 • Welded Heat Exchanger – Packinox大型焊接板式换热器 • Plate Evaporator板式蒸发器 • Plate Condenser板式冷凝器 • Miscellaneous HE’s其他板式换热器 Hydrocarbon China Beijing 25-26 April 2006

  6. General refinery overview Gas plant Light ends Sulphur LPG Isomerization Light naphtha Gasoline Cat. reforming Aromatics Desalting Gasoline treatment Naphtha hydrotreating Crude oil Naphtha Gasoline Lt distillate hydrotreating Light distillate Atmospheric distillation Kerosine and jet fuel Diesel treatment Heavy distillate hydrotreating Heavy distillate Diesel and heating oil Atmospheric gas oil FCC Alkylation Gas oil hydrotreating Atmospheric residue Hydrogen generation Hydrocracking LVGO Lube treating Gas oil HVGO Vacuum distillation Lube oils Coke Coking Vacuum residue Heavy fuel oil Visbreaking Hydrocarbon China Beijing 25-26 April 2006

  7. Alfa Laval Packinox Introduction 法国阿法拉伐帕奇诺公司 简介

  8. Alfa Laval PackinoxOrders in M€销售业绩 （单位：百万欧元） Hydrocarbon China Beijing 25-26 April 2006

  9. Heat Exchangers Catalytic Reforming 催化重整 Stripper 汽提塔 Hydrotreater 加氢 Hydrocarbon China Beijing 25-26 April 2006

  10. Alfa Laval Packinox Emissions 法国阿法拉伐帕奇诺板换在排放方面的收益

  11. Heater stack emissions NOx加热炉烟囱排放：NOx • Thermal NOX热产生的NOx • Primarily function of flamme temperature 主要源于燃烧温度的作用 • Estimate : 3 tons per year (tpa) / process MW 估算的排放量： 工艺流程中每MW每年可产生3吨 • Fuel NOX燃料产生的NOx • Depends on Nitrogen in fuel (N% wt.) 取决于燃料中氮的量（N重量百分比） • Emission = 36*N tpa / process MW 排放量= 工艺流程中每MW每年可产生36x氮的重量百分比 • Estimate : N = 0,25%9 tpa / MW 估计：氮的重量百分比N = 0.25%, 则排放量为：每MW每年9吨 • Total NOX = Thermal + Fuel NOX总的NOx排放量=热产生的NOx+燃料产生的NOx • Estimate = 12 tpa / MW 估计： 总的NOx排放量=12吨每年每MW • Valuation = 1000 USD / ton $12,000 / MW / year 估价= 1000 美元/每吨相当于每年每MW 1万2千美元。 Hydrocarbon China Beijing 25-26 April 2006

  12. Heater stack emissions SOx加热炉烟囱排放：SOx • SOX • Function of Sulfur in Heater fuel (S% wt) 加热炉燃料中硫的作用（S重量百分比） • Typically much higher S in fuel oil than in fuel gas 特别是燃料油中的硫要远高于燃料气中的硫 • Emission = 27*S tons per year (tpa) / process MW 排放量 = 27xS(重量百分比)吨/ 每MW每年 • Estimate : S = 0.6% 16 tpa / MW 估计： S = 0.6%, 即排放量= 27x 0.6 =16 吨每MW每年 • Valuation = 1000 USD ton $16,000 / MW / year 估价 = 1000 美元/吨， 即 1万6千美元/每MW每年 Hydrocarbon China Beijing 25-26 April 2006

  13. Heater stack emissions GHG加热炉烟囱排放： 温室气体 • Greenhouse Gas (GHG)温室气体 • Carbon in fuel transformed into CO2 during combustion 燃料中的碳在燃烧过程中转化成CO2 • Average carbon content in fuel : 71% wt. 燃料中平均碳含量：71% 重量百分比 • GHG emission = 2500 tons per year (tpa) / process MW 温室气体排放量 = 2500 吨/每年，每MW • Valuation = 20 USD / ton $50,000 / MW / year 估价 = 20 美元/每吨， 即， 温室气体排放量=5万美元/每年， 每MW • Kyoto Accord京都议定书 • In effect as of 16 February 2005, 于2005年2月16日生效 • Europe : Shortfall fine set at 40 Euros / ton (>50 USD / ton) 在欧洲， 不足的罚金为每顿40欧圆 （>50美元/每吨） Hydrocarbon China Beijing 25-26 April 2006

  14. Heater stack emissions加热炉烟囱排放 SUMMARY: Value of 1 MW Duty Gain at the CFE 通过板式换热器每MW热负荷可获得的收益总结如下： Primary Assumptions基本假设: Primary Assumptions: Rule Of 50 USD per BOE 油价50美元/桶 0.6% S in Fuel硫在燃料中的重量百分比 - - - - 65% Heater 加热炉的工艺效率65% Heater not equipped with SOX or NOX - - - - Thumb 粗略估值 abatement devices (Scrubbers, SCR, 0.25% N : 氮在燃料中的重量百分比 - - etc.)加热炉没有消除SOX 和NOX 装置 Fuel Cost Savings at $380,000 100% 100% Heater加热炉燃油节省 NOX + SOX Emissions $28,000 $28,000 +10% +10% Savings减少NOX和SOX 排放节省 GHG Emissions $50,000 $50,000 +15% +15% Savings减少温室气体排放节省 Hydrocarbon China Beijing 25-26 April 2006

  15. Alfa Laval Packinox法国阿法拉伐帕奇诺板式换热器 • Hydro Desulfurization • 在加氢脱硫装置中的应用 • Cleaning by Controlled Combustion • 控制燃烧清洗法 Hydrocarbon China Beijing 25-26 April 2006

  16. Alfa Laval PackinoxHydro Desulfurization加氢脱硫装置 Stripper 汽提塔换热器 Combined Feed Effluent 混合供料 换热器 Hydrocarbon China Beijing 25-26 April 2006

  17. Alfa Laval PackinoxHydro Desulfurization加氢脱硫装置的应用 Plate Bundle板束 Stainless steel 304, 321 or 316, 不锈钢 304，321 或316 Thickness 0.8 to 1.5 mm， 壁厚 0.8 到 1.5mm Bellows 膨胀节 Cold side冷端: Inconel 625, Hot Side热端: Incoloy 800 or 825 Pressure vessel压力容器 Cr-Mo steels 1.25 Cr-0.5 Mo, 2.25 Cr-1 Mo, Cladded Stainless steel, Carbon steel ， 铬钼钢，复合不锈钢，碳钢 Hydrocarbon China Beijing 25-26 April 2006

  18. Alfa Laval PackinoxHydro Desulfurization加氢脱硫装置 Combined Feed Effluent Heat Exchanger混合供料换热器 - One shell, vertical立式单台设备 - Pressure plates on bundle板束外有压力板 - 5 bar diff. pressure reversal预留5bar压差 - Two manholes on shell壳体上有两个人口 Hydrocarbon China Beijing 25-26 April 2006

  19. Alfa Laval PackinoxHydro Desulfurization加氢脱硫装置 Stripper Liquid Liquid Heat Exchanger汽提塔液相－液相换热器 One bundle, vertical单台立式板束 Pressure plates on bundle板束上有压力板 x bar diff. pressure reversal预留”x“ bar压差 Hydrocarbon China Beijing 25-26 April 2006

  20. Alfa Laval PackinoxHydro Desulfurization加氢脱硫装置 FLOW DIAGRAM 流程图 Hydrocarbon China Beijing 25-26 April 2006

  21. Alfa Laval Packinox实例Diesel Hydrodesulfuration – Formosa Petrochemical台湾某石化公司柴油加氢脱硫装置 AXENS license法国AXENS 工艺包 Two parallel units of 65,000 bpd each两套65000桶/天并联装置 Heat / material balance optimized with Packinox由PACKINOX板换对加热炉及配套工艺设备进行优化 Optimization with a Packinox on Stripper bottoms另由一台PACKINOX对汽提塔底部装置进行优化 Capital cost reduction投资成本减少$ 5.0 million 5百万美元 Energy savings per unit每套装置能耗节约$ 3.3 million/y 330万美元（再乘2.5倍＝2006价格) GHG emission valorisation$ 温室气体排放成本节约$ 1.2 million/y 120万美元 （再乘2.5倍＝2006价格 On line since 4Q20002000年第四季度投入生产 Now under revamp for ULSD现为生产超低硫柴油再改造中 Hydrocarbon China Beijing 25-26 April 2006

  22. Alfa Laval PackinoxDiesel Hydrodesulfurization, Formosa Petrochemical原计划配备管壳式换热器时的工艺流程图 Hydrocarbon China Beijing 25-26 April 2006

  23. Alfa Laval PackinoxDiesel Hydrodesulfurization, Formosa Petrochemical采用PACKINOX优化后的工艺流程图 Hydrocarbon China Beijing 25-26 April 2006

  24. Alfa Laval Packinox台湾实例Diesel Hydrodesulfuration – Formosa Petrochemical Low Temperature Separator低温分离器 Eliminated减少75% 加热炉负荷of Heater Duty 40% 压缩机马力of Compressor HP 40% 冷却器负荷of cooler duty Utility consumption Shell & tubes Packinox Unit 设备消耗管壳式 帕奇诺 单位 Fire heater加热炉194 cents (US)/bd Recycle compressor 循环氢压缩机6 4 cents (US)/bd Total 总计25 8 cents (US)/bd Basis year 2000基于2000年的价格 1 BTU = 1 kJ 1 MM BTU = $ 4 1kWh = $ 0.045 345 stream days / year 65 000 bpd or 3 Million t/y 每年345个开工日， 年处理量300万顿 CAPEX Savings投资成本节省=500万美元Million USD OPEX Savings/y 操作成本节省/年= 3 80万美元Million USD/y GHG Reduction/y温室气体减少/年=5万顿CO2/年tons CO2/y Hydrocarbon China Beijing 25-26 April 2006

  25. Alfa Laval PackinoxDiesel Hydrodesulfuration – Formosa Petrochemical台湾某石化公司柴油加氢脱硫装置 Capacity 3 Million t/y, 300万顿的年处理量 Savings according 2006 energy cost 根据2006年能源成本，实际节约： CAPEX Savings投资成本节约 =600万美元MillionUSD OPEX Savings/y操作成本年节约 = 950万美元Million USD/y GHG reduction/y温室气体年减少 = 5万顿CO2 50 000 tons CO2/y SOX reduction/y年减少SOX = 320 顿tons SOX/y NOX reduction/y年减少NOX =240 顿tons NOX/y Emission savings排放量年节约 =150万美元Million USD/y Hydrocarbon China Beijing 25-26 April 2006

  26. Alfa Laval PackinoxPyrolysis Gasoline HDS – MITSUI板换在汽油裂解加氢脱硫装置的应用 --- 三井技术 Feed from an Ethylene Cracker原料来自乙烯裂解 One diolefine pre-Reactor一台双稀烃预反应器 1 Packinox replaces 3 x Shell & Tubes一台Packinox板换替换3台管壳式 Unit runs without using external energy (heater duty lowered from 8.3 MW to 0 MW) 装置运行时不再使用额外热能 (加热炉负荷由原来的8.3MW将为0) No capacity reduction during emissions restriction period 即使在排放量受限制的季节, 装置处理量也无需减小. On line since 1995 改造后1995投入使用 Energy savings 1 Million USD/y (2005 energy cost) 参照2005年的价格, 每年能源节约100万美元 Emission valorisation150,000 USD/y (2005 energy cost), 参照2005年价格,每年排放量减少带来的收益为15万美元/年 Hydrocarbon China Beijing 25-26 April 2006

  27. Alfa Laval PackinoxPyrolysis Gasoline HDS – MITSUI板换在汽油裂解加氢脱硫装置的应用 -- 三井技术 (管壳式) Hydrocarbon China Beijing 25-26 April 2006

  28. Alfa Laval PackinoxPyrolysis Gasoline HDS – MITSUI板换在汽油裂解加氢脱硫装置的应用 -- 三井技术 (板式) Hydrocarbon China Beijing 25-26 April 2006

  29. Alfa Laval PackinoxPETROBRAS (Repar) distillate HDS板换在馏分加氢脱硫装置的应用 Cenpes / Petrobras Technology New 32,000 bpd Gasoil HDS unit新装置处理量32000桶/天瓦斯油 90 Bar / 1300 psi压力90巴 Heat / material balance optimized with Packinox 由PACKINOX板换对加热炉及配套工艺设备进行优化 PFD very similar to that of Formosa与台湾实例中的PFD相似 16°C / 29°F Hot End Approach热端温差 16°C / 29°F Significant CAPEX and OPEX reduction非常显著的投资和操作成本减少 On line since early 2004二零零四年初投入使用 Hydrocarbon China Beijing 25-26 April 2006

  30. Alfa Laval Packinox Distillate HDS – OMV板换在馏分加氢脱硫装置的应用– OMV 技术 5 ppm Sulphur Diesel为了生产5ppm的低硫柴油 Capacity: 45,000 BPD 处理量为45000捅/天 Design Press: 80 bar设计压力:80巴 Single Shell Design Start Up: 4Q 2003单台板换, 2003年底投产 44 MW热负荷 44MW Preheat Duty Modulated with Partial Liquid Feed By-pass to Maintain HHPS Temperature 通过将部分进料旁路以维持热高压分离器的温度, 来调节原料预加热负荷 Small, Variable Duty at “Make-Up” Charge Heater “补充”加热炉的负荷很小且是可变的. Hydrocarbon China Beijing 25-26 April 2006

  31. Alfa Laval PackinoxDistillate HDSOMV板换在馏分加氢脱硫装置的应用– OMV 技术 Hydrocarbon China Beijing 25-26 April 2006

  32. Alfa Laval PackinoxHydrotreatment – Installation Recommendations (1)板换在加氢脱硫装置中应用的建议 (1) Equipment装备 Filters on liquid feed : 25 micron,原料进料前装25微米过滤器 Chloride guard bed on hydrogen supply,补充氢气前加氯离子保护床 Screen on Reactor effluent line (500 microns to 1 mm), 反应热物料管线加装50微米至1毫米的筛网 Stainless steel lines between: feed filter and Packinox inlet, reactor outlet and Packinox inlet, 板换的入口, 无论是原料油入口还是反应热物料入口, 均应采用不锈钢管 Hydrocarbon China Beijing 25-26 April 2006

  33. Alfa Laval PackinoxHydrotreatment – Installation Recommendations (2) 板换在加氢脱硫装置中 应用的建议 (2) Hydrocarbon China Beijing 25-26 April 2006

  34. Alfa Laval PackinoxHydrotreatment – Installation Recommendations (3)板换在加氢脱硫装置中应用的建议 (3) Liquid Feed Contamination原料油污染物 Limitation for Naphtha Free water < 150 ppm 石脑油中游离水的量控制在< 150 ppm Good retension time inside surge drum, Deep boot on surge drum, Drain boot frequently (twice every shift),在集水器中要保持足够的时间, 集水器要足够深, 要定期排水(每班要排两次) Limitation for Naphtha Chlorine < 5 ppm 石脑油中氯离子的量控制在< 5 ppm Iron particules铁金属颗粒 (来自上游的腐蚀, 可以采用磁性过滤芯) (corrosion from upstream, possibility of magnetic filter core) Oxygen Max 1 ppm(oxygen is a strong coke promoter), 氧气的含量最大为1PPM (氧气是较强的助长结焦因素) Straigth run feedas much as possible尽可能采用直馏油) Feed tanks Nitrogen blanket(Floating roof not acceptable)油儲罐采用氮气保护层(不接受浮顶罐) Hydrocarbon China Beijing 25-26 April 2006

  35. Alfa Laval PackinoxHydrotreatment – Chlorine impacts板换在加氢脱硫装置中 – 氯离子的影响 No ammonium salt deposit in Alfa Laval Packinox heat exchanger in two-phase service 在两相物流的Packinox板换中不会出现氨盐结晶 corrugated plate geometry eliminates low turbulence and low velocity areas (static mixer effect) 波纹板的几何形状消除了低湍流和低流速区(源于静态混和效应) design prevents low liquid local velocity设计本身防止了局部低流速 liquid gas oil wets and washes all the plates (no dry points) 液体原料油湿润并清洗所有的换热板(无干点) Hydrocarbon China Beijing 25-26 April 2006

  36. Alfa Laval PackinoxCleaning by Controlled CombustionPackinox 板换的控制燃烧清洗法 ALFA LAVAL PACKINOX HEAT EXCHANGERS CLEANING BY CONTROLLED COMBUSTION (DECOKING)通过控制燃烧法来清洗Packinox 板换(除焦) Issued by Gilles Cazin Revised by Bernard Fontaine PACKINOX WON THE 2004 TECHNOLOGY INNOVATION AWARD FOR THIS DEVELOPMENT Hydrocarbon China Beijing 25-26 April 2006

  37. Alfa Laval PackinoxCleaning by Controlled CombustionPackinox 板换的控制燃烧清洗法 Usual Cleaning Methods通常的清洗法 Chemical Wash化学清洗 Cold Oxidation氧化清洗 Vacuum / Rupture Disk (back blowing) 真空吸附或反吹法 Hydrocarbon China Beijing 25-26 April 2006

  38. Alfa Laval PackinoxCleaning by Controlled CombustionPackinox 板换的控制燃烧清洗法 Cleaning Hardened Gums清洗硬质的结焦 Chemical Cleaning had Only Produced Partial Recovery化学清洗只能产生局部的恢复 Hydro-blasting is not an Option for welded plate heat exchangers水冲洗对焊接板式换热器不是好的选择 Hydrocarbon China Beijing 25-26 April 2006

  39. Alfa Laval PackinoxCleaning by Controlled CombustionPackinox 板换的控制燃烧清洗法 Cleaning Hardened Gums清洗硬质结焦 SOLUTION 解决方法 Carbon burn by steam-air decoking 通过蒸汽-空气燃烧碳除焦 (similar to that is used to burn carbon deposits in fired heater tubes).近似于燃烧加热炉炉管中的积碳 CHALLENGE面临的挑战 Not to damage the Heat Exchanger in the process 操作中不能损坏换热器 PILOT TESTING实验 Jointly with IFP Axens at Solaize (France)与法国IFP AXEN联合实验 Over one year period approximately.几乎用了一年的时间 Hydrocarbon China Beijing 25-26 April 2006

  40. Alfa Laval PackinoxCleaning by Controlled CombustionPackinox 板换的控制燃烧清洗法 Cleaning Hardened Gums清洗硬质结焦 Pilot Plant : Coke Deposits from FCC Naphtha 实验: 来自于FCC 石脑油的结焦 Pilot result: 100% coke removal, no damage to material 实验结果: 结焦100%清除, 对材料没有损害. Hydrocarbon China Beijing 25-26 April 2006

  41. Alfa Laval PackinoxCleaning by Controlled CombustionPackinox 板换的控制燃烧清洗法 Steam to Sewer Decoking In-Situe CO2/O2 Analyzer N2 150# Steam Heat Exch. Plant Air Preheating to 300°F with N2 ( by Recircul. In this Case) Heater Hydrocarbon China Beijing 25-26 April 2006

  42. Alfa Laval PackinoxCleaning by Controlled CombustionPackinox 板换的控制燃烧清洗法 Commercial Scale Validation # 1 (2002) 工业应用:案例1 Heating with electric pads 采用电加热 Hydrocarbon China Beijing 25-26 April 2006

  43. Alfa Laval PackinoxCleaning by Controlled CombustionPackinox板换的控制燃烧清洗法 Commercial Scale Validation # 2 (2003) 工业应用:案例2 Heating with portable heater 用移动式加热炉 Hydrocarbon China Beijing 25-26 April 2006

  44. CLEANED 除焦后 Alfa Laval PackinoxCleaning by Controlled CombustionPackinox板换的控制燃烧清洗法 Commercial Scale Validation # 2 (2003)案例2 COKED 结焦时 Hydrocarbon China Beijing 25-26 April 2006

  45. 碳燃烧速率Burnt carbon rate (LB/HR) 最大累积燃烧碳量Cumulated Burnt Carbon, MAX 最小累积燃烧碳量Cumulated Burnt Carbon, MIN Alfa Laval PackinoxCleaning by Controlled CombustionPackinox 板换的控制燃烧清洗法 Commercial Scale Validation # 2 (2003)案例2 70.0 1800 1600 60.0 1400 50.0 1200 40.0 1000 lbs/hr lbs TOTAL 800 30.0 600 20.0 400 10.0 200 0.0 0 16/4/03 0:00 18/4/03 0:00 20/4/03 0:00 17/4/03 0:00 19/4/03 0:00 16/4/03 12:00 17/4/03 12:00 18/4/03 12:00 19/4/03 12:00 Hydrocarbon China Beijing 25-26 April 2006

  46. Alfa Laval PackinoxCleaning by Controlled CombustionPackinox 板换的控制燃烧清洗法 Conclusion结论 Proven Methods to Clean经过验证的清洗方法 Foreseeable fouling forms in Catalytic Reforming, HDT, HDS, 可应用于催化重整, 加氢, 加氢脱硫装置中可预见性的结垢 In situe procedure,现场处理 Quick to Implement, 快速实施 At reasonable costs,费用合理 Hydrocarbon China Beijing 25-26 April 2006

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