Page 1 © Copyright Cal Gavin Enhancing performance of tubular heat exchangers using hiTRAN Systems INTHEAT Friday 8 th July 2011

Page 2 © Copyright Cal Gavin Providing solutions to: Increase plant capacity Reduce energy costs Increased equipment performance Reduce production costs Provide operational flexibility Increase plant profit !

Page 3 © Copyright Cal Gavin Identify equipment and control system limitationsReview technology options to overcome limitationsIncorporate selected retrofit technologiesSimulate performance of new production plan Implement low cost retrofit solutions

Page 4 © Copyright Cal Gavin hiTRAN tube-side heat transfer enhancement system – increases heat transfer up to 8 times reducing fouling by increasing fluid sheer Direction of Flow

Page 5 © Copyright Cal Gavin How hiTRAN Wire Matrix Elements work hiTRAN Matrix Elements remove the boundary layer and mix it with the bulk flow. Fluid from the centre is displaced in the direction of the wall Residence time of the fluid at the wall is considerably reduced. Improved heat and mass transfer and reduced fouling Red dye: A) Laminar flow B) turbulent flow Blue dye: hiTRAN Matrix Element

Page 6 © Copyright Cal Gavin hiTRAN video – how hiTRAN works

Page 7 © Copyright Cal Gavin Case study LUKOIL Refinery, Volgograd Feed Effluent Exchanger Problem Plant capacity limited by low heat exchanger performance (mal-distribution) Recovered heat was 19 MW but …… 23.1 MW needed to meet target temperature Fired Heater performance much too low! 4.1 MW not available from Fired Heater High on-going energy cost if upgraded Plant expansion now requires 28MW

Page 8 © Copyright Cal Gavin Case study Lukoil - refinery Volgograd Optimised Engineering Solution Study identified hiTRAN System would solve the problem Reduce maldistribution on tubeside - balance flow Increase tubeside heat transfer hiTRAN System retrofitted in just 2 weeks

Page 9 © Copyright Cal Gavin Case study Benefits to Lukoil hiTRAN System increased performance from 27.8MW to 32.4MW 4.6 MW energy load saving without requiring new fired heater Fuel saving of over US$500K per year (at full flow rate) Enables higher plant throughput Increased plant profit!

Page 10 © Copyright Cal Gavin Benefits: Smaller units Less bays Increased efficiency Reduced capital costs Case study Rosneft - Novokuibyshevsk New Air Coolers with hiTRAN System enhancement

Page 11 © Copyright Cal Gavin Design Comparisons Empty tube design design No. of bays/bundles5/101/2 No of passes122 Flow length m10818 Tubeside htc W/m 2O C44307 Overall htc (bare) W/m 2O C35180 Total Surface Area m 2 18,1003,600 Plot space m Weight tonnes8416 Total Fan Power kW16533 Pressure Loss, Bar0.71 Annual cost of electrical fan power US$ 105,00021,000 Case study Rosneft - Novokuibyshevsk

Page 12 © Copyright Cal Gavin Cal Gavin’s Deliverables Work Package 2: “Combined tube-side and shell-side heat exchanger enhancement” D2.1: Report on state of the art of heat transfer enhancement technologies and their benefits. (May 2011) D2.2: Report on tube side and shell side enhancement research (August 2011) D2.3: Mathematical models and the software implementation of tube- and shell side heat transfer enhancement ( May 2012)

Page 13 © Copyright Cal Gavin State-of-art of heat transfer enhancement technologies and their benefits D2.1, 6 month Heat Transfer Promoters - Twisted Tapes, Static mixers, Helically-coiled wires, Core Tubes and hiTRAN turbulators Comparisons - Between hiTRAN, Twisted tapes and coiled wires The Influence of the boundary layer and overcoming the limitations in the heat transfer.

Page 14 © Copyright Cal Gavin Report on tube side and shell side enhancement research D2.2, 9 month Other deliverables Cal Gavin is involved in WP1 ‘Analysis of intensified heat transfer under fouling’ ( 4 person months) WP4 ‘Design, retrofit and control of intensified heat recovery networks’ (3 person months) WP5 ‘Putting into practice’ (2 person months) WP6 ‘Technology transfer’ (2 person months)

Page 15 © Copyright Cal Gavin Thank-you for listening Questions?