Page 1© Copyright Cal Gavin 2011 www.calgavin.com
Enhancing performance of
tubular heat exchangers
using hiTRAN Systems
INTHEAT
Friday 8th July 2011
Page 2© Copyright Cal Gavin 2011 www.calgavin.com
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 2011 www.calgavin.com
Page 4© Copyright Cal Gavin 2011 www.calgavin.com
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 2011 www.calgavin.com
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 2011 www.calgavin.com
hiTRAN video – how hiTRAN works
Page 7© Copyright Cal Gavin 2011 www.calgavin.com
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 2011 www.calgavin.com
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 2011 www.calgavin.com
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$500K per year (at full flow rate)
• Enables higher plant throughput
• Increased plant profit!
Page 10© Copyright Cal Gavin 2011 www.calgavin.com
Benefits: • Smaller units • Less bays• Increased efficiency• Reduced capital costs
Case study Rosneft - Novokuibyshevsk
New Air Coolers with hiTRAN System enhancement
Page 11© Copyright Cal Gavin 2011 www.calgavin.com
Design Comparisons Empty tube design
design
No. of bays/bundles 5/10 1/2No of passes 12 2Flow length m 108 18
Tubeside htc W/m2OC 44 307Overall htc (bare) W/m2OC 35 180
Total Surface Area m2 18,100 3,600Plot space m2 123.3 24.1Weight tonnes 84 16
Total Fan Power kW 165 33Pressure Loss, Bar 0.71 0.71
Annual cost of electrical fan power US$
105,000 21,000
Case study Rosneft - Novokuibyshevsk
Page 12© Copyright Cal Gavin 2011 www.calgavin.com
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 2011 www.calgavin.com
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 2011 www.calgavin.com
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 2011 www.calgavin.com
Thank-you for listening
Questions?
www.calgavin.com
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