PTQ Q4 2025 Issue

is allocated to repairing the corroded and damaged plates due to micro-welding and pitting, and the remaining is directed toward increasing the number of heat transfer plates to meet the process demand. The total cost of installing the heat exchangers, according to the project scope, is shown in Figure 5 . Most of the over- all Capex is spent on new bare equipment, with 34% going toward the additional foundation and piping modifications required to replace the aged installations. Additionally, the annual cleaning schedule is substantially minimised due to the advanced design features of the heat exchangers. Figure 6 depicts a comprehensive key performance matrix that helps to precisely define the value delivered to the cus - tomer. The completed project is an excellent example of sus- tainable energy efficiency in action, setting a standard for future implementations. The investment has demonstrated both economic and environmental sustainability, with a net present value (NPV) of €1.0 million, a simple payback period of 2.3 years, and annual savings of €0.4 million. The project not only exceeds the traditional industry investment bench- mark but also positions itself as a financially appealing path to decarbonisation and energy efficiency. Circular impact and environmental contribution The refiner’s move towards the upgradation of technology is a significant step towards achieving sustainability and net-zero goals. As highlighted in Figure 7 , the project deliv- ered tangible benefits in terms of both performance and environmental benefits. Given the fundamentally complicated and energy- intensive production procedure of titanium grade from ore extraction (in general, ilmenite) to fabricate the heat trans- fer plates (non-pressure retaining parts), any minor savings in terms of resource allocation have a positive impact on the environment. Titanium production necessitates stringent control set- tings to avoid contamination, making it one of the critical metals to demand too much energy during production. In this upgradation project, as of today, saving a total of more than 9.0 tonnes of titanium grade 1 (approximately 99.5%) represents a substantial achievement towards a greener planet, encouraging sustainable practices and making a mark towards a circular economy by lowering embedded carbon emissions. Contributing to both environmental and operational advantages, a 16% reduction in seawater consumption per kWh is an impressive outcome. In the Middle East, where water scarcity, high salinity, and rising seawater tempera- tures are just a few of the major issues, reducing seawater intake not only relieves strain on marine ecosystems that are already under severe stress due to human activity but also aligns with sustainability objectives. Furthermore, using less seawater minimises the energy utilised for pumping and decreases excess stress on filtration systems designed to screen suspended particulates. It also minimises excessive saline loads, debris, and seaweed car- ryover. By eliminating the reliance on significant utilisation of seawater, the new heat exchangers improve operational effi - ciency while lowering equipment wear exposed to corrosion

Installed costs 64%

Piping modication 34%

Additional plates to meet process demand 0.1%

Cost of re-gasketing 0.1%

Performance audit 0.1%

Cost of cleaning 1.8%

Figure 5 Capex for three new heat exchangers

• Footprint reduction : The installed area is 10-12% less than the existing installation. • Better performance: Higher thermal coefficients and less tendency to fouling. • Material savings : With the new features incorporated, more than 9.0 tonnes of titanium grade 1 were saved. • Lower Opex : Better performance and fewer cleaning cycles mean simpler maintenance. The upgradation project began in 2017, and over the course of eight years, 21 existing aged installations were replaced, with an average of three exchangers per year, one additional exchanger in the project execution phase, and another four exchangers this fiscal year. The information about uninstalled units is not included in the project metrics. Financial impact: Opex and Capex The yearly Opex for an average of three aged heat exchang- ers is displayed in Figure 4 , where most of the expenditure

PTQ Q4 2025