PTQ Q4 2025 Issue

and thermally demanding duties, and, most importantly, minimising the environmental impact. A 41% increase in heat removal capacity with the new technology exempli- fies the cooling system’s enhanced thermal perfor- mance, allowing for more efficient energy recovery and increasing plant production

Internal rate of return (IRR) 14.8% @ 7-year period

Net present value 1.0 M€

Simple payback 2.3 years

Savings-to-investment ratio (SIR) 2.0 M€

Present value (PV 2023) 1.9 M€

Savings per year 0.4 M€

Figure 6 Key financial metrics for the upgradation project

capacity requirements. This enhancement directly trans- lates to less reliance on auxiliary cooling equipment, result- ing in lower overall energy consumption and emissions. Such improved performance not only increases process efficiency but also contributes to larger sustainability and decarbonisation goals. These bespoke advantages lower the Scope 1 and 2 emissions by minimising the direct or indirect means of energy utilisation and improving the performance of the refinery utility systems. The upgradation project serves as a proven model for combining environmental responsibility with innovative new engineering. Lessons learned and strategic takeaways The performance of heat exchangers in utility systems is not only determined by the selection of a suitable material, but also by the finer details of the heat exchanger design. This includes factors such as flow distribution with optimised chevron angles (ß), port geometry, and, most importantly, precision in thermal design. Even the exotic corrosion- resistant alloys (CRA) fall short on the deliverables unless carefully engineered to maximise the flow dynamics and minimise the fouling concerns. The longevity and thermal efficiency of the exchanger are achieved by a combination of appropriate materials and smart design improvements. Any static equipment employed beyond 25-30 years should be provided with additional care and frequent maintenance. As infrastructure ages, the best investments are in upgrading to innovative solutions designed specifically to meet the new thermal demands and address inefficiencies. These renovations, when accompanied by accurate RCA of the thermal effi - ciency decline, can result in significant returns and long- term operational savings. Most importantly, this collaboration offers access to tai - lored solutions through process optimisation, on-site ser- vices, performance and thermal audits, and long-term value through lifecycle optimisation, bringing facilities one step closer to their sustainability and net-zero goals. Conclusion: leading the sustainability revolution In line with the Paris Agreement, industries globally are trying to accelerate their decarbonisation efforts and cope with more strict regulatory frameworks. It is essential to reconsider how thermal systems are designed and main- tained. These challenges can be addressed through stra - tegic collaborations, technological smart innovations, and

Reduction in seawater consumption/k W h 16%

Additional heat removal 41%

Titanium savings Over 9 tonnes

Figure 7 Depiction of sustainability metrics of the project

performance and condition monitoring via remote support. This will pave a way for more energy-efficient solutions and a better environment for future generations to come. For operations dependent on seawater cooling, second- ary loops, or key process equipment, performance setbacks and unplanned downtime can disrupt efficiency and esca - late costs. Implementing trusted and high-performance heat exchangers designed to meet the specific demands of each plant can be a decisive step toward improved reli - ability, reduced maintenance, and long-term operational resilience. CurveFlow, OmegaPort, and FlexFlow are trademarks of Alfa Laval. Viswanth Ramba is Product and Application Manager for the Process Industries at Alfa Laval, Energy Efficiency Hub (EEH), Middle East and Africa. His specialisation spans thermal engineering, drilling mechan - ics, optimisation, anomaly detection, and machine learning. His work has been published in several renowned international journals, confer - ences and patents and has received numerous citations for its impact in the field. He holds a PhD in mechanical engineering from the IIT Guwahati, India, and a Master’s in advanced heat transfer from Andhra University, India. Sebastian Fogel leads Alfa Laval’s global GPHE business in petro - chemical applications, offering expert solutions to customers. He promotes energy efficiency, conducts training, and provides technical support to sales teams, driving operational improvements and sus- tainability through innovative heat exchanger technologies. He holds a PhD from DTU, Technical University of Denmark, and an MSc in chem - ical engineering from LTH, Faculty of Engineering, Lund University. Rahul Patil is Business Head of Gasketed and Welded Plate Heat Exchangers for Process Industries at Alfa Laval, Middle East and South Africa. With more than 27 years of experience in sales and leadership, he leads the Capital Equipment business within the Energy Division, focusing on strengthening Alfa Laval’s network by managing existing partnerships and developing new ones to expand market reach. He holds a degree in chemical engineering and an MBA.

PTQ Q4 2025