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entire networks, aiding in operational plan- ning and turnaround activities.
ules, extend equipment run times, and enhance operational efficiency. Figure 3 illustrates the predictive analytic capabili- ties of SmartPM, specifically how past and future performance metrics are tracked and used to inform decision-making. Proven Success of Digital Twin Modelling HTRI tools have been successfully applied across numerous real-world scenarios. Several case studies, available on https:// www.htri.net/software/smartpm/case- studies, highlight the tangible results: u Monitoring fouling and slagging in fired heaters: SmartPM identified critical links between furnace fuel types and oper- ational lifespan, enabling energy efficiency improvements. v Optimising cleaning and energy savings: Strategically implementing exchanger bypasses and optimising clean- ing schedules resulted in significant fuel savings and reduced CO₂ emissions. w Maximising productivity across refin- eries: Adopting SmartPM within digital
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Furnace
Driving the Future of Heat Transfer Innovation As industries embrace digital transfor- mation, tools like HTRI’s X changer Suite , HTRI connect , and SmartPM provide a solid foundation for achieving climate goals while enhancing operational effi- ciency. These innovations not only sup- port COP29 pledges but also establish a framework for sustainable practices in the process industry. Leveraging digital twin technologies makes a company’s jour- ney toward reducing emissions and opti- mising energy usage both attainable and profitable. HTRI remains committed to leading this transformation through rigorous research, advanced software, and practical solutions for the process industry. Together, these efforts position us to make meaningful con- tributions to global climate action, one heat exchanger at a time.
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EX4 A Resid-ashed crude
EX4B Resid-ashed crude
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Resid.
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EX3 (Heat exchanger) Filtered - average ( m onitoring/reconciliation data only +/– 2.5σ
0 0.006 0.004 0.002 0.008
Date
Fouling resistance (overall) - Reconciliation Fouling resistance (overall) - Tracking
Fouling resistance (overall) - Simulation Fouling resistance (overall) - Cleaning
Figure 3 Snapshot of performance monitoring and predictive maintenance capabilities of SmartPM
transformation programs allowed opera- tors to maximise energy recovery and vali- date in-house research.
x Forensic analysis of heat exchanger networks: SmartPM facilitated detailed analysis of individual exchangers and
Contact: simon.pugh@htri.net
Practical case study: Enhancing diesel hydrotreater capacity and reducing CO 2 emissions
SINDY STONE and THIERRY TISON Heurtey Petrochem solutions JAN RENETEAU NECTIS
Introduction In the pursuit of emission reductions and sustainable growth, the Axens Group, through its business lines Heurtey Petrochem Solutions and Nectis (a joint venture between ZPJE and Axens), offers a flow scheme with advanced technology equipment. For process unit heat integra- tion, traditional shell-and-tube exchang- ers are replaced by high-efficiency spiral tube heat exchangers (STHE) distributed by Nectis. This reduces heat consumption in fired heaters and decreases energy use in compressors and pumps thanks to its low-pressure drop. Additionally, in facilities with access to an electrical source, replac- ing process fired heaters with electric tubu- lar radiant heaters from Heurtey Petrochem Solutions enables zero carbon emissions at unit level. The diesel hydrotreater (DHT) revamp project is an excellent example of how this advanced technology scheme can be applied to achieve both operational and environmental improvements. The goal of the project was to increase the DHT unit’s capacity from 30,000 to 40,000 BPSD while reducing CO₂ emissions. The project faced several constraints, including a fired heater operating at maximum capacity, a hot approach temperature (HAT) of 81ºF (45ºC) in the heat exchangers, and limited space for new equipment. Despite these challenges, two solutions were identified and evaluated. Project Objective and Constraints The key objectives were increasing capac- ity and reducing CO₂ emissions. The main constraints included:
• Fired heater operating at maximum capacity: Limited thermal energy available for increased processing. • HAT of 81ºF (45ºC): Poor heat transfer efficiency. • Limited plot plan: Restricted space for new equipment. Given these constraints, two identified solutions were evaluated and are outlined below as Option 1 and Option 2. Option 1: Stripper reboiler and heat exchanger modification Option 1 proposed replacing seven tradi- tional shell-and-tube heat exchangers with three STHEs. These exchangers could recover all available heat, enabling the unit to operate without the fired heater dur- ing normal operations. The fired heater would only be needed for start-up and tran- sient operation, reducing CO₂ emissions DID YOU KNOW? replacing fired heaters with electric tubular radiant heaters from Heurtey Petrochem Solutions enables zero carbon emissions at unit level
Water Injection
Reactor 1
Hex A/B
Hex C/D
Hex E/F
Reactor 2
Feed
Heater
1 Fired Heater
Air cooler Water injection
Stripper
H
Makeup
7 Horizontal Shell & Tube Heat Exchangers
HP separator
Diesel
BP separator
Hex Reboiler
Existing flow scheme
STHE-1
STHE-3
Reactor 2
Feed
Heater
Reactor 1
1 Fired Heater
STHE-2
Stripper
Water injection Air cooler
3 Spiral Tube Heat Exchangers
Makeup H
Stripping steam
HP separator
BP separator
Diesel
Advanced technology equipment flow scheme: Option 1
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