Heat Exchanger Simulation
Energy Optimisation | HX Monitor™

 

Fouling related issues cost a typical 100KBD refinery $1-2M per year compared to those with a HX Monitor exchanger management system. Fouled exchangers cost money due to increased energy use and lost production when furnaces become a constraint, and exchanger cleaning incurs direct costs of chemical or mechanical cleans as well as production downtime or slowdowns to carry out cleaning activity.

Monitoring heat exchanger performance and using that information to optimise the cleaning cycles poses several challenges:

  • Reconciliation of the plant data (mass and heat balance, and exchanger performance) is complex, and correcting for variations in crude type, production rate is essential to truly untangle fouling issues from the noise of other changes to the system
  • There are non-intuitive interactions between cleaning options, in a system with several fouled exchanger cleaning, a given exchanger will change the business case for cleaning the next.
  • Homemade spreadsheet tools for calculating fouling performance quickly become complex to use and difficult to maintain as key staff change roles.

 

HX Monitor provides a system for exchanger monitoring, which is a plug-in to the Petro-SIM platform. This provides a single environment for monitoring a preheat train along with the distillation column. This results in a single version of the truth being used for both monitoring systems, and allows the rigorous distillation column model to help with mass balance reconciliation and generation of accurate stream properties for the exchanger models. HX Monitor has an exceptionally robust built-in reconciliation algorithm, and automatic systems to calculate the impact of cleaning single or combinations of exchangers.

 

ProSteam™ & Energy Suite

Real time monitoring and optimisation of utility systems offers scope to reduce energy costs by up to 5% without incurring capital investment.

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SuperTarget™

Reduce energy costs by 10-30% and minimise the capital spend when designing or revamping heat exchanger systems, by using SuperTarget to perform Pinch-based analytics.

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GT-SIM™

Speed up gas turbine selection, and make design iterations faster when optimising a system with a gas turbine and a production process, to allow faster decision making.

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heat exchanger simulation
Energy Optimisation | SuperTarget™

Reduce energy costs by 10-30% and minimise the capital spend when designing or revamping heat exchanger systems, by using SuperTarget to perform Pinch-based analytics.

Despite the fact that Pinch Technology is well documented and has supposedly been applied since the early 1980s, energy benchmarking consistently shows significant energy improvement potential from heat integration. In addition more recent energy saving trends such as low grade heat recovery, inter-unit (TotalSiteTM) integration and energy optimisation rely on Pinch analysis techniques.

In a capital project or revamp situation, the following challenges are solved by using SuperTarget:

  • Select the best value for pinch parameter DTmin to allow you to make the right economic trade-offs. SuperTarget contains a selection of methods and algorithms for getting this fundamental decision right based on capital, energy costs and the properties of the fluids
  • Optimise the use of existing exchangers and the placement of new ones in revamps for both refinery and petrochemical-type processes with SuperTarget's proprietary algorithms
  • Optimise entire sites or even multi-company complexes using the TotalSite module to optimise inter unit integration, select the most appropriate utility conditions and evaluate the best strategy for low grade heat recovery
  • Quickly and conveniently import data from Petro-SIM or other process simulators and manage multiple design and operating cases using the SuperTarget interfaces

 

ProSteam™ & Energy Suite

Real time monitoring and optimisation of utility systems offers scope to reduce energy costs by up to 5% without incurring capital investment.

LEARN MORE >>

HX Monitor™

Fouling related issues cost a typical 100KBD refinery $1-2M per year compared to those with a HX Monitor exchanger management system.

LEARN MORE >>

GT-SIM™

Speed up gas turbine selection, and make design iterations faster when optimising a system with a gas turbine and a production process, to allow faster decision making.

LEARN MORE >>

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