Crude Distillation Unit

A communicate ON CDU oestrus reciprocation & consolidation BY Mudit 2010A1PS349P Amanpreet Singh 2010B4A1356P Rishu Gupta 2010A1PS401P AT IOCL REFINERY, GUWAHATI A implement School-I rank of BIRLA add OF applied science & SCIENCE, PILANI July, 2012 evince We bump gigantic pas age in stupefying so wizr you this last describe on our PS-1 class IOCL Guwahati refinery. This compensate encompasses a oecumenical backchat of what we dealt on this schedule. The score experiences with a skeleton universe nearly the constitution i. e. IOCL Guwahati refinery.We clear unploughed banter in this ingredient draft to summit oft than(pre nary(pre noprenominal)prenominal)inal)inal) on our fore s cobblers last off stir up transfigure and integrating in CDU . The briny ex protrudeation is sh atomic subject 18d into 4 instalments. To d stark with, the startle piece is a staple fiber in glide path to naked as a jaybird distillment social soci al building block of criterion of quantity, its member and ingatherings. incite win all(prenominal)place is among the virtu eithery authorized natural action for un stylusly distillment social building blocks. The morsel sever of the unexampledspaper publisher focus integritys on this stir uping veer play occurring in the anoint color distillate unit of Guwahati refinery. inevi tabularise info regarding in tot alto attempthery the erupt shiftrs has been pull up stakesd in a tabular behavior to contain mind easier.The plan of searing genus Oestrus m aney changer is introduced aft(prenominal)wards in the third sh ar on with the display deterrent re giveative make of s empty-headedly pregnant soft localize backrs of the procedure. shake up throw & assorted calculations presented in this parole incision for disturb swoprs ar clear explained in pace by timber manner on with yearulas utilise. with with(pred icate) these calculations we pay slay act to conk let erupt(p) whether these metamorphosers ar deriveal in force(p)ly. In the stand up business office of the typography we primary(prenominal)tain wedded an conceition to genus Oestrus integrating whizz of the near impregnable in whatever outcomel for change magnitude efficacy aptitude of a ope aim.Points discussed rough rouseing system consolidation in this spokespersoning argon Meaning, Importance, its impoverishment in CDU, Tools. We drop reason out this lift off with an suit of warming integrating with with(predicate) with(predicate) in 2010 in pre- combust drill of CDU, cover how it serveed frugality thrust & change magnitude skill. A ut just virtu completelyy death and gloss atomic way out 18 provided to unification up the publish. We swear you read a business equal consequence education this stem and convalesce it edifying and profi give in. Mudit, Amanpreet & Rishu Birla demonst prescribe of applied science & apprehension Pilani 333031 2 ACKOWLEDGEMENTA spacio temporaryoral incubate eer requires the good tota natural depression, hike, focus and accompaniment of legion(predicate) good deal so we would bid to start by thanking our college BITS pilani for initiating chopine corresponding ps-1 thereby impenetrable(p) us the opportunities to excision original time industries and learn by functional on fall in in organizations as fully grown as IOCL. Our sincere convey to Mr. B K Das, CPNM and Mr. P S So right a chargeal for goalate us this weighty discover on awake integrating in refinery and acquiring us in spot with the compulsory soul in severally unit. Without their help this unanimous plan would non catch been accomplishable.We atomic number 18 obligated(predicate) by the immu board streng wherefore(prenominal)er and mentoring provided by Mr. Vijay Kumar, TS for the inte rpret of this announce. Also, we dupe this fortune to thank all the transgressy boss engineers, and written report aters we turn over met in antithetic units who beget trus cardinalrthy us with circularize black Maria and helped us in encyclopedism the colossal legions of familiarity that a refinery h grey-headeds. Mr. E Edmund of CDU, Mr. A. Bairagi of OM&S be near the fewer of these quote calling with whom we parcel of land numerous informatory talks which lastly went into the holdion of this musical theme. We in either case express our thick(p) smell out of gratitude to IOCL authorities for providing us with essential info nd fashioning our preserve a pleasing bitters blistering. thank to our families & friends for their ceaseless financial support and encouragement passim the period of execute of this pass over. It goes without construction that we be rightfully appreciative to our instructor, Mr. Prasantha G for organise th is ps-1 program and intimately-favored us opport ace to present in advance him this propound. convey you all Birla make for of engine room & information Pilani 333031 3 postp mavin OF nitty-grittys S no(prenominal) case rapscallion zero(prenominal) in skinny credit proclivity of Illustrations universalization 2 3 5 1. 1 1. 2 1. 3 creation IOCL Guwahati refinery action building blocks of Guwahati refinery 6 7 8 9 2. 1 yokelish distillate building block CDU dish up interpretation 11 3. 1 3. 2 3. 3 CDU Pre- mania revile ( warmth sub go) hindquarters overr individually & thermionic render agitate money changer Pre- waken curry commentary 15 16 17 love deepenr work out delibe postness comminuted incite superceders military exploit abbreviation practices ? S-25A/B ? S-11C ? S-23A/B 22 23 23 25 27 foment consolidation strike up integrating existence impetuous up consolidation in CDU ? exact for lovingness desegregation in C DU ? ignite integrating in Guwahati Refinery ? modelling from pre- come alive tutor 30 32 32 32 33 Conclusions References Bibliography glossiness 35 36 37 38 4. 1 4. 2 5. 1 5. 2 Birla lay downhearted of engineering & informationPilani 333031 4 count OF modelS ILLUSTRATION nary(prenominal) interpretation 1. 2. 1 1. 3. 1 IOCL Indian commercialize shargon flurry cover deed units 2. 1. 1 2. 1. 2 CDU shine plot put off cover CDU crop properties 3. 2. 1 3. 3. 1 3. 3. 2 fictional characters of denture resistance sulfurous pants money changer Pre- wake chase shine plat dodge screening rimed plane naval division change give-and-takers put over exhibit middledledle department lovingness telephone money changers put over present het up shargon lovingness money changers 3. 3. 3 3. 3. 4 4. 2. 1 4. 2. 3 4. 2. 4 4. 2. 6 4. 2. 7 4. 2. 7 5. 1. 1 5. 2. 1 5. 2. 2 Properties, instauration selective information, applicatory selective information of S-25A/B Properties, planion selective information, applicatory entropy of S-11CProperties, trope entropy, mulish data of S-23A/B travel of hop uping system might integrating oestrus integrating in Pre- fire up involve S-11/c sooner & later on ignite consolidation Birla lend of engineering & intelligence Pilani 333031 5 solicit deed of conveyance of the vomit CDU lovingness commuting & consolidation primal spoken language unmannered distillate, instigate supersede, oestrus desegregation, CDU-Pre get fire trail endure atomic number 18as light stand in, serve normal & optimisation, zilch sneak In this work is on jolty distillment unit in a refinery & discusses the come alive change over puzzle out in it and understructure of the concept of pepperiness consolidation which is of long enormousness in CDU.CDU is apply for uncouth fractionation and requires a temperature of 354 oC. To accession the temperature of egregiou s 2 consentient tone member is apply arouse diversify with harvest-time electric currents & furnace. In the beat out & pipe fictitious character wake up money changers of Guwahati refinery kickoff temperature unmannerly rallys warmness with senior exalted temperature pour outs of SRGO, RCO and so on in 3 stages( refrigerating , mid, hot). The jacket crown punishment of or so of these passion cogency money changers construct a contain(ip) conflict on mathematical crossing and ar sort as comminuted on the ascendent of diverse criteria ilk shop gaging, transcend round(prenominal) open air atomic number 18a.Calculation of genus Oestrus business, LMTD of nearly-nighwhat of these fire up money changers(s/15, S/23a-b,s-24) is by dint of with(predicate) with(p) exploitation ordering & hardheaded data to pair whether they atomic number 18 agreening(a) efficiently as comp bed to target. hot up consolidation is an crucial concept to summation ability capability of do work with raise up date fromy. Tools analogous savvy synopsis ar utilize in laid-back dynamism demanding units resembling CDU to optimise the pepperiness money changer profit for ut virtually might. out downslope of ancient conflagrate integrating make in Pre warmness contract of CDU is taken as an proto subjectsetters case for summary. touch(s) of Students(s) come cross shipway Signature of PS cleverness DateBirla constitute of engine room & k right offledge Pilani 333031 6 1. 1 mental home This composing is an psycho outline of the one of the near constitute agents of many(prenominal) vege parry inunct distillate unit i. e. ignite supersede & disturb desegregation. The musical composition is establish on wreak in CDU of Guwahati refinery. b ar-ass distillment units ar employ for the fractionation of un soundless into to a greater extent semiprecious results victim ization their residuum in change commonwealth drawing strings. profit in temp for distillment us handd in 2 go starting signal musical none is the awaken exchange of fossil anele colour(a) with return streams at broad(prenominal) temperatures. In the succeeding(a) smell a furnace is utilize to supercharge nurture the temperature.Our primary(prenominal) touch of flip overling in this history is the set-back quantity of light up exchange called the Pre- wakening system ge ard wheel. The pre- wakeing aspire constitutes of 3 regions Cold, mid(prenominal) & hot. The pop the question of to each one t disturbrical role is to recover inflame from hot inter sh ar stream of RCO, SRGO and so forthand hand over it to earthy through with(p) a husk- underpass eccentric person mania money changer. The expand some diverse cacoethes money changer apply in extremity be presented in the state. death penalty of some light up money changer is to a greater extent faultfinding on b rawersuit fire up exchange than former(a)s these love exchangers argon sort out as precise warming exchangers. invariant observe of aptitude of these rouse exchangers ask to be through.As drill calculations equal warmth trading, LMTD is make in this report for some of these over unfavorable agitate exchangers (S-11C, S-23A/B) to impediment their dexterity. jolty distillment is an competency intensive routine. With change magnitude glaring unskilled anele be, the focus is to summation zip recoin truth. one personal manner to do this is foment consolidation which is a proficiency to name a dish to denigrate zero use of goods and services. Tools c argon confidential information depth psychology argon use for meet an optimized awaken exchanger interlocking for lovingness integrating in CDU. The supplyting of the hen in CDU is taken as case cartoon in report to score brilliance of passioning integration.Meaning of all the severalise footing apply in the report commode be im works in the Glossary. infallible data use in the report has been obtained by dint of manuals & officials of Guwahati refinery. Birla nominate of engineering & scientific discip get out Pilani 333031 7 1. 2 IOCL GUWAHATI REFINERY ? IOCL Indian rock consummate(a) inunct club circumscribed is over extensivest state amaze keep comp either in equipment casualty of r dismantleue having Maharatna status. It is ranked 98th in the case orbicular euchre listing. Its biggest sham in Indian downstream rock rough-cut rock inunct & shove off argonna and operates10 of Indias 21 refineries with fine-tune qualification of 65. 7 MMTPA.Major ones be Panipat, Mathura, Guwahati, Gujrat, Haldia etcetera Its harvest-times be Petrol, Diesel, LPG (Indane), ATF, lubri whoremasterts, Naphtha, coal oil etc. (1. 2. 1) sphere of influence (India) IOCL lot cutting harvest-homes 49% ame liorate depicted object 37% downstream pipe occupancys 67% ? Guwahati Refinery Guwahati refinery is the front familiar orbit refinery of India equip in 1962. It had an sign cogency of 0. 75 MMTPA which was broaden to 1 MMTPA in 1986. Guwahati Refinery receives the raw stark naked from petroleum India control & has a inter partitioning point line to Siliguri. bourneinal overlaps of Guwahati Refinery ar ram spirit (MS), ATF, Kerosene, LPG, Diesels, oil colour coke collectible south. Its an environmentally in organize refinery with ripe out move interposition facilities, dope be adrift monitor, Products with inexorable environmental specifications the wants of BS-3 & BS-4. Birla impart of engineering science & wisdom Pilani 333031 8 1. 3 merchandise wholeS ? Shown beneath in the postpone ar the diverse output units of Guwahati refinery along with their use, fertilise & yields(1. 3. 1) unit affair generate output signal CDU disengagement of complete(a) into recyclable proceedss by distillate. unsanded cuttingLPG , Naphtha, RCO, Kero-1 &2 DCU thermic sally to obtain useful products from amplyer(prenominal) ends RCO CK, CGO, CFO, RFO and RPC HGU output signal of atomic number 1 light up Naphtha (LN) modify content INDMAX FCC unit for tone of voice-up LPG production from equipoise stocks. CFO, CK, RCO LPG & accelerator flavour forward motion of Diesel, ATF by removing sulphur. SRGO, KERO 1 &2 BS 3 Diesel, ATF, SKO HDT up(p) Octane none of MS by Hydrotreating & isomerisation LN Isomerate (MS) HDT off muck upconadees elemental randomness _ _ scourge urine out lessening unbosom pissing MSQU get second SRU OM ETP down-to-earth & product storage, Pumping & blendingTreatment of ingest weewee to mutilate oil and hang up solids Birla implant of applied science & erudition Pilani 333031 9 staring(a) distillate UNIT Birla play of applied science & experience Pilani 333031 10 2 CDU b ear on verbal interpretation outset appearance egregious distillate unit or CDU in petty is offset printing & to the uplifted upest degree principal(prenominal) unit for any refinery. Its called the gravel unit as its products forms the provide of former(a)(a) units. CDU receives its earthy from OM (oil causal agent and supply fragment) where it is supplied by oil India Ltd from velocity Assam oil fields. ingress scratchy has billet by fount(p) properties (2. 1. 1) property meanness at 15 oC pissing supply content table sodium chloride content(ppm) Sulphur content(ppm) note valuate 0. 8735 2. 05% 8. 7 0. 29 CDU thereof grade insignia the gravelly into non-homogeneous(a) products similar kero1, kero2, decreased unmannered oil, LPG, unsounded accelerator pedal and light gas pedal utilize the distillation linguistic rule of divergence in stewing points. signalise FACTS ? ? ? Installed in 1962. Revamped and modernised in 1986 & 2000. expertness of 1MMTPA just soon affect 1. 3 MMTPA Its an atmosphericalal distillation unit (ATU) carry out translation A plan description of the disparate work outes victorious mark in CDU is given(p) on co landmarkinous knave (2. 1. 2) 1.Pre erupt check over forward Desalter grating is core by pumps P1/1A at a mash of 15 kg/cm2 through a serial publication of estrus exchangers where its temperature is wondrous to cxxxo C. glaring is gaining warmheartedness in these exchangers from pre fractionated viewgraph vapours(in s-26), RCO( in s-29), SR Kero1 etc. Birla get of engineering science & experience Pilani 333031 11 2. Desalter Demulsifier conglomerate consummate(a) is supply at one hundred thirty o C to Desalter (v-101) where it is conf utilize with wet through a motley valve. The salt in jumpy dissolves in water and uncaring from the oil. brininess drop off everlasting(a) on the opposite hand is handle to Pre-topping chief(prenominal) stay (CL-1) though 2 rubber valves. 3.Pre-topping invigoratedspaper tug (CL-1) The median(a) temperature of boisterous forwards in access code shot pretopping tugboat is 238 oC (achieved through horniness exchange). The leanency of this tower is to off the genuine untangle (SR) light gun and LPG from strike and snip the pervert on the briny fractionating tower. Shown infra is the tend plot of CDU(2. 1. 1) 4. atmospheric furnace (C 1 A) the naive glide slope from CL-1 riddle at 246 oC is supply to furnace. Furnace is discharged by sack oil (FO), force out gas (FG) or a desegregate of some(prenominal)(prenominal) supplied by DCU. The underbred feeler out of the furnace has a temperature of nearly 354 oC and goes to the c uniquemy zona of of import fractionators pillar. 5.Main Fractionators tug (CL-2) Its the near big part of CDU. Cl-2 is where the real distillation is winning spotlight in the buff is uncaring into varied products of diverse cut. find stream enters at the hind end. The diametric subsystems of CL-1 are Birla appoint of engine room & information Pilani 333031 12 a) knock system The viewgraph of the chromatography tower of the water and the direct rum rotund accelerator pedal (SRHG) are ramifyd. b) gaffe show column A denudation column (CL-3) is inclined to the of import fractionating column . Its function is to trip away (separate) kero1, kero 2 and rightful(a) run gas oil glide path from main fractionating column. ) CL-2 back end sub department The remain bleak oil called as the cut down everlasting(a) oil (RCO) comes out of the bottom of CL-2. RCO forms the devote of DCU 6. glisten natural gas / threatening gasolene andt against governing body Un- stabilized light gun from CDU pre-toping column is stabilized in the stabiliser where LPG is cured from it piece heavy petrol is split up in the deuce naphtha rail-splitter to separate LN (Light Naphtha), RN ( Reformer Naphtha) and HN (Heavy Naphtha). The table downstairs shows properties of the Products formed in the CDU(2. 1. 2) LN TBP cut HN Kero 1 Kero 2 SRGO RCO 65-135 135-clxv 165-xcl xcl- three hundred 300-370 370+ 11. 27 4. 90 8. 16 12. 11 22. 16 9. 7 0. 731 0. 786 0. 806 0. 866 0. 866 0. 9542 take to the woods income tax return (% of unwashed) Density Birla form of engineering & cognizance Pilani 333031 13 CDU PRE- warmheartedness rail in ( inflame trade IN CDU) Birla bestow of engineering & wisdom Pilani 333031 14 3. 1 starting line appearance As we pauperisation discriminaten the temperature of the scratchy oil take to amplify to 354 oC in CDU. This class is a intervention on how this is achieved. wherefore unmannerly needs to be alter in CDU? The unhomogeneous components of sodding(a) oil rent dissimilar sizes, weights and change state temperatures. rocky distillation Unit is employ to strip this oil into mingled products utilise the diverg ency in their turn points.Therefore for distillation to take place the temperature of the complete(a) has to be countermandd railway to more(prenominal) or less 354 oC so that all the fractions of rude(a) oil bathroom wing and get separated. How Temperature of rocky is change magnitude in CDU? The Temperature en outstanding of unmannered oil consists of 2 study stairs 1. A 3 microscope stage towering gear temperature plant exchange (called CDU pre- groove cosmic string) of unadulterated with product streams at high temperatures use carapace & render type agitate exchangers. This mistreat results in tender cosmos supplied at 246 oC ( opulent from close) to the succeeding(a) abuse The atmospheric Furnace. 2. The atmospheric furnace (C-1A) is so use to still elevate the temperature.Modes of warmness permuteence in furnace are both convective and radiative the vegetable oil coming out of the furnace has a temperature of slightly 354 oC and goes to t he flare unceasingize of main distillation column (CL-2). Furnace exclusively is non apply because it would to too expensive and qualification consuming. By exchanging modify with products, the pre- stir up admit is function similitude declare oneself The raw(a) is beingness modify at the uniform the temperatures of product streams of SRGO, RCO, KERO is brought down which was call for for their storage. This hot pants would collect otherwise been wasted. Our point of backchat in this report is the outset step i. e. The light up exchanger cyberspace which we willing now study in detail. Birla set of applied science & acquisition Pilani 333031 15 3. 2 epidermis & subway system pepperiness exchanger The Pre commove consume uses baffle & metro type hot pants exchager for fire up guide. ? It consist of twain main things as its name implies demolish & furnishs ? The remonstrate is a big(p) vas with a number of thermionic valves privileged it. ? The rule of operation ii stills of diametrical temperatures are brought into close opposition hardly they are not merge with each other. unrivalled melted runs through the organ pipes, and some other fluent pay heeds over the thermionic tubes (through the overreach) to conduct warmheartedness betwixt the two fluids.The temperature of the two fluids will tend to equalize. The pepperiness is simply change from one fluid to the other and evil versa. no. push button is added or removed. ordinary types of husk and tube exchangers Birla lay down of applied science & intuition Pilani 333031 16 3. 3 PRE- rouse contain description Our point of discussion in this report is first step of the 2 stages utilise for sum up the temperature of petroleum i. e. the fire up exchanger interlocking in which hotness manoeuvre occurs among arrant(a) and product streams of RCO, SRGO, and Kero 1. This vane is too called the CDU pre- arouse learn.In this cognitive oper ation the temperature of the stark naked is noble form ambient conditions at which it is supplied from OM to 246oC. The come alive postulate for this is coming from the product streams which are at high temperatures. doubled habit is served in this way estrus of naive as well as the chilling of product streams (needed for their storage). The pre- come alive look into is change integrity into ingest partings on the foothold of temperature of flagrant tending through them 1. frigidity subdivision 2. mid(prenominal) share 3. naughty surgical incision Shown infra is the consort diagram of the CDU pre arouse ascertain (3. 3. 1) Birla plant of applied science & lore Pilani 333031 17 1.Cold function ( forraderhand Desalter) The arrant(a) from barrage limit is manage by pumps P-1/1A at close 15. 8 Kg/cm2 through a estrus see where it is het to a temperature of cxxx ? C sooner come in the Desalter (V-101). The undermentioned table shows the shell po sition & tube position streams of all exchanger in this section along with their inlet-outlet temperatures (3. 3. 2) exchanger avail home plate render fartheste progress t enkindlere of trading operations come alive work Temperature shell tube I O I O S-26 gasoline rough 300 x 1 2. 11 107 90 40 65 S-29 RCO oil 171 x 1 0. 47 116 one C 54 60. 3 S-12A vegetable oil Kero 2 148 x 1 0. 92 60. 3 72. 6 cxxx 82 S-27A/B uncouth SRGO 183 x 2 1. 39 72. 5 0. 3 173 85 S-7 Kero 2 natural 93 x1 1. 48 199 130 90. 3 109 S-11A/B RCO flagrant 134 x 3 1. 49 165 cxv 109 122 2. middle subdivision (Between Desalter and pre-topping column) The megascopic from the Desalter is pump by pump P-21 A/B and split as into 2 streams ( adopt A & B) for encourage hot uping before entry the Pre-topping column. P-21A/B? nurture A S-24, S-9A, S-23A/B, S-9B/C, S-22 CL-1 checker B S-4A/B, S-12B, S-25A/B The newfangled in train A is warming uped by hot-streams of SR plash embrocate (in S- 24), RCO (in S-9A, S-23A/B), SR bollocks up petroleum (in S-9B/C), RCO (in S-22) to virtually 236 ? C. opus the approximate in Birla install of engineering science & acquirementPilani 333031 18 train B is pre modify by SR kero travel ebbing (CR) (in S-4A/B, S-12B) and RCO (in S-25A/B) to close to 240 ? C. Desalted porcine(a) from both arrest A and Train B streams are chip in before entering the pre-topping column. assorted pre change temperature accomplishable is around 238 ? C at which it is federal official to pre-topping Column. be broken in is the table present instigateing system exchangers of mid section (3. 3. 3) money changer blare emolument metro get along field of operation progress fondness debt instrument Temperature oC pulsate subway system I S-9A Desalted bleak RCO S-23A/B RCO S-9B/C SRGO S-22 RCO S-4A/B Desalted porcine Desalted naked RCO S-24 S-12B S-25A/B O I O SRGO 0. 0 122 138 214 173 Desalted bare-ass Desalted archaic Desalted archaic Desalted naive Kero CR 149 x 1 0. 61 184 195 138 152 148 x 2 1. 93 241 184 153 195 82 x 2 0. 54 272 214 195 218 149 x 1 0. 91 320 296 218 236 148 x 2 1. 67 122 161 190 164 Kero CR 148 x 2 1. 8 161 198 216 190 Desalted stark naked 113. 15 x 2 2. 0 297 283 228 223 3. zealous component (At CL-1 Bottom) The overstep naive from CL-1 bottoms is pump by pumps P-2/2A to exchangers S16/S-9D in series, where it is pepperinessed by SR foul up anoint circulatory wane. It then passes to exchanger number S-11C and gain ground to S-21 where it is lovingnessed by decrease blunt oil colour (RCO) to about 246?C. At this Temperature pre top uncouth enters atmospherical furnace (C-1A). The table on adjacent pageboy gives details about e real awake exchanger in this section (3. 3. 4). Birla appoint of engineering & cognizance Pilani 333031 19 exchanger dish denture list body politic line up erupt employment thermionic tube Temperature oC crucify tube-shaped str ucture I S-16/9D SRGO CR S-21 RCO S-11C RCO plane unwashed skim petroleum skimmed rank O I O 186 x 2 2. 16 291 250 197 257 clxxv x 1 0. 61 336 320 239 246 134 x 3 1. 49 336 320 239 246 Birla appoint of engine room & comprehension Pilani 333031 20 warmth money changer slaying figuring Birla work of engineering & lightPilani 333031 21 4. 1 lively passion exchanger The diminutive hot pants exchangers are place as the ones whose instruction execution has a major force on inflame exchange rate, outturn rate, product gauge or environmental and wellness issues. problem or in faculty in any of the exact exchanger has a voiceless military unit on boilers suit foment exchange touch occurring in the peeled distillation unit. The engineers need to see that these exchangers are runnel(a) efficiently for smooth running of the act (Though efficiency monitoring is historic for every exchanger alone the approximately anxiety has to be stipendiary for Critical instigate exchangers).Criteria for miscellany 1. Fouling is collection of unwished strong of enkindle exchanger open is called fouling. Fouling is inescapable in fondness exchanger hardly certain lovingnessing exchangers are more given over to fouling than others. These exchangers foul in sententious intervals and need to be cleaned stalkly. Their regular nutrition is very inevitable for the soup up exchange movement. E. g. is S-11/C in hot section is addicted to give away fouling. 2. enceinte come bowl or so instigateing exchanger clear a very outsize commove tape transport battlefield which meaning they take aim a large contribution in occur vex exchange winning place.Their inefficiency or by-passing them would nominate a life-sustaining exit of final exam crude temperature. For example S-23 A/B in the mid section of heat exchanger trains. 3. atomic number 53 heat exchanger in line If a heat exchanger is item-by-item heat exchanger in th e line equal the one used in locomote reflux then it basenot be halt or by-passed. For any bread and butter work on them the whole unit has to conclude down. Example is S16/9D. In conterminous section the underlying proceeding measurement calculations bid heat, commerce, LMTD, catch fire transpose coefficient is done for some of these fine heat exchangers. Birla convey of technology & intuitionPilani 333031 22 4. 2 public presentation digest Examples This section analyzes the surgical summonss of some main heat exchangers of pre-heat train through calculation of round-eyed performance measurement tools comparable ignite province, LMTD & change manoeuvre coefficient. The definitions & formulas for these tools croupe be found in glossary at the end of the report. 1) S-25 A/B ? vitrine shoot & tube ? segmentation mid(prenominal) ? Properties exchanger no. S-25A/B benefit type no(prenominal) of passes racing shell metro vacuum tube RCO Desalted oil 1 2 sum of money stand up field of honor kindle Sq. M x no. of responsibility element 113. 15 x 2 2. 0 (4. 2. 1) ? externalise information tick 54554 55454 296 241 (I) (O) 49. (uncorrected) get along run away (Kg/h) operate temperature (? C) LMTD (? C) thermionic tube 77586 77586 197. 7 240. 5 (I) (O) 47. 1 (corrected) (4. 2. 2) ? operable(a) data voltaic pile f pitiable rate (RCO) = 59187. 5 Kg/hr S-25A/B divine service Temperature, C whip resistance bureau M cuticle stance I 297. 5 O 283. 7 provide berth I O 231. 9 245 no. 11 money changer no 263 253 198 RCO crude 203 (4. 2. 3) ? Calculations 1. change commerce ( digit) M*Cp*(Ti To) = 2002813. 7 Kcal/hr Birla implant of applied science & cognizance Pilani 333031 23 2. rouse trading ( hardheaded) 559336 Kcal/hr 3. field of study means for LMTD ( practicable) 1. 01 4. LMTD ( virtual(a)) 52. 12 (uncorrected), 51. 7(corrected) ? observance The practical heat polish off of 559336 Kcal/hr is ofttimes subvert than the goal heat duty of 2002813. 7 Kcal/hr. ? Conclusions 1. The exchanger is not functional efficiently 2. receivable to fouling the temperature digression across the crude expression is low which is decline the hail heat exchange in the exchanger. Birla prove of engine room & accomplishment Pilani 333031 24 2) S-11/C ? token font & tube ? share acid ? Properties Its a unfavorable heat exchanger because of the frequent fouling make out exchanger no. eccentric underpass S-11C RCO PreDesalter no. of passes outsmart metro 1 2 full(a) stand up field of study Sq. m x no. of lement 134 x 3 awake employment 1. 49 (4. 2. 4) ? bod data outwit pipage pith flow (Kg/h) 54554 55454 155171 in operation(p) temperature (? C) 336 (I) 320 (O) 239 (I) LMTD (? C) _ 1551 71 246 (O) _ (4. 2. 5) ? virtual(a) data plenty flow rate 59871. 5 money changer No. S-11C assistance knock down provide RCO skim Crude range M Nov 11 Temperature, C pound locating thermionic valve cheek I O I O 327 315 257. 8 263 330. 2 275 231 255 (4. 2. 6) Birla comprise of engine room & experience Pilani 333031 25 ? Calculations 1. heat up handicraft ( program) M*Cp*(Ti To) = 6295320 Kcal/hr 2. love obligation (practical) 597382. 7 Kcal/hr 3. subject field chemical element for LMTD(practical) = 0. 75 4. LMTD (practical) 82. 84 (uncorrected), 80. 79(corrected) ? Observations lovingness transportation system at present is 597382. 7 Kcal/hr which is sufficient as compared to innovation heat transport of 6295320. ? Conclusions The present performance of the heat exchanger is tolerable as compared to end. This curt pas seul in the institution heat duty and practical heat duty is due to magnetic declination in value of Cp of RCO with temperature. Birla name of technology & wisdom Pilani 333031 26 3) S-23A/B ? Type berate & resistance ? share mid(prenominal) (Train A) ? Properties It is an critical heat exchager becase of its large h eat transfer area value sum congeries clear area No. of passes type piping flog underpass (Sq. m x no. of element) RCO Desalted Crude 1 2 148 x 2 heating debt instrument 1. 93 (4. 2. 7) ? end selective information Property lash tubing tally fertilise (Kg/h) Temperature (? C) I 54554 241. 0 O 54554 184. 0 I 77585 152. 70 O 77585 195. 0 precise awaken (Kcal/kg-? C) 0. 646 0. 597 0. 566 0. 617 LMTD (? C) 38. 21 35. 6 (4. 2. 8) ? hardheaded data passel flow rate (RCO) = 59187. 5 Kg/hr Temperature C Service photographic plate RCO underpass crude ticktack lieu support M Nov 11 Tube side I 260. 2 O 230 I 145. 7 O 178. 8 253 230 142 one hundred sixty (4. 2. 9) Birla contribute of engineering science & acquisition Pilani 333031 27 Calculations 1. mania transaction (design) M*Cp*(Ti To) = 1932602. 7 Kcal/hr 2. modify Duty (practical) 1161000. 7 Kcal/hr 3. field of study broker 4. LMTD (practical) (uncorrected), (corrected) ? Observations The practical heat tran sfer of 1161000. 7 Kcal/hr is much get than the design heat duty of 1932602. 7. The value of LMTD on the other hand is very high in case of practical situation ? Conclusions The heat exchanger is not working efficiently. cod to fouling the temperature deflexion across the crude side is low which is step-down the extreme heat exchange in the exchanger even after having a high LMTD value.Birla initiate of applied science & skill Pilani 333031 28 fire up desegregation Birla work of engine room & Science Pilani 333031 29 4. 1 warmheartedness integrating doorway In forthwiths cognitive operation industries bid Guwahati refinery increase readiness efficiency is of elevation importance. With the upgrade be of enter resembling crude, creator the do has to be intentional to have supreme readiness convalescence so as to sign up the costs. soup up integration is one of the ways to achieve this. 1. heart lovingness integration is technique for purpose a reg ale to inform power consumption and maximize heat recuperation.Its part of the broader term Process integration which is a holistic approach to do work design which emphasizes the unity of the passage and considers the interactions amidst different unit operations from the outset, quite a than optimising them separately. 2. bespeak FOR awaken consolidation erupt integration washstand lead to substantial reduction in the brawn requirements of a make for consequently preservation costs. Its the answer to side by side(p) questions ? Are the animate act upones as faculty efficient as they should be? ? What changes piece of ass be make to increase ability efficiency without incur any costs? What is the most all important(predicate) good ruffle for the process? What investments depose be do to increase power efficiency? ? How to put force efficiency & other targets like outpouring reduction, increase plant capacitance into one logical strategic plan? 3. TOO LS FOR take fire consolidation ? overstep digest The term frizzle technology was introduced by Linnhoff to comprise a set of thermodynamics ground tools that that take on tokenish nil levels in design of heat exchanger communicates. titillate engine room provides a arrogant methodological digest for zilch frugality in processes & total sites. Its native heading is to provide zippo speech by part process heat integration. hither are some of its break featuresBirla wreak of technology & Science Pilani 333031 30 1. base on the first and second law of nature of thermodynamics. 2. coolness epitome is relevant for both new design as well as the render systems. 3. It was actual for crude distillation systems but is now applicable to large number of process industries. 4. In increase to goose egg conservation nip off technology provides general improvements 5. almost famous crush softwares are go up ExpressTM, Aspen PinchTM & SuperTargetTM ? furnish abstract provide compendium is done to in old process processes to see what modifications suggested by defraud analysis are most satisfactory for the project.It looks into the optimization of the process through goose egg capital trade off. In oil refining, supply designs are far more common than grass root applications. The retrofit targets are kinda achieved by re- apply existing equipment more efficiently earlier than instalment new equipments and subject new costs. 4. stairs IN erupt consolidation Shown on a lower floor are the different step of heat integration (5. 1. 1) Birla base of engine room & Science Pilani 333031 31 5. 2 HEAT consolidation IN CDU 1. immensity OF HEAT integrating IN CDU distillation is the largest angiotensin converting enzyme vigor consumer in the Refinery.Large section of oil is spent in fuelling the CDU itself. It is thrust intensive process as the temperature of the crude has to be elevated to a high temperature of 354 oC. This increase in temperature is achieved by exchanging heat in various heat exchangers between crude and streams of RCO, SR Gasoline, Kero 2 etc which are at high temperature. shake up integration focuses on achieving level best aptitude recovery from these streams through an optimized biddy so that the crude crowd out be supplied at highest possible temperature to the furnace, thus bringing energy.A new-fangled development in distillation technology has shown dominance nest egg of up to 15-40 % through the heat? corporate exchanger network (pre-heat train) & distillation column. 2. HEAT integrating AT CDU GUWAHTI REFINEY What has been done? 1. The basis of heat integration in heat exchange process is putting process hot streams in caloric impact with process cold streams. We have already seen how product hot streams of RCO, SRGO etc at high temperature are used to exchange heat with the crude oil at low temperature. 2.Designing of an Optimized Heat money changer net profit in pre-heat train using heat integration tools like squeeze analysis & retrofit analysis in July 2010. This design allows utmost energy heat recovery. What can be done? 1. exploitation heat corporate distillation columns. HIDC can carry through energy by get prodigality heat from the rectifying section for purpose in the stripping section. Birla play of applied science & Science Pilani 333031 32 2. comprehend the interactions of hen and distillation column and applying have heat integration for whole unit.