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Enhancing performance of

tubular heat exchangers


using hiTRAN Systems

INTHEAT
Friday 8th July 2011

Copyright Cal Gavin 2011

www.calgavin.com

Page 1

Providing solutions to:


Increase plant capacity
Reduce energy costs
Increased equipment
performance
Reduce production costs
Provide operational flexibility
Increase plant profit !

Copyright Cal Gavin 2011

www.calgavin.com

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Copyright Cal Gavin 2011

www.calgavin.com

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hiTRAN tube-side heat


transfer enhancement
system
increases heat transfer up to 8 times
reducing fouling by increasing fluid
sheer
Direction of Flow

Copyright Cal Gavin 2011

www.calgavin.com

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How hiTRAN Wire Matrix Elements


work
hiTRAN Matrix Elements remove the boundary layer and
mix it with the bulk flow.
Fluid from the centre is displaced in the direction of the
wall
Residence time of the fluid at the wall is considerably
reduced.

hiTRAN
Matrix
Improved heat and mass transfer
and reduced
fouling
Blue dye:
Element

Red dye:
A) Laminar flow
Copyright Cal Gavin 2011

B) turbulent flow

www.calgavin.com

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hiTRAN video how hiTRAN works

Copyright Cal Gavin 2011

www.calgavin.com

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Case study

LUKOIL Refinery, Volgograd


Feed Effluent Exchanger

Problem

Plant capacity limited by low heat


exchanger performance (maldistribution)
Recovered heat was 19 MW but
23.1 MW needed to meet target
temperature
Fired Heater performance much too low!
4.1 MW not available from Fired Heater
High on-going energy cost if upgraded
Plant expansion now requires 28MW
Copyright Cal Gavin 2011

www.calgavin.com

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Case study

Lukoil - refinery

Volgograd
Optimised Engineering
Solution
Study identified hiTRAN
System would solve the
problem
Reduce maldistribution on
tubeside - balance flow
Increase tubeside heat
transfer
hiTRAN System retrofitted in
just 2 weeks
Copyright Cal Gavin 2011

www.calgavin.com

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Case study

Benefits to Lukoil
hiTRAN System increased
performance from 27.8MW
to 32.4MW
4.6 MW energy load saving
without requiring new fired
heater
Fuel saving of over
US$500K per year (at full
flow rate)
Enables higher plant
throughput
Increased plant profit!

Copyright Cal Gavin 2011

www.calgavin.com

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Case study

Rosneft - Novokuibyshevsk

New Air Coolers with hiTRAN System


enhancement
Benefits:
Smaller units
Less bays
Increased efficiency
Reduced capital costs

Copyright Cal Gavin 2011

www.calgavin.com

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Case study

Rosneft - Novokuibyshevsk

Design Comparisons
No. of bays/bundles
No of passes
Flow length m
Tubeside htc W/m2OC
Overall htc (bare) W/m2OC
Total Surface Area m2
Plot space m2
Weight tonnes
Total Fan Power kW
Pressure Loss, Bar
Annual cost of electrical fan power
US$
Copyright Cal Gavin 2011

Empty tube
design
5/10
12
108
44
35
18,100
123.3
84
165
0.71
105,000

www.calgavin.com

design
1/2
2
18
307
180
3,600
24.1
16
33
0.71
21,000

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Cal Gavins Deliverables


Work Package 2:
shell-side
enhancement

Combined tube-side and


heat exchanger

D2.1: Report on state of the art of heat transfer


enhancement technologies and their benefits. (May
2011)
D2.2: Report on tube side and shell side enhancement
research
(August 2011)
D2.3: Mathematical models and the software
implementation of tube- and shell side heat transfer
enhancement
Copyright
Cal Gavin 2011 ( May 2012)
www.calgavin.com

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State-of-art of heat transfer


enhancement
technologies and their benefits

D2.1, 6 month
Heat Transfer Promoters
Twisted Tapes, Static mixers, Helically-coiled
wires, Core Tubes and hiTRAN turbulators

Comparisons
Between hiTRAN, Twisted tapes
and coiled wires
The Influence of the boundary layer and overcoming the
limitations in the heat transfer.

Copyright Cal Gavin 2011

www.calgavin.com

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Report on tube side and shell side


enhancement research
D2.2, 9 month
Other deliverables Cal Gavin is involved in
WP1 Analysis of intensified heat transfer
under fouling ( 4 person months)
WP4 Design, retrofit and control of intensified
heat recovery networks (3 person months)
WP5 Putting into practice (2 person months)
WP6 Technology transfer (2 person months)

Copyright Cal Gavin 2011

www.calgavin.com

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Thank-you for listening


Questions?
www.calgavin.com

Copyright Cal Gavin 2011

www.calgavin.com

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