Alfa Laval Refinery

General Refinery Overview Gas plant
Light ends
Sulphur
LPG
Isomerization
Light naphtha Gasoline
Desalting Cat. reforming Gasoline treatment Aromatics

Naphtha hydrotreating
Crude oil Atmospheric distillation Naphtha
Gasoline
Lt distillate hydrotreating
Light distillate Kerosine and
jet fuel
Heavy distillate hydrotreating Diesel treatment
Heavy distillate Diesel and
heating oil
Atmospheric gas oil
Gas oil hydrotreating FCC Alkylation
Atmospheric residue
Hydrogen generation
Hydrocracking
LVGO
Vacuum distillation
Gas oil Lube treating

HVGO
Lube oils
Coke
Coking
Heavy fuel oil

Vacuum residue
Visbreaking
Asphalt
© Alfa Laval Deasphalting

Slide 1 Bitumen www.alfalaval.com
Crude Oil desalting process
Cooling water
Brine/crude sludge
Cooling water
Crude oil, 25°C
Desalter
Desalted crude oil
Desalter water, 130-150°C
4000 mg/l Cl, H2S, NH3, etc
Feed water, 30-40°C
Feed water, 120°C Cooling water
Desalter water to treatment, 30°C
Desalter water, 50°C
Cooling water
© Alfa Laval Slide 2 www.alfalaval.com

Material Selection
Temperature pH = min 7.0
°C
Crevice
corrosion
100
C-276
50
254 SMO
No
corrosion 316
10 102 103 104 105 ppm chlorides

References – Interchanger
PCK Schwedt, Germany
Feed water
Desalter water 120 ºC 50 ºC
130 ºC
Feed water
40 ºC 40 ºC
Cooling water
25 ºC
90 ºC
Desalter water
80 ºC 30 ºC
Three Compablocs in C276 replaced six S&Ts with corrosion problems

PCK Schwedt, Germany
In operation since 1997

US West Coast Refinery, Wilmington CA
Steam
Crude Desalter Desalter Crude @ 320°F
#1 #2
Wash water Brine sludge Brine @ 290°F

CW @ 80°F
Crude @ 120°F
Make-up water
@ 250°F
Recycle Brine Make-up water Brine @

@ 290°F Steam @ @ 120°F 180°F
420°F
Recycle Brine CW @ 80°F

@ 120°F

US West Coast Refinery, Wilmington CA
One out of two

desalter trains
In total eight
Compablocs in
Avesta 254SMO
and one Spiral in
Duplex 2205 in
Desalter Service
In Operation since
2001

Atmospheric distillation
Petroleum Gas & Light Naphtha
Distillation ~40°C
tower
Crude oil
~25-175°C Heavy Naphtha

feed
~150-260°C Kerosene
Fired
heater
~235-360°C Light Gas Oil (LGO)
~350- ~330-380°C
370°C
Heavy Gas Oil (HGO)
Atmospheric residue
Preheated Crude oil

© Alfa Laval ~250-280°C Slide 8 www.alfalaval.com
Economical study
Crude preheaters
Input data
Refinery capacity 100 000 bbl/day
Fuel cost 40 USD/bbl
CO2 cost 20 USD/ton
SOx cost 1 100 USD/ton
NOx cost 1 100 USD/ton
S&T CP
Preheating before heater 250 275 °C
Reduced energy needs 0 -9,2 MW
Energy savings
Fuel saved 1 068 tons/year MW
Fuel cost saved -2 844 245 USD/year
Emission savings
CO2 -514 203 USD/year
SOx -163 217 USD/year
Thermal NOx -30 503 USD/year
Fuel NOx -89 381 USD/year
Total savings -3 641 547 USD/year

Economical study - Naphtha Condensers
Tamoil, Collombey, Switzerland
1st stage – BFW preheating:

Toppings 124  101°C
BFW 95  °C
2nd stage – Crude preheating:

Toppings 101  77 °C
Crude feed 71  25 °C
Total recovered heat: 16.5 MW
Typical pay back for 50 000 bbl/day crude preheat train:

Installed cost for 4 CPs in Ti $2.2 million
Annual savings in fuel cost $5.0 million/year
Annual savings in emissions $1.3 million/year
Total annual savings $6.3 million /year
©Pay back
Alfa Laval Slide 10 ~ 5 months www.alfalaval.com
References – O’head Condensers
Nynäs refinery, Gothenburg, Sweden
Pre-fractionator o’heads 180  100 °C

Distric heating water 81  74 °C
Total heat recovered: 1.8 MW
Two CP50 in titanium
In operation since spring 2003

Economical Study
Crude preheaters – medium NTU
Crude oil / diesel exchanger

Diesel 173  88 °C NTU = 2

Crude oil 89  70 °C NTU = 0.45
Compabloc S&T
Number exchangers 1 1 (diesel – tube side)
Number passes 11 / 4 (diesel/crude) 4 per S&T (tube side)
Pressure drop (Pa) 85 / 115 60 / 82 (tube/shell) *
Shear - tau (Pa) 31 / 112 (diesel/crude) 4 (tube side)
Total heat transfer area (m2) 70 400
* Allowable pressure drops cannot be be utilised. www.alfalaval.com

© Alfa Laval Slide 12
Economical Study – Crude preheaters
Sinclair, Wyoming, USA
75,000 bbl/day Crude Train Compabloc S&T

Heater Charge Temperature (°C) 299 238
Exchanger Cost X 1.5X
Exchanger Cost, Installed 2X 4.5X
Number of Shells 7 14+
Exchanger Flooded Weight, tons X 3X
Heater Fuel Savings / Year, Million USD @
$7/MMBTU
$2.41 0
Emissions Savings/ Million USD / Year $1.411 0
Installed cost = 3,6 MUSD -> less than one year pay-back time

Economical Study – Crude preheaters
Sinclair, Wyoming, USA
All Compabloc positions are preheating the crude by using

various fractions from the atmospheric distillation tower:
• 2 CP75-V-200 in 254 SMO for condensing of overhead vapours
• 1 CP50-150 in 316 for cooling of the Kerosene fraction
• 2 CP75-400 in 254 SMO for cooling of hot –Vacuum tower
residue
• 2 CP75 (identical to above) further cool the Vacuum tower
bottoms by returning it to the middle of the preheat train, taking
further advantage of low-value heat from the vacuum residue.

Economical Study
Crude preheaters – COP, USA
Duty:
HVGO 298  271 °C

Crude oil 263  239 °C
Q = 7.0 MW
Crude = mix of Mexican Mayan and

Canadian Heavy
Typical payback for 80 000 bbl/day crude preheat train:

Installed cost for 2 CPs $1.1 million
www.alfalaval.com
Pay
© Alfa back
Laval Slide 15 ~ 5 months
Economical Study
Crude preheaters– USA
Performance since March 05 until October 06

Blue line is temperature out from CPs
Purple line is temperature out from S&Ts in series with the CPs.
Their performance has dropped 40 deg F, corresponding to energy
www.alfalaval.com
© Alfa Laval loss of $1,3 million Slide 16
References – Crude preheater
Rosneft - Russia
Atmospheric residue 288  162 ºC
Crude oil 201  107 ºC
Heat load 7000 kW

One Compabloc replaced 3 S&Ts
HTA:  > 1000 m2 HTA: 170 m2

© Alfa Laval In operation since Feb. 2002
Slide 17 www.alfalaval.com
Economical Study
BFW preheaters – real case in Petroplus, UK
Conventional vs increased heat recovery

Duty Conventional Increased HR
AR 300 t/hr 165 -> 103°C 165 -> 90°C
BFW 140 t/h 60 -> 132°C 60 -> 148°C
NTU = 1.7/2.0 NTU = 3.4/4.0
Q = 12 MW Q = 14,5 MW
1 CP vs 2 S&Ts 2 CPs vs 4 S&Ts
Typical payback for 100 000 bbl/day crude preheat train:
Added installed cost for 1 CP extra $0.3 million
Total added annual savings $0.95 million /year
Pay back
~ 4 months www.alfalaval.com
Economical Study
BFW preheaters – real case in Petroplus, UK
© Alfa Laval In continuous operation since Slide

beginning
19 of 2002. www.alfalaval.com
References – Fraction coolers
Totally 14 Compablocs:
• Gas oil cooling

• Gasoline cooling
• Vapour condensing
• Bitumen heating
• Bitumen cooling
• Steam heaters
Original S&Ts needed cleaning every

year (1 week operation / S&T)
CPs need chemical cleaning every
third year (<1 day operation / CP)
Total maintenance cost reduction: Three Compablocs for cooling of gasoline

96% and gas oil in operation since 1996.
Vacuum distillation
Steam
HC + water
Vacuum Offgas
Distillation
Fired tower Water
heater
Heavy Vacuum
Separation
Gas Oil (HVGO)
vessel
~360°C Light Vacuum
Gas Oil (LVGO)
Water
Atmospheric residue
Preheated Atm residue
Vacuum residue
References – Vaccum condenser
Lukoil Neftochim refinery, Burgas, Bulgaria
Four spiral heat exchangers will

replace 20 fin-fan air coolers as
pre-condensers on the vacuum
distillation tower, In operation
during 2006

References – Vacuum condenser
Vacuum tower
condenser
© Alfa Laval Compabloc CP50 Slide 23 www.alfalaval.com
References – Atm res. preheaters
Slavneft, Yaroslavl, Russia
Compablocs – totally 13 units delivered in 2005
• 2 CPL75 + 4 CPL50 Vac. residue / atm. residue
• 1 CPL75 Metal. fraction / atm. residue
• 2 CPL75 + 2 CPK40 VGO / atm. residue
• 2 CPL50 Lt vac. distillate / atm. residue

OMV refinery, Austria
Duty:
Vacuum gas oil 10000 kg/hr 177  94 ºC
Boiler feed water 10300 kg/hr 120  70 ºC
Heat load: 600 kW recovered
One CP40/160 in 316L, HTA 27 m2

Design fouling margin: 20%
Footprint: 0,5 m2
Test period: November 1999 - May 2000

References – Fraction Coolers
NCRA, USA
Heat load 9 MW 3 MW
Steam generation 197 C @ 14.6 bara 160 C @ 6.2 bara
Vacuum residue
336 C 217 C 177 C
Water Water

Slavneft, Yaroslavl, Russia
Compablocs – totally 5 units delivered in 2005
• 2 CPL75 Vac. residue / BFW
• 2 CPL50 VGO / BFW
• 1 CPL30 Metal. fraction / BFW

Fluid Catalytic Cracking, FCC
C4 and lighter
Steam
Main fractionator
Condenser
O’heads condenser
Reactor effluent
Flue gas Gasoline
Reactor
Distillate coolers
Regenarator and PAs
Gas Oil
e nt t
s
S p t al y
Ca Heavy Gas Oil
FCC mix
Clarified slurry oil cooler
Regenerated
Catalyst
FCC feed FCC bottoms cooler

Economical Study – Overhead condenser
Shell Sarnia, Canada
1st Stage – Heat recovery:

Overhead vapour 141  87°C
BFW 128  43°C
2nd Stage – Cooling:

Overhead vapour 87  29°C
Cooling water 45  24°C
Total recovered heat: 14 MW
Typical payback for 14 400 bbl/day FCC unit:

Installed cost for 8 CPs in HC $7.0 million
Annual savings in emissions: $1.1 million/year
Pay back ~ 15 months
Economical Study – Overhead condenser
Shell Sarnia, Canada
O’head vapour
286 °F (141 °C)
262 °F (128 °C)
Boiler feed water
110 °F (43 °C)
188 °F (87 °C)
113 °F (45 °C)

Cooling water
75 °F (24 °C)
84 °F (29 °C)

References – O’head Condensers

References – Condensers
Petrobras REPLAN refinery, Brazil
One Compabloc CP75
condenser installed after
the compressor.
Replaced the two S&Ts

on the right side.
Heat load: 8.3 MW
Material in Compabloc:
254SMO due to chlorides
in c.t.water
In operation 2005

References - Naphtha cooler
Petrobras REVAP refinery, Brazil
Duty:
Naphta 328 t/hr 48  36°C
C.T. water 138 t/hr 43  28°C
Heat load 2400 kW
Model CP75 with 200 plates

H.t. Area 130 m2
Plate material 254SMO
In operation since Nov. 2002

References – Clarified slurry oil cooler
Fuji Oil, Japan
Duty:
Clarified slurry oil 220  70 °C
Cooling water 38  28 °C
Heat load: 1.6 MW
Compabloc CP75 in titanium
In operation since 2001.

No cleaning so far!

Economical study – Slurry cooler
Total Mider, Leuna, Germany
Duty:
FCC Bottoms 163  65 °C
BFW 90  50 °C
Heat load: 1,8 MW
Original installation:
Two double-pipe exchangers
Cleaned 40 times during first year
Replaced by:
Two spiral heat exchangers,
each 148 m2 in AISI 316Ti
Start-up November 1998

No cleaning required so far!
Installed Cost = 360 kEUR

Annual savings in maintenance = 180 kEUR www.alfalaval.com
References – Bottom slurry cooler
BP Veba, Gelsenkirschen, Germany

No cleaning needed so far www.alfalaval.com
References – Bottom slurry cooler
Formosa Petrochemical, Mai Liao refinery, Taiwan
One SHE out of totally four

for cooling of FCC bottoms
Total heat load: 4.4 MW

No cleaning needed so far

Hydrocracking
Fractionator O’head
Hydrogen condenser
make-up Recycle gas
compressor
1st stage 2nd stage

reactor reactor HP
separator
Distillate coolers
and PAs
LP
separator
Reboiler
Reactor
effluent
Bottom fraction
Reactor
feed
Economical Study – PA cooler/steam generation
Major Refinery in Netherlands
Mid-pump-around (MPA) Superheated steam
221 ºC 215 ºC
Steam super-heating MPA 221  220 ºC

Steam 215  180 ºC
MPA 220 ºC Steam 180 ºC
MPA 220  186 ºC

Steam generation
Steam gen. 180  179 ºC
MPA186 ºC 179 ºC
MPA 186  181 ºC

Water heating
Water 179  120 ºC
MPA
181 ºC 120 ºC
Water
15 tons/hour of 9 bar steam produced. Totally 8.4 MW recovered.

Economical Study – PA cooler/steam generation
Major Refinery in Netherlands
Steam generator
Typical payback for 50 000 bbl/day hydrocracker Water pre-heater

Installed cost for 4 CPs $0.8 million
Annual value of steam $1.2 million/year ($10/ton)
Total
© Alfa Laval annual savings $1.8
Slide 40million /year www.alfalaval.com
Pay back ~ 5 months

HDT/HDS C3S and lighter
+H2S to gas
Fired O’head condenser sweetening
heater
Reactor
Stripper
Hydrogen
recycle Reflux
drum
Recycle gas Sour water

compressor
Wild naphtha
HP cooler
separator
Reboiler
Feed/effluent
heat exchanger Desulphurized
product cooler
Hydrogen
Feed recycle
© Alfa Laval Slide 41 Feed/bottoms www.alfalaval.com
Economical Study
Feed/Effluent heat exchanging - HDT
• Increased heat recovery in Feed/effluent Packinox heat
exchanger
Charge heater inlet temp – S&T option 305°C
Charge heater inlet temp – PKX option 350°C
 Heater duty lowered with 18 MW, annual energy savings of 5.5
MUSD, additional annual savings in emission of 1,5MUSD
• Reduced pressure drop in the reactor circuit
Pressure drop S&T option 18 bar (5 S&Ts in series)
Pressure drop PKX option 11 bar (1 PKX exchanger)
 Reduced compressor power consumption 1,5 MW, annual
savings of 0,7 MUSD
* Based on a HDS capcity of 100 000 bbl/day with a crude oil price of 40 USD/bbl, CO2 cost of 20
USD/ton, NOx and SOx cost of 1100 USD/ton and energy cost of 60 USD/MWh
Economical Study
Feed/Effluent heat exchanging – Gasoline HDT

exchanger, heater by-passed during normal operations, 8.3
MW saved
• Reduced steam boiler firing and increased steam demands
(stripper reboiler), total 2.6 MW lost
 Overall savings 5.7 MW, annual energy savings of 1.7 MUSD,
additional annual savings in emission of 0,4 MUSD
• Reduced H2 flow, reduced compressor power consumption
 Savings of 0.1 MW, annual savings of 50 kUSD
* Based on a HDT capcity of 100 000 bbl/day with a crude oil price of 40 USD/bbl, CO2 cost of 20
USD/ton, NOx and SOx cost of 1100 USD/ton and energy cost of 60 USD/MWh

Economical Study
Feed/Effluent heat exchanging – Gasoline HDT
3 S&Ts
Replaced by:
1 PKX heat exchanger

References – Overhead condenser
Tamoil refinery, Switzerland
Duty:
Fractionator o’heads cooled
by means of Reactor product
Heat load 4,5 MW
Two CPL75

Economical Study
Feed preheating/Bottoms cooling – high NTU
Diesel stripper feed / bottom exchanger

Bottoms 251 → 83 °C NTU = 6.04

Feed 215 ← 62 °C NTU = 5.5
Compabloc S&T
Number exchangers 3 parallel 4 in series
Number passes 16 (each side) 4 per S&T (tube side)
Pressure drop (Pa) 90 / 120 90 / 115 (tube / shell)
Shear - tau (Pa) 16 / 21 3.2 (tube side)
Total heat transfer area (m2) 770 3344

References – Stripper feed/bottoms
Tamoil refinery, Switzerland
Diesel product cooled by

means of Fractionator feed
Duty 3,4 MW
One CPL75

Alkylation - Sulfuric Acid process
Deisobutanizer Condensor
Depropanize Iso Butane
Depropanizer
r Condensor cooler
bottoms cooler
Feed/Bottoms Propane
cooler
Butane
cooler
Reboiler
Compressors Pumparound
Refrigerant
cooler
condensor
Reboiler
Recycled acid
5°C
Feed/Bottoms Alkylate
cooler
Settler
Reactor
Feed/Effluent
© Alfa Laval
Olefin feed Slide 48 www.alfalaval.com
Material Selection for Sulphuric Acid
Iso-corrosion diagram 0.1 mm/year
°C °C
Diabon
150 150
Hastelloy
D-205
100 100
Alloy G-30 Hastelloy
C-276
50 50
AISI 316 254 SMO

AISI 316
0 0
0 10 20 30 40 50 60 70 80 90 100%
References – Reactor feed pre-cooler
ExxonMobil, Baton Rouge, LA, USA
Duty:
Olefin 38  10 ºC
Reactor product 33  4.5 ºC
Two Compablocs in AISI 316L material installed in 2005

References – Reactor feed pre-cooler
Reliance, Jamnagar, India
Duty:
Reactor Feed 1400 t/h 38  19 ºC

Reactor Effluent 1300 t/h 30  8.5 ºC
Eight Compablocs in AISI 316L material sold in 2006

References – DIB feed preheater
Duty:
Heating of alkylation mix (iso-
butane + gasoline) by means of
1st Step: Gasoline

2nd Step: Steam condensate
Two Compablocs in Alloy C276

(Alkylation mix contains 15%
H2SO4) replaced S&Ts

Catalytic Reforming
Fired Fired Fired
Reformate overheads
heater heater heater
Reactor
Stabilizer
Condenser
Reactor
Reactor
Reactor
Cooler
Recycle gas
compressor
Feed/effluent
heat exchanger
Reboiler
HP
separator
Reformate
cooler
Hydrogen
Feed recycle
© Alfa Laval Slide 53 Feed/bottoms www.alfalaval.com
Economical Study
Feed/Effluent heat exchanging – Fixed Bed CRU S&T

Economical Study
Feed/Effluent heat exchanging – Fixed Bed CRU PKX

Economical Study
Feed/Effluent heat exchanging – CRU
• Reduced size and weight
Weight & Size S&T option: 2 S&Ts, 160 tons, 26 m height, 1.7 m ø
Weight & Size PKX option: 1 PKX, 85 tons, 19 m height, 2.5 m ø
 Same installed cost (around 2.2 MUSD)
exchanger
Hot Approach Temperature – S&T option 58°C
Hot Approach Temperature – PKX option 43°C
 Heater duty lowered with 1,1 MW, annual energy savings of
350 kUSD, additional annual savings in emission of 90 kUSD
* Based on a CRU capcity of 20 000 bbl/day with a crude oil price of 40 USD/bbl, CO2 cost of 20
USD/ton, NOx and SOx cost of 1100 USD/ton
References – Reactor feed/effluent
Shell Berre refinery, France
• Installation:
12 (2*6) horizontal S&TS
replaced by 1 vertical PKX
• Heat recovery:
Hot Approach Temperature
increased from 60 to 25°C
• Pressure drop:
Reduced from 4 to 1,3 bar
• Throughput:
Increased with 33% In operation since 1987
References – Reactor feed/effluent
Major refinery in Middle East
One Alfa Laval Packinox heat

exchanger replaced 12 S&Ts
High performance heat recovery

and hydraulics increased
throughput with 50% while
retaining all existing ancillary
equipment, such as heaters and
compressors.
The investment was paid off

within months

References – Stabilizer
BP Bulwer Island, Australia - Benzene saturation unit
One CPL50 for interchanging

light reformate / splitter o’head
vapour
One CPK40 for reformate
splitter o’heads condensing
One CPL75 installed as reboiler

Reference list
Example of world-wide installations
End customer Country Process Duty Year
BP Brisbane Australia Benzen sat Stripper feed/o’heads 04
O’heads cooling 04
Stripper reboiler 04
BP Germany HC slop cooling 06
PCK Schwedt Germany Solvent reform Interchanger 95
Solvent cooling 95
Toa Oil Japan ARU/SEU splitter Presplitter ohead cond 03
NK stripper Splitter ohead cond 03
Ukrtatnafta Ukraine Stripper condenser 02
Gasoline cooling 06
Stabilizer oheads cond 06

Isomerization
Fractionator/Stabilizer Condensor
• Deisobutanizer or Light
isomerate
• Deisopenatnizer or
• Deisohexaniser
Fractionator
feed Pumparound
cooler
Reboiler
Heavy isomerate
cooler
Isomerate from
Feed/Bottoms
reactor
References – Stabilizer
Shell Geelong Hysomer de-isopentaniser, Australia
< 1% benzene
40°C
30% benzene
SW @ 40°C
Deisopentiser
Light platformate
@ 85°C
Platformate 124,3°C SW
(7-9% benzene ) BFW
@ 85°C 119,5°C Steam
Hot water cooler

SW
Heavy platformate
@ 165°C 95°C
220°C MP Condensate cooler
SW
Reference list
End customer Country Process Duty Year
Lukoil Bulgaria Butane Propane condensing 05

Propane/Butane cond 05
PCK Germany Pentane/Hexane Caustic heater 95
ENI Taranto Italy Butane Isopent condensation 04
Yukos Russia Pentane/Hexane Pentane reboiler 06
Pentane reboiler 06
Repsol Spain Butane Feed/product interch 06
Preem Sweden Pentane/Hexane Caustic heater 04

Hydrogen - Steam reforming
Feedstock purification Steam reforming Shift conversion
Steam
HTS LTS
Hydrocarbon feed
Hydrogen to PSA process Process condensate

Methanation www.alfalaval.com
© Alfa Laval CO2 removal
Slide 64
Reference – Syngas cooler
Petroplus, Cressier, Swítzerland
• One CPL50 in 254 SMO is sold as HTS effluent

cooler.
• Delivered in 2003

Hydrogen - Pressure Swing Adsorption
Ultra pure hydrogen gas
Purge gas
Syngas feed

Reference – Trim gas condensers
Total, Vlissingen, Netherlands
• One CPL50 in 316L is sold as PSA feed gas cooler.

Delivered in 2004
• One CPL50 in C276 is sold as PSA feed gas cooler
Delivered in 2006

Delayed Coking process
Gas +
gasoline
Vapour: Steam, gas, naphtha, gas oils
Gas
Unstabilised
naphtha
Coke drum
Coke drum
Fractionator
Stripper
Furnace Gas oil to
FCC or
hydrocracker
Pump
around
Atmospheric or vacuum residue

Coke

Visbreaking process
Gas +
gasoline
Gas
Naphtha or
gasoline
Fractionator
Stripper
Reactor
Furnace
425-
500°C
Gas oil
Quench
Atm or vacuum residue
Visbroken residue (tar, fuel oil)

Economical study – Visbreaker bottoms cooler
Duty:
Visbroken residue 210 m3/hr 370  181 ºC P.D. 541 kPa
Atmospheric residue 310 m3/hr 244  115 ºC P.D. 808 kPa
Heat load: 20.8 MW
12 S&Ts with severe fouling problems – cleaning in hot end needed every 2
months
Extremely fouling duty due to coke formation and presence of asphaltenes
Replaced by:
8 SHEs in successful operation since January 2001.
No cleaning required so far!
Installed Cost = 2 200 kEUR

Annual savings in maintenance, heat recovery
and
© capacity = 1 100 kEUR
Alfa Laval Slide 70 www.alfalaval.com
Economical study – Visbreaker bottoms cooler
12 S&T replaced by 8 SHEs with shorter residence time, avoiding coke formation

Reference list – Bottoms cooler
End customer Country Unit type Licence Year
Lukoil Bourgas Bulgaria 8 SHEs 2001

Lukoil Ukhta Russia 3 SHEs 2006
Lukoil NNOS Russia 12 SHEs FW 2006
Lukoil Odessa Ukraine 4 SHEs Axens 2007
Due to the success of the Bourgas installation, Lukoil has now specified the
use of Alfa Laval SHEs for the Visbreaking bottoms cooling for all their
Visbreaking units.

Reference list - Feed preheater
End customer Country Unit type Year
Lukoil NNOS Russia 1 CPL75 2006

Lukoil Odessa Ukraine 1 CPL75 2007

Propane Deasphalting
Recovered propane
LP MP
Steam Steam Steam
Deasphalter
Steam
Vacuum
residue
Stripper
DAO to lube oil plant
PDA to asphalt process,

FCC or coker

Asphalt oxidation process
Oxidation column
Hot air
Hot
oil
Oxidised bitumen
Hot
oil Oxidised bitumen
to storage (asphalt)
Bitumen feed (vacuum residue)

References – Product/Feed interchanger
Nynas Petroleum, Gothenburg, Sweden
ty:
idised bitumen 265  230 ºC
umen feed 220  170 ºC
umen feed = Vacuum residue
ne Compabloc cleaned by CIP

ce every year

References – Product/Feed interchanger
Simosa bitumen refinery, Taiwan
Duty:
Bitumen product 220  170 °C
Vacuum residue 190  165 °C
Heat load 1500 kW
One Compabloc
No cleaning needed
so far!!

Reference list – Product/Feed
User Country CPs Year
OMV Austria 3* CPK40 05
Paramo Czech 1*CPL50 05
BP France 4*CPL75 03
MBW Germany 1*CPL50 05
Raff Gdanska Poland 2*CPL75 04
Salavatnefteorgsyntez Russia 2*CPL50 & 2*CPL75 05
Slavneft Russia 1*CPL75 01
Nynäs Sweden 2*CP50 93 & 03
FPCC Taiwan 1*CP75 00

References – Feed heater
Nynas Petroleum, Gothenburg, Sweden
Duty:
Hot oil 230  270 ºC
Bitumen feed 170  220 ºC
Bitumen feed = Vacuum residue
One Compabloc cleaned every

hree years by means of CIP

Reference list – Feed heater
User Country CPs Year

Paramo Czech 1*CPL30 316L 06
MBW Germany 1*CPL50 316L 05
Falconara Italy 11*CPL30 316L 05
Raff Gdanska Poland 5*CPL50 316L 04 & 05
Raff Jaslo Poland 2*CPL75 316L 05
Salavatnefteorgsyntez Russia 2*CPL30 & 2*CPK40 05
Tjeljabinsk Russia 2*CP75 99
Nynäs Sweden 1*CP30 93

Solvent-extraction
Solvent
Solvent
Solvent
Extract solvent evaporator
Raffinate distillation
contractor
Rotating disc
evaporator
Raffinate solvent
Extract +
Solvent
Raffinate +
solvent
Extract +
Solvent
Raffinate product
Extract product
References - Lube Oil
Mineraloel-Raffinerie Dollbergen, Germany

References - Lube Oil
Mineraloel-Raffinerie Dollbergen, Germany
23 Compablocs for:
• Distillate duties
• Raffinate duties
• Extract duties
• Solvent duties
• Liquid/liquid
• Condensing
• Reboiling

References - Motor Lube Oil
ExxonMobil Baytown, TX, USA
Raffinate
Hydroconversion Unit
Duty:
Raffinate product
Raffinate feed
Heat load 2,2 MW

De-waxing
Solvent
Rotary filter
Slack wax evaporator

Dewaxed oil evaporator
Filtrate
Dewaxed lube
Stack wax
Solvent
Lube feed
References - Dewaxing solvent reboiler
H&R Salzbergen, Germany
Reboiling/evaporation of oil and solvents in two Compablocs

References - Dewaxing solvent condenser
Water side of a Compabloc

used as methylene chloride
condenser in the solvent
recovery section of the
paraffing recovery plant in
the lube oil process, 12-15
months of operation.

References - Dewaxing solvent condenser
Same Compabloc after

cleaning with high pressure
water jet. Cleaning takes
8-10 hours and cost around
2500 EUR
Cleaning of original
installation, 3 S&Ts with total
HTA of around 400 m2,
required 2-3 days and cost
around 20 000 EUR.

Gas Sweetening process
Purified gas CO2/H2S + H2O
Absorption column CO2/H2S
Stripper column
Condensate
Lean liquor
Rich
liquor
Sour gas

References – Lean/Rich interchangers
Sarlux refinery, Sardinia, Italy
Duty:
Lean Selexol 36  18,7°C
Rich Selexol 31,9  15,1°C
Heat load 8 MW
Totally 14 Compablocs in 316L

installed
Start-up in 1999
Service of one CP in 2005

No service required of the other 13
CPs since start-up.

Sarlux refinery, Sardinia, Italy
Heat Transfer Surface before and after chemical cleaning

Motivia Delaware, USA
• 2 CPL75/400 & 2 CPL50/300 in series

– Improved energy recovery
– Size constraints
– Lower installed cost

References – Stripper reboiler
Syzran refinery, Russia
Duty:
Steam 170°C
15% MEA reboiling 127°C
Heat load 4 MW
Totally 2 Compablocs in
316L installed
Start-up in February 2002

References – Partial reflux condenser
Syzran refinery, Russia
Duty:
H2S + H2O cond 115°C@
2.1 bara -> 40°C
Cooling water
Heat load 1,7 MW
One Compabloc designed

as a top mounted partial
reflux condenser
Start-up in February 2002

Sour water stripping
H2S and NH3 H2S and NH3
Overhead
To disposal
condenser CW
Condensate
Sour water Feed surge

tank
Stripper
Sour water Treated

water
Steam
CW
Treated water
Treated water to
waste water
© Alfa Laval Slide 95 treatment plant www.alfalaval.com
References – Sour/Stripped interchanger
Eni Gela refinery, Italy
Heat load: 2.6 MW
Original installation needed

cleaning every 12 days
The 6 Compablocs are in

operation since early 2004
They require cleaning every
12 weeks

Service - Sour/Stripped interchanger
Petrobras, REVAP refinery, Brazil
Hot side inlet Cold side outlet
Before
cleaning
After CIP
cleaning with
NaOH and
H3PO4

References - Stripper Condenser
Petrobras, REPLAN refinery, Brazil
Heat load: 15 MW
Original installation was

corroding and underperforming
Compabloc in Titanium
replaced S&T

Service - Stripper Condenser
Petrobras, REPLAN refinery, Brazil
HP water jet cleaning was needed after 4 years of

operation due to sand particles on cold side.
Before After HP water

cleaning jet cleaning

References – Stripper Reboiler
Holborn Europa Refinery, Germany
Duty:
Steam 144 ºC
Sour water reboiling 117 ºC
Total heat load: 6 MW
Two Compablocs in Titanium
In operation since Dec. 2001

Alfa Laval Refinery

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Alfa Laval Refinery

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General Refinery Overview Gas plant

Desalting Cat. reforming Gasoline treatment Aromatics

Gas oil hydrotreating FCC Alkylation

Gas oil Lube treating

Heavy fuel oil

© Alfa Laval Deasphalting

Feed water, 30-40°C

Feed water, 120°C Cooling water

Desalter water to treatment, 30°C

Desalter water, 50°C

© Alfa Laval Slide 2 www.alfalaval.com

10 102 103 104 105 ppm chlorides

Three Compablocs in C276 replaced six S&Ts with corrosion problems

In operation since 1997

Wash water Brine sludge Brine @ 290°F

Recycle Brine Make-up water Brine @

Recycle Brine CW @ 80°F

© Alfa Laval Slide 6 www.alfalaval.com

One out of two

© Alfa Laval Slide 7 www.alfalaval.com

~25-175°C Heavy Naphtha

Preheated Crude oil

Total savings -3 641 547 USD/year

1st stage – BFW preheating:

2nd stage – Crude preheating:

Total recovered heat: 16.5 MW

In operation since 1997

Typical pay back for 50 000 bbl/day crude preheat train:

Pre-fractionator o’heads 180  100 °C

Total heat recovered: 1.8 MW

Two CP50 in titanium

In operation since spring 2003

Crude oil / diesel exchanger

Diesel 173  88 °C NTU = 2

Total heat transfer area (m2) 70 400

* Allowable pressure drops cannot be be utilised. www.alfalaval.com

75,000 bbl/day Crude Train Compabloc S&T

© Alfa Laval Slide 13 www.alfalaval.com

All Compabloc positions are preheating the crude by using

© Alfa Laval Slide 14 www.alfalaval.com

HVGO 298  271 °C

Crude = mix of Mexican Mayan and

In operation since 2004

Typical payback for 80 000 bbl/day crude preheat train:

Performance since March 05 until October 06

Heat load 7000 kW

HTA:  > 1000 m2 HTA: 170 m2

Conventional vs increased heat recovery

© Alfa Laval In continuous operation since Slide

• Gas oil cooling

Original S&Ts needed cleaning every

Total maintenance cost reduction: Three Compablocs for cooling of gasoline

Four spiral heat exchangers will

© Alfa Laval Slide 22 www.alfalaval.com

Compablocs – totally 13 units delivered in 2005

• 2 CPL75 + 4 CPL50 Vac. residue / atm. residue

• 1 CPL75 Metal. fraction / atm. residue

• 2 CPL75 + 2 CPK40 VGO / atm. residue

• 2 CPL50 Lt vac. distillate / atm. residue

© Alfa Laval Slide 24 www.alfalaval.com

Heat load: 600 kW recovered

One CP40/160 in 316L, HTA 27 m2

Test period: November 1999 - May 2000