Advanced Fouling Management through Use of HTRI SmartPM: Case Studies from Total Refinery CDU Preheat Trains

Heat exchanger fouling is a persistent problem contributing to process economics, plant capacity, environmental concerns, and safety. Advances in research on hydrocarbon fouling have changed the impact of fouling in crude refinery operations, through the use of rigorous performance monitoring and process optimization methods, use of fouling predictive models, use of fouling mitigation technologies (e.g., use of tube inserts), etc. This work presents case studies from two TOTAL refineries preheat trains where the exchangers are subject to fouling. TOTAL has implemented performance monitoring and predictive maintenance software (HTRI SmartPM (TM)) throughout their refineries to improve existing fouling management practice. The software performs advanced data reconciliation, including simulation of detailed exchanger operational data using HTRI shell-and-tube heat exchanger calculation methods and inferring fouling resistance for individual shells for shells-in-series based on dynamic fouling behavior. Dynamic fouling models are used to assess the impact of fouling on the overall network performance. Several heat exchangers in the network have tube inserts (Turbotal (R) and Spirelf(R) inserts from Petroval), and their performances are monitored and predicted. The case studies demonstrate successful implementation of SmartPM software in TOTAL Normandy and Grandpuits refineries, enabling economically feasible, technically viable, and environmentally desirable decision-making for refinery operation.