Oil Fouling Research Articles

Refinery Pre-Heat Train Network Simulation Undergoing Fouling: Assessment of Energy Efficiency and Carbon Emissions

Fouling in crude preheat trains in oil refineries causes additional fuel and production costs, operating difficulties, CO2 emissions, and safety issues. Crude oil fouling deposition mechanisms are still not well understood. Current exchanger design methodologies (based on empirical fouling factors), operating practices, and mitigation solutions (ranging from the use of chemical additives to tube inserts) do not prevent efficiency losses or disruption of operations. Moreover, current analysis and design methodologies neglect local effects and dynamics of fouling, in favor of lumped, steady-state, “averaged” heuristic models. In this paper, a dynamic and distributed model recently developed that accounts for localized fouling growth as a function of process conditions is used to simulate the dynamic behavior of the hot end of a refinery preheat train. The network is simulated by a simultaneous solution of all exchangers, combined according to a desired configuration, within gPROMS, a commercial dynamic simulation environment. The overall network model allows capturing some complex interactions within the network over time and enables the rigorous computation of several key indicators which are highly dependent on fouling. These include throughput reduction, additional energy requirements, and overall economic and CO2 emission impacts.

Fouling in Crude Oil Preheat Trains: A Systematic Solution to an Old Problem

A major cause of refinery energy inefficiency is fouling in preheat trains. This has been a most challenging problem for decades, due to limited fundamental understanding of its causes, deposition mechanisms, deposit composition, and impacts on design/operations. Current heat exchanger design methodologies mostly just allow for fouling, rather than fundamentally preventing it. To address this problem in a systematic way, a large-scale interdisciplinary research project, CROF (crude oil fouling), brought together leading experts from the University of Bath, University of Cambridge, and Imperial College London and, through IHS ESDU, industry. The research, coordinated in eight subprojects blending theory, experiments, and modeling work, tackles fouling issues across all scales, from molecular to the process unit to the overall heat exchanger network, in an integrated way. To make the outcomes of the project relevant and transferable to industry, the research team is working closely with experts from many world leading oil companies. The systematic approach of the CROF project is presented. Individual subprojects are outlined, together with how they work together. Initial results are presented, indicating that a quantum progress can be achieved from such a fundamental, integrated approach. Some preliminary indications with respect to impact on industrial practice are discussed.

A Dynamic, Distributed Model of Shell-and-Tube Heat Exchangers Undergoing Crude Oil Fouling

Fouling in refinery preheat trains causes major energy inefficiencies, resulting in increased costs, greenhouse gas emissions, maintenance efforts, and safety hazards. Fouling deposition is not well understood, and current exchanger design and monitoring practices neglect the local effects and dynamics of fouling, in favor of lumped, steady-state, heuristic models (e.g., Tubular Exchanger Manufacturers Association (TEMA) fouling factors). In this paper, a dynamic, distributed model for a multipass shell-and-tube heat exchanger undergoing crude oil fouling is proposed. The model calculates fouling rates as a function of local conditions and time. It accounts for heat exchanger geometry, variation of oil physical properties with temperature, local accumulation of fouling deposits, and their structural change over time (aging). The interaction between fouling growth and fluid dynamics inside the tubes is accounted for by solving a moving boundary problem. Moreover, a procedure to analyze refinery data and support the estimation of a set of model parameters has been established. The model is validated using data from an ExxonMobil refinery and shows excellent agreement (less than 2% error) with primary plant measurements even when it is tested for its predictive capabilities over long periods (i.e., 1 year). It is concluded that the model can be used with confidence to identify and predict the fouling state of exchangers, to assess economic losses due to fouling, to support operating decisions such as planning of cleaning schedules, and to assist in the design and retrofit of heat exchangers.

Fouling thresholds in bare tubes and tubes fitted with inserts

Maya crude oil fouling reveals a straightforward dependency of initial fouling rate on surface temperature but a rather complex dependency on velocity in bare tubes, the initial fouling rate showing a maximum and then decreasing significantly towards zero as the velocity is increased. Surface shear stress clearly is an important parameter. CFD simulation of fluid flow in a tube fitted with a hiTRAN® insert reveals a complex distribution of surface shear stress. To compare the insert situation with the bare tube, an equivalent velocity concept is introduced on the basis that at a given average velocity the fluid flow results in the same average wall shear stress regardless of whether the tube is bare or is fitted with an insert. Using the equivalent velocity concept, the fouling data obtained using both a bare tube and a tube fitted with inserts can be correlated using a single model. Moreover, the fouling threshold conditions below which fouling is negligible, can be predicted for both situations.

Effects of fouling on performance of retrofitted heat exchanger networks: A thermo-hydraulic based analysis

The energy recovery performance of crude pre-heat trains (PHTs) in oil refineries is typically impaired by deposition over time of fouling on the thermal surfaces. Such time varying effects are normally not considered in the design or retrofit of heat exchangers networks. In this paper, the importance of taking into account such effects is demonstrated, by means of a case study. An existing industrial PHT network is simulated using a dynamic, distributed mathematical model for shell-and-tube heat exchangers undergoing crude oil fouling. To systematically assess the impact of fouling at the network level, several key performance indicators are proposed and used to analyse three retrofit options aimed at maximising overall heat recovery. Simulation results show that network designs that maximise energy recovery at steady state are not the best when fouling occurs. It is concluded that a proper retrofit design must include consideration of time varying fouling effects.

Crude Oil Fouling: A Review

Fouling in crude preheat train heat exchangers in refineries is a complex phenomenon. Crude oil fouling undergoes different mechanisms at different stages of preheating. Understanding the fouling mechanisms is essential in formulating appropriate fouling mitigation strategies. The use of the concept of threshold fouling conditions is one of the approaches for mitigating fouling through operating conditions. In this study, an attempt has been made to review the various fouling models available in literature, their advantages and limitations.

Impact of deposit aging and surface roughness on thermal fouling: Distributed model

AbstractA kinetic model was recently proposed to describe the effect of aging on deposit thermal conductivity and the thermal performance of a shell‐and‐tube heat exchanger undergoing crude oil fouling. The model is adapted for implementation within a dynamic, distributed system with spatial and temporal distributions, relaxing several of the previous assumptions. The evolution of surface roughness is also considered, using conjectural linear and asymptotic functions. Simulations are performed for a single tube representative of a refinery exchanger. The results demonstrate the substantial effects over time of aging and roughness on heat transfer and pressure drop. Roughness effects yield apparently negative initial fouling resistances, as reported in some experimental tests. The importance of accounting for roughness dynamics in short time scale pilot plant scale tests and aging over longer time scales in industrial applications is highlighted. © 2010 American Institute of Chemical Engineers AIChE J, 2010

Evaluation of the anti-fouling properties of nm thick atmospheric plasma deposited coatings

Both organic and inorganic fouling are significant problems for stainless steel surfaces used in industrial applications as diverse as shipping and paper making. The objective of this study is to evaluate the anti-fouling properties of a range of fluoropolymer, fluorinated and non-fluorinated siloxane coatings on stainless steel substrates. These nm thick coatings were deposited using the atmospheric plasma jet system called PlasmaStream™. The surface properties of the plasma polymerised coatings were examined using optical profilometry, SEM–EDX, ellipsometry, contact angle measurement and FTIR. Accelerated wear testing of the coated heat exchangers indicated that coating durability was a significant issue for the nanometre thick coatings investigated. A crystallization fouling study was carried out using a laboratory scale heat exchanger test apparatus. In this the heated steel surface was in contact with flowing fluid containing CaCO 3 particles. The coated steel exhibited both a delay before fouling was initiated and in addition a decrease in the fouling rate. A lubricant oil fouling study was also carried out involving a comparison between both coated and uncoated stainless steel separator discs over a 30 day period, in the engine of a passenger ferry. A significant reduction in the level of oil fouling was observed for the fluorosiloxane and fluoropolymer coated separator discs compared with the uncoated discs.

Crude Oil Fouling in a Pilot-Scale Parallel Tube Apparatus

Maya crude oil fouling reveals a seemingly straightforward dependency of initial fouling rate on surface temperature, but a maximum is found in the initial fouling rate–velocity relationship, which mirrors that found in a model chemical system of styrene polymerization. The linear dependency of the logarithm of the pre-exponential factor on apparent activation energy for the crude oil is also found in the styrene system. The apparent activation energy for the crude oil ranged from 26.4 kJ/mol at 1.0 m/s to 245 kJ/mol at 4.0 m/s. Such strong dependencies of apparent activation energy on velocity, even at high velocity, are consistent with Epstein's mass transfer reaction attachment model. Surface temperatures at which the fouling rate becomes velocity independent are 274°C and 77°C for Maya crude oil and styrene, respectively. For surface temperatures in excess of this isokinetic temperature, an increase in velocity would lead to an increase in the rate of fouling.

HiTRAN® Wire Matrix Inserts in Fouling Applications

Fouling characteristics are dictated largely by the properties of the thermal and hydrodynamic boundary layers. As a result, fouling mitigation strategies must take into account the conditions in this region. hiTRAN wire matrix tube inserts are a useful tool in altering the conditions near the tube wall, especially in the laminar and transition flow regions. This review article considers particle image velocimetry and laser doppler velocimetry measurements, which were employed in order to show the hydrodynamic differences between plain tubes and those containing inserts. Measurements indicate that the wall shear rate in tubes containing hiTRAN inserts operating in the laminar flow regime is similar to that for plain bore tubes operating in the turbulent flow regime. Moreover, the increased tube-side heat transfer coefficient that results from the reduction of the thermal boundary layer allows operation with smaller Effective Mean Temperature Differences (EMTDs). This enables the designer to reduce the tube wall temperature to a level below the fouling threshold temperature, e.g., to combat crude oil fouling. The results from the laser analyses into the hydrodynamic boundary layer are backed up by recent research data investigating the effect of hiTRAN inserts on sedimentation and particulate fouling. The thickness of the fouling layer was measured by applying a combination of photographic and laser measurement techniques. The results are compared to plain tube data and are reported as a function of both flow rate and hiTRAN insert packing density. The impact of altering the hydrodynamic and thermal conditions near to the wall is subsequently demonstrated for different fouling mechanisms. Studies of the impact of hiTRAN inserts on biological and chemical reaction fouling in crude oil processing are also reviewed. A better understanding of the threshold shear rates and wall temperatures for different fouling mechanisms is required for any study into the impact of fouling. Combining this knowledge with the principles outlined in this article clearly emphasizes the benefit of using hiTRAN wire matrix inserts as a powerful tool to mitigate fouling.

Observation of an Isokinetic Temperature and Compensation Effect for High-Temperature Crude Oil Fouling

The initial fouling rates of four crude oils were determined at a nominal bulk temperature of 315°C, an initial heated wall shear stress of 13 Pa, and initial surface temperatures between 375 and 445°C. These initial fouling rates ranged from 1.3(10− 6) to 7.8(10− 5) m2 K/kJ. Corresponding Arrhenius plots were linear with the initial fouling rates passing through an isokinetic temperature of 407.5°C. A plot of the natural logarithm of the pre-exponential factors [7.6(104)–5.2(1015) m2 K/kJ] versus the apparent activation energies (128–269 kJ/mol) was also linear, confirming the validity of the isokinetic temperature and the presence of the compensation effect. Below the isokinetic temperature, the relative fouling rates were Crude Oil C > Crude Oil A > Crude Oil D > Crude Oil B; above the isokinetic temperature, the relative fouling rates were reversed (Crude Oil B > Crude Oil D > Crude Oil A > Crude Oil C). Chemical characterization of a fouling deposit suggested that the dominant fouling mechanism at these conditions was coking, with significant contributions from sedimentation (iron sulfide) and corrosion (∼ 340 μ m/yr) of the 304 stainless steel test material.

Fouling During the Use of “Fresh” Water as Coolant—The Development of a “User Guide”

IHS ESDU recently published its latest “User Guide” to fouling in heat exchange systems, for systems with fresh water as the coolant. ESDU 08002 is the third in a group, following the development of the Crude Oil Fouling User Guide (ESDU 00016) and the Seawater Fouling User Guide (ESDU 03004). ESDU 08002 was developed by IHS ESDU over a period of 5 years under the guidance of the Oil Industry Fouling Working Party, a collaborative team of oil refiners, heat transfer equipment and services suppliers, and universities. It provides designers and operators of cooling-water facilities with a practical source of guidance on the occurrence, the mechanisms, and the mitigation of freshwater fouling in these systems. IHS ESDU's Oil Industry Fouling Working Party was formed in recognition of the huge economic and environmental importance of heat exchanger fouling and the potential benefits that can accrue from better understanding of mitigation strategies. Work is now underway on reboiler and FCCU fouling. The development of the User Guide ESDU 08002 is discussed in this article and its technical content is summarized.

Visualization of fouling and diffusion behaviors during hollow fiber microfiltration of oily wastewater by ultrasonic reflectometry and wavelet analysis

Oil fouling during crossflow microfiltration of oily wastewater using a single hollow fiber membrane filtration module as outside-in conformation was analyzed experimentally by ultrasonic reflectometry and wavelet transform in real time. Three 10 MHz ultrasonic sensors mounted along the tubular test module were utilized to monitor the fouling profile of the hollow fiber membrane. Results showed that the instantaneously rapid flux decline at the onset of fouling was caused mainly by concentration polarization and the fast oil adsorption on the lower part of the hollow fiber near the inlet of the membrane module. Further, wavelet analysis of the ultrasonic spectra revealed that the amount of oil deposited on the lower part of the hollow fiber near the inlet of the membrane module was more than those on the other parts of the hollow fiber due to the inertial impaction of oil droplets and local shell-side hydrodynamic effects. Moreover, the oil diffusion behavior (the relaxation and disappearance of the fouling layer) was also visualized by ultrasonic reflectometry in real time after the microfiltration system was shut down. The flux decline data and SEM micrographs corroborated the ultrasonic measurements and wavelet analysis. Overall, this technique will provide a useful and quantitative approach to the on-line assessment of fouling remediation and cleaning strategies of hollow fiber membranes.

Treatment of stable oil/water emulsion by novel felt-metal supported PVA composite hydrophilic membrane using cross flow ultrafiltration

The novel felt-metal supported PVA composite hydrophilic ultrafiltration membrane was used for the treatment of oil/water(O/W) emulsion. The effects of transmembrane pressure(TMP), cross flow velocity, feed concentration on membrane performance were investigated, and ultrasonic cleaning of the fouled membrane was also investigated. The results show the flux increases with the increase of cross-flow velocity and TMP within the given TMP range from 0.20 MPa to 0.40 MPa. With increase of initial oil concentration increases, the oil rejection increases while the permeate flux decreases. The composite membrane shows more than 90% oil rejection within the initial oil concentration range from 0.05% to 0.50% (mass fraction) at TMP of 0.30 MPa. The fouling of the composite membrane increases rapidly during the initial 20 min at given TMP range from 0.20 MPa to 0.40 MPa, and it increases slowly after 30 min. The results also show that ultrasound is very effective in removing oil fouling of the fouled membrane, and the properties of the composite ultrafiltration membrane can be completely recovered by 10 min of sonication.

Effective factors in the treatment of kerosene–water emulsion by using UF membranes

The effects of different parameters including membrane type (regenerated cellulose and polysulphone), transmembrane pressure (TMP), the content of oil in the feed, the flow velocity of the feed and pH on the ultrafiltration of an emulsion of kerosene in water were studied. It was found that the important factors affecting ultrafiltration were, in order, membrane type, pressure and oil concentration. The greatest flux at the optimum conditions here of 3 bar, an oil content of 3% (v/v) and with membrane type C30F was predicted as 108 L/(m 2 h) that was within the range of the confidence limit of the measured value of 106 L/(m 2 h). The normalised FTIR results of the virgin cellulosic membranes C30F and C100F showed more abundant OH groups. The bigger number of OH groups implies a greater hydrophilicity. The larger observed flux in the C30F is related to a higher number of pores as well (surface porosity) compared with the C100F membrane. In the “polarised regime” from 3 bar upwards, flux was independent of pressure for all membranes and was assumed to be determined by the back diffusion transport. Despite the fact that both the PS100H and C100F membranes had the same cut-off (100 kg/mol), the hydrophilic C100F showed a superior permeate flux. The strongest drop of flux with time due to oil fouling was observed for the C100F although it was hydrophilic. In the case of the PS100H, both FTIR and SEM showed that cake layer formation was not the cause of fouling. Meanwhile the SEM and FTIR results of fouled C100F provided evidence of adsorptive and gel formation fouling.

Industry-Recommended Procedures for Experimental Crude Oil Preheat Fouling Research

Of all heat transfer research arenas, few have the investment return potential of crude oil fouling mitigation. However, crude oil fouling is a very complex phenomenon that occurs via the simultaneous activity of multiple mechanisms. Advances in this field of research are complicated further by the lack of standardized procedures, which would permit unequivocal comparisons of non-proprietary data. As a result, Heat Transfer Research, Inc. formed the Crude Oil Fouling Task Force (COFTF), which is composed of heat transfer experts from many of the world's leading energy companies. The principle endeavor of the COFTF is to ensure that crude oil fouling research is both standardized and industrially relevant. The COFTF recommendations are detailed in this paper.

Application of Threshold Model with Various Tube Wall Temperatures for Crude Oil Preheat Train Fouling

The Propose of this paper is to introduce a new model for crude oil fouling in preheat trains of crude distillation unit. The experimental results of Australian light crude oil with the tube side surface temperatures between 200-260 o C and fluid velocity ranged 0.25 to 0.4m/s were used. The activation energy of chemical reaction depends on the surface temperature has been calculated. The model includes two parts. In the first part it deals with a term for fouling formation and the second part with a term for fouling removal due to chemical and tube wall shear stress respectively. By using the proposed model for Australian crude oil based on Saleh et.al.data the fouling formation rate has been calculated and the threshold curves to identify fouling and no fouling formation zones have been drawn. Finally, a model was developed for various temperatures and shows better results in relation to available models.

Extraction of Crude Oil Fouling Model Parameters from Plant Exchanger Monitoring

Most of the semi-empirical “threshold fouling” models for crude oil fouling in shell-and-tube exchangers have been developed and validated using data collected at what may be considered to be “point” or localized conditions. In practice, both velocity and wall temperature can vary significantly within a heat exchanger, leading to difficulty in applying the models in exchanger design and extracting fouling information from exchanger performance monitoring. A partial simulation model is presented here, incorporating a linear temperature distribution. This short-cut model is compared with a more detailed simulation in order to establish its reliability. Pressure drop using a smooth layer model is also considered. The short-cut approach is employed in a data reconciliation study of an operating crude preheat train, which indicates that the original threshold fouling model of Ebert and Panchal gives a better description of the observed fouling behavior.

Modeling of crude oil fouling in preheat exchangers of refinery distillation units

The aim of this paper is to propose a new model for crude oil fouling in preheat exchangers of crude distillation units. The experimental results of Australian light crude oil with the tube side surface temperature between 200 and 260 °C and fluid velocity ranged 0.25–0.4 m/s were used [Z. Saleh, R. Sheikholeslami, A.P. Watkinson, Heat exchanger fouling by a light australian crude oil, in: Heat Exchanger Fouling and Cleaning Fundamentals and Applications, Santa Fe, 2003]. The amount of activation energy depends on the surface temperature has been calculated. A new model including a term for fouling formation and a term for fouling removal due to chemical and tube wall shear stress was proposed, respectively. The main superiority of the model are independent to Pr number, thermal fouling removal and determination of β based on experimental tests. Finally using the proposed model the fouling rate of Australian light crude oil has been calculated and the threshold curves to identify fouling and no fouling formation zones have been drawn.

Chronic oil pollution harms Magellanic penguins in the Southwest Atlantic

Petroleum pollution is a problem for seabirds along the Southwest Atlantic coast. Twenty-five groups from Salvador, Brazil (12°58′S) to San Antonio Oeste, Argentina (40°43′S) survey or rehabilitate sick or oiled seabirds. Four groups, one each in Brazil and Uruguay, and two in Argentina, kept counts of birds found alive and in need of rehabilitation. An average of 63.7% of the seabirds found were Magellanic penguins ( Spheniscus magellanicus), with 3869 reported since 1987. Mainly adult penguins were found in Argentina (1605 of 2102 penguins of known age class) and Uruguay (158 of 197). Juveniles were most common in Brazil (234 of 325). Oil fouling was the most frequent cause of injury or sickness. The number of oiled penguins reported in their wintering range has greatly increased since the early 1990s and is strongly correlated with petroleum exports from Argentina. Our results show that chronic petroleum pollution is a problem for wildlife from Southern Brazil through Northern Argentina, and regulations and enforcement are failing to protect living resources.