(166c) Crude Unit Fouling:Consequences and Costs
AIChE Spring Meeting and Global Congress on Process Safety
2019
2019 Spring Meeting and 15th Global Congress on Process Safety
22nd Topical Conference on Refinery Processing
Energy Conservation II
Wednesday, April 3, 2019 - 11:15am to 11:45am
Previous work [1] based on a literature identified reasonable fouling factors for commercial units. These factors are at last three times higher than the commonly used TEMA (Tubular Exchanger Manufacturer Association) values. For highly fouling crudes, the fouling factors may reach eight times TEMA values. Operating data from four crude units supported the use of fouling factors at three times TEMA values.
Fouling rates may vary dramatically from unit to unit and from exchanger to exchanger within the same unit. The previous work focused on using unit-average fouling rates.
This paper includes
- additional comparisons with operating data,
- a Monte Carlo analysis comparing using average fouling rates versus a distribution of fouling rates,
- an analysis identifying specific preheat configurations that have higher risk of operating problems with fouling, and
- estimates of energy efficiency and capacity costs of fouling in crude units.
[1] A. W. Sloley, âCrude Unit Fouling: Whatâs Normal? Whyâs it Important?,â presented at the AIChE Southwest Process Technology Conference, Galveston, TX, 2018.
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