Examining the Cost Return Ratio for CFD in the Gas, Oil and Chemical - - PowerPoint PPT Presentation

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Examining the Cost Return Ratio for CFD in the Gas, Oil and Chemical - - PowerPoint PPT Presentation

Jul 17, 2023 412 likes •832 views

Porter McGuffie, Inc. Engineering Measurement and Analysis Services Examining the Cost Return Ratio for CFD in the Gas, Oil and Chemical Industries Mike Porter, P.E Principal Engineer Porter McGuffie, Inc. 544 Columbia Dr., Lawrence, KS 66049

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

Examining the Cost Return Ratio for CFD in the Gas, Oil and Chemical Industries

Porter McGuffie, Inc. 544 Columbia Dr., Lawrence, KS 66049 www.pm-engr.com Mike Porter, P.E Principal Engineer

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

512,000 lb/hr 85’ long 20’ ID

Tail Gas Unit

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

The initial goal:

Reduce pressure drop

− Driven by low available fan power

Evaluate two different inlet piping geometries

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

Inlet piping system pressure magnitudes

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

Surface plot of Y-velocities above bed

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

Streamlines colored by velocity

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

Inlet piping system pressure magnitudes

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

Streamlines colored by velocity

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

Surface plot of Z-velocities above bed

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

Savings? 1.5” w.c. reduced pressure drop Catalyst life – 4-8 years − 8,000 ft3 catalyst − $400/ft3 catalyst cost

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

Plane 1 Plane 2 Plan 3

Feed water heat exchanger

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

Velocity Magnitudes on Cut Plane 1

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

Inlet Modifications

Additional Extraction Steam Nozzle

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

Near Inlet Modifications

Additional Tube Support Plate Additional Tube Support Plate Increased Impingement Plate Size

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

Velocity Magnitudes on Cut Plane 1

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

Savings? Vessel life – 30 vs 15 years Capacity increase – 15%

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

SRU Boiler

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

The Problem:

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

When that happens:

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

The variables:

  • Heat Flux
  • Superheat
  • Void fraction
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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

Water Side Model– 4.3 Million Cells

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

Volume Fraction of Steam at time = 25 seconds

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

Volume Fraction of Steam at time = 28 seconds

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

Upper Tubes Showing Steam Void > 0.9

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

External Tube Temperature

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

SRU Data vs. Peak Heat Flux Curve

20000 40000 60000 80000 100000 120000 20 40 60 80 100 120 140 160 180 200 Superheat Temperature (F) Flux (BTU/hr*ft^2) Flux Curve Point 1 Point 2 Point 3 Point 4 Point 5

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

The heat flux is proportional to the Mass Flow Rate and the Dynamic Viscosity

− Unfortunately, the Dynamic Viscosity is not a process parameter

If the parameters are plotted and curve fit, for a particular geometry, it is possible to relate the heat flux to the mass flow rate and the process temperature.

− These are measured process parameters

This allows the development of a simple graph to control the process

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

Savings? SRU repair cost – less than analysis Plant throughput reduction – less than analysis – per hour

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

Baghouse flow analysis

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

Velocity Pressure

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

Location % Difference from Mean 1 3.55% 2 .090% 3

  • 1.35%

4

  • 4.68%

5

  • 3.65%

6

  • 6.68%

7

  • 3.90%

8

  • 6.44%

9

  • 3.65%

10

  • 7.43%

11 17.32% 12 15.49% 13 1.78% 14

  • 1.26%
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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

Before After

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

Result? 2006 installation

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

“Overall this was a very successful project for Lafarge” said project manager Nick Trout. “The results exceeded our expectations in terms of providing an excellent quality product that continues to perform within the operating parameters set forth in the justification for the project. We have gone from spending over US $40,000 per month on baghouse repairs to no cost at all. In addition, we are using a lot less compressed air to clean the filter bags and we have reduced the static pressure on the fan by over 4” (10 mm) w.c….”

World Cement, May, 2009

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Porter McGuffie, Inc.

Engineering Measurement and Analysis Services

Porter McGuffie, Inc. 544 Columbia Drive – Suite 19 Lawrence, Kansas 66049 V: 785.856.7575 F: 785.856.3658