Refining summit 2015
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Bronswerk provides process design, thermal design, and mechanical design services to help clients optimize plant efficiency and recover waste heat. Their Radiax compressor can significantly reduce the size and energy usage of vapor recompression systems. Their Whizz-wheel fan uses curved blades to lower noise levels by 6-20 dB compared to conventional fans, reducing energy usage by 45-60% for the same airflow. Case studies show their technologies helped a client in Mexico debottleneck a gas compression module by 40% in space usage and 24% in energy, and helped a refinery in Germany reduce fan noise by 20 dB while lowering energy usage by 56%.
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Refining summit 2015
- 1. Optimizing plant efficiency Heat recovery and saving energy Hans van Essen Den Haag – April 22 2015
- 2. Content • Introduction Bronswerk •Radiax® – Case 1: Mechanical vapour recompression • Whizz-wheel® – Case 2: Debottlenecking – ACHE offshore – Case 3: Debottlenecking – ACHE refinery • Site survey
- 3. History: 1940 1988 – Privately owned 2015
- 4. What we do: • Process design • Thermal design • Mechanical design • Manufacturing • Supply • Installation & Commissioning • After market
- 5. Radiax®: Developing the Radiax® started from the beginning, a fully new principle compressor / turbine / pump was designed.
- 6. Radiax® : Key features: • Compact (up to factor 10) • Fully integrated drive and seal system • Oil free system behavior • Flexible in extended ranges • No surge and No stall • Flat pressure vs flow curves (no specific work point) • High pressure ratio • High efficiencies over extended ranges
- 7. Radiax® : Applicatoins - Wet compression & wet expansion - Well gas conditioning for gas turbines - Waste Heat Recovery (ORC & RC) - Vapour recompression
- 8. CASE 1: Steam Recompression
- 9. Case description : Stripper flash drum Steam ejector 4 bara 7000 kg/h 144°C / 4 bara Water: 312352 kg/h HP steam 2500 kg/h 3,29 bara 4500 kg/h 3,29 bara Operating cost: €537.000,- / year
- 10. Solution : Stripper Flash drum 4 bara 7000 kg/h 144°C / 4 bara Water: 312352 kg/h 2,85 bara 7000 kg/h Radiax 2,85 bara E-power: 200kW Operating cost: €137.600,- / year • OPEX reduction: €400.000,-/year • ROI: <2 year
- 11. Whizz-wheel®: Develop ultra low noise fans to meet the stricter client requirements.
- 12. Conventional :
- 13. Whizz-wheel®: Main features •Rim •Small hub •Blades are fully curved
- 14. Whizz-wheel® : Developed for low noise: 6 – 20 dB lower noise Benefits: • 45 - 60% lower absorbed power • Up to 40% more cooling air flow with same absorbed power • Or a combination • Minimal vibrations • Rigid construction • Less sensitive to wind
- 15. Whizz-wheel® : Trends: • Upgrading existing facilities • Decreasing OPEX – absorbed motor power – Maintenance • More strict noise requirements
- 16. CASE 2: Debottlenecking 2 new gas compression modules – Mexico Litoral-A
- 17. Case description : Plant • Existing platform • Two new gas compression trains (modules) Challenges: 1. Plot space 2. Maximal absorbed power 3. Maximum noise level
- 18. Solutions : Conventional Whizz-wheel® Plot space area 582m2 412m2 Installed motor power 390 kW 308 kW Sound pressure level 90 dB(a) @ 1m <85 dB(a) @ 1m Total height 7,6m 7m Total weight of units 141 ton 126 ton
- 19. Results: • 40% reduced plot space • 24% lower absorbed power • 8% reduced height • 12% less weight • No noise issues Quote PM: “without the whizz-wheel we could not have executed this project.”
- 21. CASE 3: Debottlenecking Air Cooled Coolers – Germany
- 22. Case description: Plant • 120.000 barrels/day • Located in a populated area • More then 60 fans • Different services Challenge: • Reduce high noise emissions
- 23. Solutions : Option 1: Standard low noise fans • Noise level of 72 dB(a) • 12,6 kW absorbed power Option 2: Whizz-wheel ® system • noise level of 66 dB(a) • 5,6 kW absorbed power
- 24. Results: • 20 dB(A) proven lower noise • 56% lower absorbed power • 5% more airflow • Installation during operation
- 26. Site Survey What is your specific challenge? Or where can you safe energy With a Site Survey the problem can be identified and a solution is within reach!
- 27. Thank you for your attention. Questions? Let’s talk more in our booth (No. 12)
- 28. How to contact us: Hans van Essen essen@bronswerk.com +31-33-24-72-562 www.bronswerk.com