| Customization: | Available |
|---|---|
| After-sales Service: | Repairable Within The Warranty Period |
| Warranty: | 2 Years |
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Middle East Oil Refining Integration Project
Project Background
In order to optimize the layout of the refining industry chain and increase the production capacity of light oil products, a national oil company in the Middle East invested in the construction of a 10 million ton refining and chemical integration base. The project focuses on deep processing of crude oil and clean energy production, and requires matching an efficient heat exchange system to cope with the needs of high temperature, high pressure and high sulfur crude oil processing. Tongyang Chemical was selected as its core heat exchanger supplier with its ASME and API 660 certification qualifications and project experience in the Middle East, and delivered 24 customized heat exchange equipment, covering the entire process of crude oil pretreatment, fractionation and energy recovery.
Technical Challenges
- Extreme working conditions adaptation: The medium has high sulfur content (≥2.5%) and the operating temperature reaches 450ºC, and the material stress corrosion and coking problems need to be solved;
- Energy efficiency optimization: The thermal efficiency of traditional shell and tube heat exchangers is insufficient, and the heat transfer coefficient needs to be improved to reduce the overall energy consumption of the device;
- Modular delivery: The project is located in the heart of the desert, requiring the equipment pre-assembly rate to reach more than 80% to reduce the on-site construction period.
Solution and equipment highlights
Tongyang adopts the "one machine, one policy" design principle to customize efficient heat exchange solutions for different process sections:
1. RC-KEROSENE/CRUDE-GASOIL heat exchanger
- Material upgrade: Titanium-molybdenum alloy (Grade 12) is used for the tube side, and duplex stainless steel 2205 is used for the shell side, and the sulfur corrosion resistance life is increased to 20 years;
- Structural innovation: Built-in spiral baffles and corrugated tube bundles, the heat transfer coefficient is increased by 35%, and the pressure drop is reduced by 18%.
2. NAPHTHA-COOLING WATER/FUELGAS-STEAM heat exchanger
- Intelligent control: integrated temperature-pressure interlock system, real-time adjustment of cooling water flow, to avoid naphtha coking;
- Waste heat recovery: steam condensation latent heat is used to preheat feed crude oil, saving 1.2×106 cubic meters of gas consumption per year.
3. CRUDE-RC/FUEL OIL-STEAM heat exchanger
- Anti-fouling design: silicon carbide coating is sprayed on the surface of the tube bundle, the scaling rate is reduced by 60%, and the cleaning cycle is extended to 3 years;
- Compact layout: modular shell adapts to small device area, pre-installed tube bundle and valve, and the on-site installation cycle is shortened by 40%.
Project Achievements
- Capacity breakthrough: 24 heat exchangers operate in coordination, refining efficiency increased by 22%, and light oil yield increased to 68%;
- Energy saving and carbon reduction: The comprehensive thermal efficiency reaches 92%, reducing CO2 emissions by 45,000 tons per year, helping customers achieve ESG goals;
- Stable operation: After commissioning, it has been running continuously without failure for more than 8,000 hours and passed API 570 inspection and certification.
Customer evaluation
"Tongyang's heat exchanger has shown excellent reliability in high-temperature sulfur corrosion environment. Its modular design has greatly shortened the project construction period and created key conditions for the refinery to start production ahead of schedule." - Project Chief Engineer
Core advantages of the case
- Material technology: Jointly developed special alloys with Baosteel and TISCO, and passed the NACE MR0175 sulfur corrosion resistance certification;
- Green smart manufacturing: The carbon footprint of the equipment throughout its life cycle has been reduced by 30%, and ISO 50001 energy management system certification has been obtained;
- Global service: The localized technical team in the Middle East provides 7×24 hours of operation and maintenance support, and the spare parts response time is ≤48 hours.
| YEAR | 2017 | 2018 | 2019 | 2020 | 2021 | 2022 | 2023 |
| Reactor | 129 | 133 | 177 | 180 | 220 | 303 | 339 |
| Heat Exchanger | 119 | 132 | 153 | 210 | 260 | 375 | 452 |
| Column | 112 | 128 | 177 | 147 | 180 | 285 | 317 |
| Storage Tank | 95 | 150 | 162 | 142 | 203 | 300 | 556 |
| Special Equipment | 190 | 106 | 98 | 119 | 138 | 350 | 378 |
| Annual Output | 645 | 649 | 707 | 798 | 1001 | 1613 | 2042 |
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