PETROCHEMICALS

The stakes are high

PBI dedicates its expertise to the service of environmental problems, process optimisation and energy efficiency with universal and sustainable solutions. The stakes are indeed higher than ever in the downstream processing (DSP) units. As well as solving accidents or emergency situations, let's take on your optimisation projects together! In order to withstand the mainly thermal and chemical constraints which prevail among petrochemical furnaces, we use very high-quality materials. Our NEFATEX 1390 fabric, combined with a proven design and closing systems, is practical, simple and very resistant to attack and has long been acclaimed by engineering offices and petrochemical groups, we work closely with EPCM from FEED till OEM and worn parts replacements.

The virtuous strategy of decarbonization initiated by the oil industry began with energy sobriety, by improving the energy performance of equipment, better insulation and integrating of the latest generations of burners.

The related industries of gas, green hydrogen, ammonia, fertilizers, Agro-Nutrients and fertilizers, polymers.... are committed to the same dynamic of energy transition, reducing atmospheric emissions while gaining in competitiveness.

Essential for furnaces fuelled by heavy fuel oil, our thermal/chemical tube protections remain invaluable even when it comes to upgrading to new-generation gas burners. The latter ensure more controlled operation and reduced NOx emissions, but the condensation produced during combustion will always lead to oxidation of metals, and hence to corrosion. Hot spot protection on targeted sections of tube will avoid the risk of leaks, hernias and unexpected stoppages.

To limit containment losses

PROTECTION

In addition to the fact that the various sensitive points of the protected tubes (elbows, part facing the burners, supports, etc.) will see their lifespan greatly increased with a significant economic impact, this will limit the formation of coke and, in the most extreme cases, which fortunately are very rare, will prevent cracks endangering the installation.

TecHeat^® Elbow Protection

10% daily production improvement (*)
Limits external corrosion and internal coking
Reduces the risk of bursting pipes and welds

(*in distillation furnace in France, 232 tubes, protection <1% of linear footage, 850°C, Furnace 30,000 T, gas energy)

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The “Bow-Tie model LOPA” calculates that an excess of coke (>60% of the thickness of the tube) inevitably generates a runaway… flux loss of +/- 0.390 kW/m2 => loss of power transferred of +/- 22.65 kW/h => obligation to compensate by increasing combustion => increase in energy consumption expenditure + increase in the skin temperature of the tubes + attack from polythionic acids + corrosion of the tubes => loss of containment + leakage of welds => Explosion or Fire. TecHeat^® protections are specially developed to preserve the integrity of tubes, elbows, connections, thermocouple junctions, reducers….

Limits external corrosion and internal coking thanks to its design and composition
Resistant to 1390°C, chemical attack, abrasion and direct flame from burners
Simplified installation on the most inaccessible or sensitive parts compared to existing solutions, without any modification to your structure
Can be removed for checks, resistant to maintenance washings

TecHeat^® Support Protection

16 units fastened in a single day (*)
Limits distortion and preserves support integrity
No external provider

(*in hydrodesulfurisation furnace in Spain, 16 supports, 650°C, refining fuel-gas energy)

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If the flame reaches the anchors/supports of the tubes (not benefiting from any "cold source") there is a risk of deformation and of the welds weakening, irreparably causing the distortion or the fall of the tubes as well as a loss of functionality, resulting in a risk of loss of containment and by extension… an Explosion or a Fire. TecHeat^® Support Protections are specially developed to preserve the integrity of pipe supports and anchors.

1390°C heat shield with high chemical inertia (H2S, SO2, etc.)
Limits abrasion and external corrosion
Simplified installation, lacing assembly
No structural modification required or needed for intervention from external providers
Can be removed for checks, resistant to maintenance washings

Other PROTECTIONS

TecHeat^® tube protection
Heat shield
TecHeat^® Thermocouple Protection

Protection curtains
Welding screen
MOV emergency cable protection
...

To reduce unwanted air intakes

SEALING

Better control of combustion, reducing energy consumption… also requires excellent sealing of the tube passages. Among all the factors which contribute to increasing the yield and efficiency of an energy process in depression, the fight against “unwanted air intakes” is a priority. For many years, we have been able to respond to countless problems concerning different types of furnaces in the petrochemical industry, taking all the specific parameters of each one into account. Aware of both issues and constraints, our technical team carries out a detailed and specific study for each project on site (design, materials, expansions, fixings, installation, planning, etc.).

TecHeat^® Expansion Collar

1% increase in furnace efficiency (*)
Reduction of atmospheric emissions of Co and Nox
Installation in less than 15 minutes by collar without furnace shutdown or an external service provider
Unlimited axial expansion

(*on crude oil heater in France, 14 crossovers, 300°C, gas energy)

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Imperfect combustion implies the presence of unburned fuel in the chamber generating an explosive atmosphere. The O2 rate has a direct impact on the quality of combustion. An explosion (even a small one) inside the chamber will irreparably impact (with a greater or lesser risk) the lyres/tubes (not only in the chamber in question); this explosion (sometimes undetectable and not detected) can cause the extinction of the flames with the chain reactions which are related to it which can lead to an explosion or Fire. The empirical fuel efficiency gain is estimated at 1% for 2% O2 gain in the flue gases The TecHeat^® Expansion Collar is a range of static seals specially developed to preserve the integrity of the tube passages at 1000°C and avoid parasitic air inlets which disturb the operation of the installations. Intended for unlimited axial expansion movements, it optimises the combustion process (reduction of fuel consumption), reduces Co and Nox emissions and reduces operating and maintenance costs. Made to measure, it is integrated into the inlet and outlet of tubes, on the radiation and convection part.

1 point fixing: casing of the furnace
Sliding sealing
Simplified installation, assembly of 2 ½ collars around the tube, mechanically fixed to the ferrules
No structural modification required nor intervention from external provider needed
Removable for checks, resistant to maintenance washings

TecHeat^® Expansion Bellows

Fuel gas combustion gain of 5 T/day (*)
Reduction of the O² rate to 2%
Axial & radial expansion of +/- 300mm

(*on atmospheric distillation furnace in France, 40 convection & radiation crossovers, 450°C, 30,000 T furnace, gas energy)

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Over the past 50 years, 70% of explosions in furnaces and +/- 90% of deaths recorded following incidents on refineries are attributed to incidents linked to the ignition of burners in the furnaces (presence of unburned fuel in the chamber or involuntary extinction of the flame). The lack in tightness of a 6" tube passage of a furnace with a depression of 10 Pa could generate an entry of parasitic air at 20°C of about 80 m3/h. The TecHeat^® Expansion Bellows is a range of dynamic seals specially developed to preserve the integrity of the tube passages at 900°C and to prevent parasitic air inlets which disturb the operation of the installations. Intended for axial & radial expansion movements of +/- 300 mm, it optimises the combustion process (reduction of fuel consumption), reduces Co and Nox emissions and reduces operating and maintenance costs. Made to measure, it is integrated into the inlet and outlet of tubes, on the radiation and convection part.

2-point fixing: passage of the furnace & tube
Bellows-type sealing
Simplified installation, assembly by High-Temperature zipper
No structural modification required nor intervention from external provider needed
Removable for checks, resistant to maintenance washings

TecHeat^® Expansion Sleeve

Increased combustion efficiency (*)
Axial compensation up to +100mm
Easy fastening

(*on refinery in Germany, 100 000 barrels / day, 22 tube passes, 420°C)

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With ageing, heaters tend to become prone to tramp air leakages. This air infiltration (unwanted air ingresses through observation and access doors, header boxes for example) leads to increased fuel consumption, which in turn increases pollutant emissions. It is thus key to ensure equipment tightness. It also leads to O2 analyser readings that are not representative of combustion at the burner level, possibly generating firing at too low O2 level locally

The Air fuel ratio (AFR) is an important measure for anti-pollution and performance tuning reasons. The lower the AFR, the “richer” the mixture

1st solution specially developed by PBI for the petrochemical sector (refineries, steam crackers, methane reformers, distillation furnaces, ethylene furnaces, …), the TecHeat® Expansion Sleeve is a range of seals that preserves the integrity of tube passages up to 750°C and prevents parasitic air ingress that disrupts plant operation.
Designed for axial expansion movements of +100 mm, it optimizes the combustion process (reduced fuel consumption).

Made to measure, it can be integrated into the inlet and outlet of tubes, on the radiation and convection sides.

2-point fixing: oven passage and tube
Quick and easy to install, assembled using clamps supplied
No structural modification required and no need for external service providers
Removable for inspection

Other SEALING

Sealing of doors and manholes
TecHeat^® expansion sheath
Butterfly valve sealing
Flue Compensators & Expansion Joints

Sealing of FCC reactor
Sealing of passages
Sealing of explosion hatches
...

PETROCHEMICALS

Obviously if these 5 examples are fundamental, we must not forget all the other possible air inlets on which it is essential to intervene because they are all sources of heat loss and unwanted air penetration if poorly sealed. Below you will find the brochure summarising these activities, as well as a non-exhaustive list of applications on which we regularly work with petrochemical sites around the world.