Heat Recovery Function

Cold crude oil entering refineries at 20-40°C requires heating to 340-380°C for atmospheric distillation. Heat integration using hot product streams including diesel, kerosene, and naphtha preheats crude oil progressively through multiple exchanger trains. This recuperation reduces fired heater fuel consumption 40-60% significantly lowering operating costs while cooling products to storage temperatures.

Design Configuration

Shell-and-tube construction with crude oil on tube side enabling cleaning access for fouling deposits and hot product on shell side. Multiple exchangers arranged in series progressively heating crude from storage temperature to fired heater inlet. ERGIL engineers exchanger trains based on crude throughput, product temperatures, and heat recovery optimization with individual units handling 5-50 MMBTU/h duties.

Fouling Management

Crude oil contains asphaltenes, salts, and particulates causing fouling on tube surfaces. Design includes fouling factors 0.002-0.005 hr-ft²-°F/BTU accounting for deposit buildup. Tube-side velocities 4-8 ft/sec minimize fouling. Removable tube bundles enable periodic mechanical or chemical cleaning. Online monitoring tracks performance degradation signaling cleaning requirements maintaining heat transfer efficiency.

Material Selection

Carbon steel construction suitable for most crude services. Stainless steel or special alloys for corrosive crudes containing high sulfur, acids, or chlorides. Tube materials resist erosion-corrosion from crude contaminants. Design per ASME Section VIII or TEMA standards with materials meeting NACE requirements for sour crude processing.

Applications

Refinery crude distillation unit preheat trains recovering heat from atmospheric tower products. Vacuum unit inlet heating using reduced crude heat. Hydroprocessing unit feed preheating. Serves refineries processing 10,000-500,000 BPD crude throughput with multiple exchanger networks optimizing energy recovery across process units.

Control Integration

Temperature monitoring throughout preheat train optimizes heat recovery and protects against overheating. Bypass systems enable operation during exchanger cleaning or maintenance. Integration with fired heater controls balances heat duty across combined system. Performance monitoring identifies fouling requiring attention.

Performance Benefits

Substantial fuel savings reducing refinery energy costs and emissions. Improved crude processing efficiency through optimized heat integration. Proper crude preheating enhances distillation performance. Materials and design ensure reliable operation with planned maintenance cycles addressing fouling.

Construction Standards

Design per ASME Section VIII and TEMA standards with full code compliance. Materials rated for crude service temperatures and corrosion. Multiple tube passes optimize heat transfer. Expansion joints accommodate thermal growth. Complete documentation including thermal design, materials, and cleaning procedures.

ERGIL inlet oil heat exchangers deliver essential heat recovery in crude processing maximizing energy efficiency and reducing refinery operating costs through proven exchanger technology.