(Updated June 18th, 2016)
"Cost Effective Debottlenecking Expansions"
Speaker: Ray Elshout, Peter Nick, Lynn Brown
In today’s tight economic market and with wide fluctuations in the cost of energy, doing new grass roots projects is no longer economically feasible. What makes more sense is to increase capacity by making modifications to existing facilities to reduce energy usage, increase capacity or improve profitability.
Debottlenecking is more difficult than new designs. Cost-effective modifications need to determine which of the major equipment items limit the overall capacity. Then the modifications would be used to increase capacity up to the limit of these key equipment items.
This requires a trial and error effort of looking at alternative options and determining what equipment can be modified or supplemented with additional equipment. Then preliminary cost estimates are made to determine if the improvement in economics can support the costs of the modifications. This can best be done using the FEED approach where cost estimates are made as engineering proceeds:
- conceptual estimate based on process flow diagram and equipment list
- factor estimate based on getting equipment prices and multiplying by cost factors
- conceptual take-off estimate utilizing estimating programs and conceptual take-offs
Three examples of cost-effective upgrading are presented to illustrate the process include refinery crude unit, vacuum unit and delayed coker unit. Screening alternatives using the FEED process to keep cost estimates up to date with engineering as it is developed. Then measures to keep the project on schedule and under budget are presented.
Ray Elshout, P.E., Energy Systems Engineering
Ray Elshout has a BS/MS in chemical engineering, a California PE and over 40 years of experience covering a broad range of chemical engineering activities including:
Process Engineer Supervisor –as lead engineer doing simulations, PFD’s, P & ID’s and equipment specs
Mechanical Process Engineer-refining P & ID’s, hydraulic studies relief loads, pump head calculations, operating manuals
Technical Service Engineer-working for Marathon Oil, Unocal and Shell oil as an operations engineer doing on site process technical service
Sales Engineer-sales coordinating and west coast sales manager for an engineering company doing revamp and debottlenecking of reefing units
Consultant as Energy Systems Engineering doing Energy Audits , Heat Pinch, refinery debottlenecking and improving on line operations
Project Engineer/Project Manager managing projects up to $25 M
Ray has extensive experience in the Refining area including:
Gas Treating including MEA, DEA, MDEA, Catacarb, Sulfinol, Fluor Solvent
Sulfur Recovery including both Claus and Tail Gas Units
Off sites, tankage, steam systems, cooling water and other utilities
Mercaptan Removal Processes including conventional and extractive Merox
Gasoline and Diesel Blending
Ray has written over 30 technical publications several of which have been presented at technical meetings. He has been involved in teaching chemical engineering part time at Cal Poly Pomona and University of Southern California and as a math instructor at Pasadena City College.
Ray can interface with people from the Refinery manager, technical service manager, process supervisor, operator and technicians through doing hands on engineering projects at most of the refineries in the LA basin and several in the Houston area.
Ray has marketing experience including sales coordinator team at Parsons and as West Coast Sales Manager for TETRA Engineering and Technology doing process design revamps and debottlenecks.
Peter Nick, P.E., Process Engineering Consultant
40+ years of optimizing design and operations of chemical process plants, has extensive process and project engineering experience in design and operations of petroleum refining, chemical, geothermal, sulfur recovery, alternative/waste-to-energy, polymer plants, oil & gas and offshore oil/gas platforms.
Lynn D. Brown, P.E., REA Chief Process Engineer Consultant – Petroleum Refining
Forty + years of experience in the Tech Service and Operations, Design and Troubleshooting of Petroleum, Refining and Gas Processing process units. Resulting in the Profit Improvement of 10’s of MM of $$/Yr in a number of units. Specifically, the Design, Operation, Tech Service, HAZOP review and Startup of over 75 Hydro-Cracking & Treating units from Naphtha to Resid worldwide. Over 70 refining projects with the residence at more than 35 refineries all over the world
To be determine.
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