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Hydro-mechanical cleaning of fired heater coilsHydro-mechanical decoking of fired heater tubes, transfer lines and most all lines containing hard deposits of Organic Coke and Inorganic such as Iron Sulfate, Sodium and Saltine is widely accepted as the decoking method of choice throughout the world today. Two basic technologies exist on the market today. “Hard Core or Solid Core Technology” and Soft Core Technology. Both successfully introduced in the early 1990’s and both are still offered to clients worldwide. “Hard Core” technology entered the market first and showed great promise. Like all new technologies the “Hard Core” had some serious shortfalls. The Hard Core was not capable of decoking unaltered return bends and actual case studies shows the aggressive nature of these scrapers to damage the interior of the tube wall. “Soft Core” entered the market with a solution for the problems caused by “Hard Core” technology. “Soft Core” solved the problems of decoking return bends and eliminated the risk of internal tube damage. MAGICROT uses only “Soft Core” technology with a difference. The MagiCrot team consists of a group of worldwide specialists, including original start up personnel from the introduction of “Soft Core” Technology in 1993. Additionally, this expertise has significantly upgraded all phases of the Mechanical Decoking Operation to give the client the best technology available. The advantages of hydro-mechaniclal cleaning
The work procedure
THE FEED TUBES (D 89 MM AND D 141 ÌÌ) CONNECTION
Our missionWe promise to provide our customers with the world’s best technologies, develop the safest, most cost effective and up-to-date plans, and protect the environment at all times. We promise to learn, listen and fully understand the values and wishes of our customers all to the mutual benefits of our generation and generations to follow. It is easy to use words to create a Mission Statement. It is only when daily documentation, verification, visualization and validation are present that we insure our clients that our MISSION is factual while other flounder in fantasy! Cost, efficiency,reliability, time saving and environmental impactSTEAM/AIR DECOKING vs MECHANICAL DECOKINGIt does not matter if the economic conditions are high in profit value or in recession, (whether Real or Perceived) the discussion of the value of Steam/Air Decoking vs Mechanical Scraper Decoking seems to never end. It is important to point to all the actual major factors involved, and then the decision of the right technology can be chosen. STEAM/AIR DECOKINGREFINERY – “We use plant steam & air so there is no cost for the Steam/Air Decoke” REFINERY – “Our fuel gas charges are absorbed into the process costs” REFINERY - “We pay out no invoices for this procedure” *Based on the above reasonable statements the basic feeling of many Refinery Costing Operations is that a Steam/Air Decoke is FREE!* In order to fully understand the costing of Steam/Air Decoking we must understand that Refineries around the world have never taken the time to cost this necessary operation, due to virtually no alternatives. It is now important to cost Steam/Air Decoking due to the introduction of Mechanical Scraper Decoking in 1993. Proper identification of Cost Benefits are viewed in two specific areas:
As explained above the Immediate Costing of Steam/Air Decoking is minimal but does contain certain Real Costs to the Refiner. Mechanical Scraper Decoking has immediate up front costs to the Refiner but contains huge Short and Long Term Cost Benefits. We now need to compare the benefits and costing in the following tables. For ease of comparison we will use a typical 2 Pass DCU Heater with each pass having an overall length of 800m.
It can be easily understood that the removal of Organic coke and Inorganic is a huge bonus to the run efficiency of the DCU Heater. It is also easily understood the value of less tube maintenance, less downtime, longer run lengths and longer tube life. Combined with the value of a shorter duration for each decoke using the Mechanical method it shows a clear picture of the value of Mechanical Scraper Decoking. In 2003 a survey showed that the average DCU Heater as used in this example gave the Refiner a PROFIT of €9,000 per hour or the equivalent of €216,000 Profit per 24 Hours of operation. (Values may slightly differ from region to region but this is a benchmark number.) Without considering the long term benefits we now compare the actual Decoking of One – 2Pass DCU Unit Heater
The overall time saving on an individual decoke of this size averages 46 Hours of more production for the refiner using the Mechanical Decoking Method. Finally, the real cost and profit comparison will show the value of Mechanical Decoking over the more traditional form of Steam/Air Decoking. The major variance in the overall value is the long term benefits which are obvious and can range in the millions of Euros over the life of the heater coil. For ease of reference we will only deal with real numbers in the short term leaving the long term calculation to each individual refiner. We base the increased profit on the minimum increase of run length of the heater of 15 Days. This number can vary significantly upward depending on variables such as heater operation, crude source and overall Refinery operations.
The actual gain by using the Mechanical Decoking Method is more than €3,500,000 for just a single decoke. If you add the long term benefits and multiply the increased profits from multiple decokes over a few year period you can now clearly see why 75-80% of all DCU Heaters are Mechanically Decoked around the world. |
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