Hard Heat Transfer Heat Exchanger Design
How do you optimize a crude preheat train in a refinery?
Answer
Optimization approach: collect field data (temperatures, flows, pressures), calculate current heat recovery and exchanger duties, identify underperforming exchangers (compare actual vs design U), determine fouling rates and cleaning schedule optimization. Improvements: address severely fouled exchangers first (cleaning or antifoulant), resequence for better temperature approach, consider parallel/series rearrangement, add new exchangers at pinch, install monitoring for fouling detection. Target is maximizing crude inlet temperature to fired heater while minimizing fouling and pressure drop.
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