BD Energy Systems works together with Steve Parrish of Parrish Process Services to generate a detailed overall plant Heat and Material Balance and bring in-depth experience on evaluating equipment performance in Syngas plants. This combination provides an edge to BD Energy Systems capabilities to provide invaluable recommendations to process and feasibility studies undertaken on existing plants.
Typical evaluations carried out in the plant for increased production/debottlenecking and improved efficiency during execution of process and feasibility studies are:
- Detailed audit at plant site
- Evaluation of tramp air in the furnace
- Evaluation of the plant steam requirements
- Evaluation of the existing flue gas or waste heat recovery coming from the primary reformer and turbines
- Evaluation of the natural gas consumption in the front end of the plant
- Evaluation of the process air system
- Evaluation of CO2 removal
- Evaluation of refrigeration system
- Evaluation of cooling water balance
- Evaluation of the hydraulic profile and pressure drop through the plant
- Evaluation of NOx requirements
- Evaluation of the fans associated with the Steam Reformer for increased production or energy savings
- Evaluation of the design parameters to current operating conditions
Some of the equipment evaluations carried out during the studies are:
- Primary Reformer
- Secondary Reformer
- Shift Reactors
- Boilers
- Heat Exchangers
- Heater
- Compressors
- Turbines
- Fans
- CO2 removal system
- Converter
- Evaluation of various leaks
- Kickback valves
- Relief valves
- Bypass valves
- BFW into condensate
- Steam directly to surface condenser
- Instrumentation for inaccuracies
- Catalyst bed for temperatures
With more than 90 revamp projects executed, BD Energy Systems stands as a world leader in evaluating options for future revamps, evaluating efficiency and energy savings, and improving reliability of the existing plants. Our proven records on such revamps indicate the ROI for efficiency and capacity increase in plants < 2 years. BD Energy Systems will be pleased to provide references for the projects executed. Regarding large Fired Heaters in the refineries and gas plants where efficiency is a target to achieve, BD Energy Systems have undivided experience in evaluating the best option for efficiency increases by carrying out a process model for the design case and comparing it to the current operating case. Tramp air issues (if any) and any losses in efficiencies are evaluated by BD Energy Systems, together with BD Heat Recovery Division, Inc., a leading supplier of compact Combustion Air Preheaters provide a full range of efficiency and capacity increase solutions for both existing and new fired heater projects.