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Team helps refineries solve problems

A Fluent product story
Edited by the Engineeringtalk editorial team Feb 28, 2006

Combination of experience optimising refining processes with flow simulation will help increase efficiency by visualising what is going wrong, then proposing and providing real engineering.

Fluent has teamed with KBC Advanced Technologies to provide high end engineering products to oil refineries and petrochemical manufacturers.

Joint service offerings will focus on improving unit operating performance, reducing refinery operating costs, increasing system reliability, safety enhancement and pollution reduction.

"We're excited about this partnership," said Dave Schowalter, Lead Engineer for Energy at Fluent.

"By teaming KBC's 25 years of experience optimising unit and refining processes with Fluent's 25 years of advanced flow simulation, we're able to help refineries increase processing efficiency by visualising what is going wrong with their units, then proposing, proving and providing real engineering".

Rob Tufts, Principal Consultant for KBC, said: "Using Fluent's CFD program we were able to perform a low cost redesign of the inlet distributor and feed collector piping for a hydrotreater reactor allowing us to increase dramatically catalyst loading and catalyst contacting, while preventing bed channeling".

Because of rapidly increasing demand for transport fuels and other crude oil derivatives, environmental restrictions calling for low sulfur fuels, emission limits on refineries, and the fact new oil refineries have not been built in the USA for more than 20 years, KBC and Fluent are positioned to address a wide range of problems faced by refiners.

The companies are helping refiners find new ways to use and improve yields, reduce risk and increase the throughput of existing processing units.

They have created a way to identify vulnerable components within refineries and have already worked with several refiners and found many problem areas, thereby reducing the risk of accident, injury to workers and otherwise costly failures.

Erosion prediction was one of the early targets of the partnership, while another area was unit operation trouble-shooting and hydrotreater reactor optimisation.

Other applications being addressed by the partnership include eliminating bottlenecks in fired heaters, improving fractionation in distillation towers and improving the operation of separation systems.

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