ToolFusion Chemical
ToolFusion Chemical
📋 Case Study

Heat Exchanger Fouling Mitigation in Ethylene Cracker Quench System

Severe coke deposition reducing heat transfer by 40% and increasing pressure drop beyond design limits

🏗 Project Overview

Revamp of 1.2 MTPA ethylene cracker in Texas Gulf Coast

🎯 Challenge

Severe coke deposition reducing heat transfer by 40% and increasing pressure drop beyond design limits

🔧 Design Approach

Optimized cross-flow velocity profile + periodic backflush cycle using CFD-guided nozzle placement

📐 Design Diagram

Ethylene Cracker Quench System Heat Exchanger Fouling Mitigation In Out BF BF BF BF Coke Zone Re = 12,800 Nu = 196 ΔP ↑ 40% Tubes Cross-flow Backflush Fouling

AI-generated project design illustration

📐 Key Calculations

Reynolds Number at Minimum Cross-Section

ρVD/Ό
Result: 12,800
Ensured turbulent flow to suppress boundary layer growth

Nusselt Number Correlation Selection

Nu = 0.023 Re^0.8 Pr^0.4
Result: 196
Validated thermal performance under fouling conditions

📊 Results

Fouling rate reduced by 65%, 18-month run length achieved, $2.3M/year energy savings

💡 Lessons Learned

  • •Turbulence intensity > critical Re delays deposit adhesion
  • •Localized velocity mapping prevents dead zones

✅ Key Takeaways

  • 1Turbulence intensity > critical Re delays deposit adhesion
  • 2Localized velocity mapping prevents dead zones