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Process-side fouling occurs in most refinery units, causing operating and maintenance problems. Fouling that limits unit throughput or forces downtime for cleaning are the most expensive problems. Excess furnace firing from lost heat transfer increases fuel cost. Other costs include increased maintenance and equipment failure.
Fouling has increased as refineries use more difficult-to-process, heavier crude oils in addition to the increase in processing of shale oil. The increased use of hydrotreaters to comply with new regulations is an additional challenge.
Our fouling control programs minimize total fouling cost by avoiding unscheduled production slowdowns or shutdowns and limiting emissions. This saves energy, maximizes conversion, maintains throughput, and increases run lengths. Our laboratory analytical capabilities, problem-solving skills, and experience enable understanding of the fouling mechanism in a given system. We work together to develop cost-effective, technically appropriate total-fouling control solutions.
Baker Hughes LIFESPAN™ exchanger fouling control programs use a practical, systematic approach to maximize the life of your exchangers. LIFESPAN programs maintain target throughput, extend run lengths, improve reliability, and decrease total cost of operations.
Baker Hughes MILESTONE™ heater-fouling control technology interrupts fouling mechanisms identified for specific delayed coker operations and feedstock types. MILESTONE applications extend heater run lengths and increase unit throughput, while reducing the frequency of coil decoking procedures.
Baker Hughes VisTec™ visbreaker technology program expands the operating envelope of the visbreaker to maximize conversion rates and extend run lengths. Our program combines VisTec additives and monitoring to control fouling and stability so severity can be increased.