Design and fabrication of an industrial-scale waste heat recovery boiler for steam generation using exhaust heat from the bitumen plant’s excess-gas burner, with the aim of reducing steam consumption from 18 to 9.5 tonnes per hour and utilizing low-grade waste energy.
Management of two-phase flow with steam quality of up to 60% at temperatures exceeding 1,200°C, control of metal surface temperatures in welded and bent sections to a maximum of 300°C, and design of a compact heat exchanger with effective sealing and the capability for installation at stack elevation.
Use of a compact heat exchanger with a sheet-metal and finned structure designed to prevent welded joints from being directly exposed to the flame; a modular design to accommodate thermal fluctuations; and the use of heat-resistant alloys.
A waste heat recovery boiler installed in the plant with a steam generation capacity of approximately 1 tonne per hour, along with documentation of the Water Wall fabrication process to ensure reproducibility and facilitate commercialization in other industries.
Jey Oil Refining Company
Design and development of magnetoactive nanoceramic coatings to inhibit the nucleation and growth of coke deposits in process equipment used in bitumen-producing refineries. Through surface engineering, these coatings prevent the initial adhesion of coke, thereby enhancing equipment efficiency and extending its service life.
Jey Oil Refining Company
Design and manufacture of an industrial turbo-compressor to supply combustion chamber air and plant compressed air by utilizing the heat generated from the combustion of excess gas. The key innovation is the elimination of the power turbine rotor and the splitting of the hot gas flow upstream of the gas-generator turbine inlet, which reduces costs while increasing aerodynamic loading.
Jey Oil Refining Company
Design and fabrication of a compact heat exchanger for preheating the compressed air supplied to the oxidation reactor from 90°C to 200°C, using direct flame heat and combustion products from excess gas. The heat exchanger is installed in the excess-gas burner wall and fabricated from A516 steel plate with minimized welding requirements.