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.
Withstanding thermal stresses and structural expansion under direct exposure to the flame and combustion products, with combined radiative and convective heat transfer. Providing extended heat-transfer surfaces with minimal welding and bending, while ensuring effective sealing for the air-to-air heat exchanger and maintaining easy accessibility.
Use of a modular design and direct installation of the heat exchanger in the combustion chamber wall to reduce the volume of refractory materials and simplify fabrication. The use of alloy steel plate instead of Inconel and stainless steel, combined with minimal bending and welding, is adopted to ensure that the connection points are exposed to the lowest possible temperatures.
Fabrication procedures and test results for the heat exchanger walls under temperature and pressure conditions 20% above the normal operating conditions. The deliverables also include a compressed-air heater utilizing the heat generated by excess-gas combustion, fully installed and integrated into the plant.
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 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.