engineering and technology partner

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
 TA B L E O F C O N T E N TS
your engineering and technology partner

COMPANY
BUSINESS CONCEPT
R&D PHILOSOPHY
CAPABILITIES AND SERVICES
PROCESS ENGINEERING

Process Simulation
Upset Analysis
Sensitive Analysis

PROCESS EQUIPMENT
Thermal-Hydraulic and FEA
CHT - Conjugated heat transfer
Equipment Design

CASE STUDIES

PROCESS ENGINEERING
Process Simulation
Upset Analysis
Sensitive Analysis

PROCESS EQUIPMENT
Thermal-Hydraulic and FEA
CHT - Conjugated heat transfer
Equipment Design

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
 C A D E
s o l u c i o n e s
P E T RO C H E M I S T R Y
d e
i n g e n i e r i a
-
-
R E F I N E R Y
E S P A Ñ A
-
S P A I N
-
O I L & G A S
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R E N E WA B L E S

C O M P A N Y
adding value to our partners
CADE is an expert provider of advanced and specialized engineering,
technology and R&D services focused on process and mechanical
engineering, serving as a technology partner to its cliens.
-

Since the beginning of its activities in 2003, CADE's philosophy has been
focused on developing close collaborative relationships with its clients.
G E N E R A T I O N

This objective is achieved by becoming an extension of our clients'

engineering and R&D staff, working together to face any challenge.

In order to meet all of the client's requests, CADE takes on each and
every project guided by the company's three main principles:

SPECIALIZATION, FLEXIBILITY AND EXCELLENCE

P OW E R
BUSINESS CONCEPT
advanced engineering and technolgy develompent
Nowadays, it is essential to face any complex problems CADE combines advanced capabilities in process and
associated with the development, operation and upgrade of mechanical engineering working collectively with its clients
existing or new technologies and the related equipment by to achieve these objectives.
applying multiple engineering and technolgy approaches.
CADE supports its client by providing custom-made advanced
With the goal of obtaining the best solution available and engineering solutions adjusted to suit the nature of the
maximizing effectiveness and efficiency, it is necessary to client's projects and technical capabilities.
understand the implicit problems of these technologies and
the related equipment during all stages. A full range of advanced engineering capabilities are applied
for reaching your goals.
This task can only be achieved by applying all the engineering
disciplines involved in the design, fabrication, start-up and
operation phases together with a comprehensive knowledge
and vast experience in different industrial fields.

Focus:
advanced mechanical and process engineering
industries served customers and parnters
- POWER GENERATION (CONVENTIONAL, NON CONVENTIONAL) - PLANT OWNERS AND OPERATORS
- RENEWABLE ENERGY - TECHNOLOGY LICENSORS
- REFINERY PLANTS - EPC CONTRACTORS
- PETROCHEMICAL INDUSTRY - PACKAGE UNIT SUPPLIERS
- WASTE TREATMENT - MANUFACTURING COMPANIES
- WASTE TO ENERGY - ENGINEERING COMPANIES
- CHEMISTRY AND PHARMACY
- FOOD INDUSTRY

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
 developing technology and applications
R & D
Due to specialized nature of CADE's activities, new applications,

P H I L O S O P H Y
potential upgrades and transfers of technology from one
sector to another are commonly required in order to take
on our client's most challenging projects.

CADE actively integrates internal R&D activities within its

business structure in order to face these challenges and
generate knowledge that allow us to develop new technologies,
applications and products.

CADE takes advantage of being integrated in the ALBACETE

SCIENTIFIC AND TECHNOLOGICAL PARK in order to count on
the most significant institution in technology and R&D for
support and collaborative work.

R &D approach and methodology

Within the scope developed by CADE for its internal R&D
projects as well as those developed jointly with its
clients/partners, the following R&D methodology is regularly
applied:

- Technology needs assesment/design basis

- State of the art research
- Potential technological solution/upgrade
- Pilot Plant / Prototype design/construction
- Experiments design
- Process simulation and optimization
- Definition of scaling models
- Feasibility research
- Industrial scaled design
C A D E

s t rategic R &D fields

s o l u c i o n e s

- SOLAR - CSP Technologies (process & equipment)

- CSP plants - Energy Storage
- Supercritical fluids tecnologies
- Extracting applications
- Reacting medium
- Thermodynamic cycles
- Waste Treatment and Enviromental Technologies
- Biomass / Biogas
- Waste Heat Recovery
- Refrigeration and cooling
d e

- Steam generation
- Drying technologies
- Biodiesel
i n g e n i e r i a

- Mixing equipment and processes

ongoing internal R &D projects

- Design and development of innovative SPRAY DRYER
- Design and development of hydrogen production technology
from humid biomass waste based on supercritial fluid technology
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- HTF System optimization of CSP plants

- Thermal Energy Storage based on concrete
E S P A Ñ A
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S P A I N
 CAPABILITIES AND SERVICES
advanced mechanical engineering
1 - Process Engineering
advanced energy, thermal and process engineering
1.1 - Process Simulation
1.2 - Upset Analysis
1.3 - Sensitive Analysis

2 - Process Equipment Engineering

2.1 - Thermal-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

key points - Complex systems (streams, variables, etc.)

- Transient State
- Multi-component systems
- Multi-phase flow
- Reacting medium
- Optimization Needs

CADE's approach

PROCESS SIMULATION PROCESS OPTIMIZATION

Steady State - Design State

Transient State - Operational State

SCOPE
PFDs Vs. Operational Conditions
Hydraulic Operational Variables Optimization
Thermal Feasibility analysis (technical - economical)
Thermodynamics Improvement and upgrades proposal
Separation Process Inputs for HAZOP
Reacting Medium

ASPEN
HYSYS
software tools MATHCAD
HTFS (ASPEN)
ANSYS

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
 CAPABILITIES AND SERVICES
advanced mechanical engineering
1 - Process Engineering
advanced energy, thermal and process engineering
1.1 - Process Simulation
1.2 - Upset Analysis
1.3 - Sensitive Analysis

2 - Process Equipment Engineering

2.1 - Thermal-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

key points - High pressure and temperature (equipment)

- High influence of operational parameters of performance
- High sensibility processes
- Complex control systems
- Low control grade
- Unstable processes

approach

P R O C E S S VA L I D A T I O N / R E - D E S I G N
Pressure Relief Systems
PROCESS SIMUL ATION Re-Design (operational condtitions, materials, etc.)
UNDER UPSET CONDITIONS By Pass Systems
Control Loops
Transient State SIL Levels
Process Instrumentation

Inputs for HAZOP

MECHANICAL ANALYSIS M E C H A N I C A L VA L I D A T I O N / R E - D E S I G N
UNDER UPSET CONDITIONS
FEA Thermal - Structural FEM analysis
Fatigue analysis
Static / Transient State Temperature/stress distribution over solid model (metal)
Pressure parts reinforcement (tubesheets, nozzles, etc.)
Internal refractory lining

ASPEN
HYSYS
MATHCAD
software tools HTFS (ASPEN)
ANSYS

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
 CAPABILITIES AND SERVICES
advanced mechanical engineering
1 - Process Engineering advanced energy, thermal and process engineering
1.1 - Process Simulation
1.2 - Upset Analysis
1.3 - Sensitive Analysis
2 - Process Equipment Engineering
2.1 - Thermal-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

key points - Unestable equilibrium state

- High sensibility processes
- High Dependance between variables
- High Performance assurance

CADE's approach

P R O C E S S VA L I D A T I O N / R E V I E W
Change of Operational Parameters
SENSITIVE STUDY Phase Diagrams
Control Strategies
Definition of Control Loops
Transient State Re-Tuning of Control Loops
Relationships between variables
"What If" Studies

Inputs for HAZOP

software tools ASPEN

MATHCAD

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
 CAPABILITIES AND SERVICES
advanced mechanical engineering
1 - Process Engineering
advanced energy, thermal and process engineering
1.1 - Process Simulation
1.2 - Upset Analysis
1.3 - Sensitive Analysis

2 - Process Equipment Engineering

2.1 - Thermal-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

- High pressure and temperature

key points - Dynamic processes
- Thermal and Mechanical Performance importance
- High Stress requirements
- Cycle operation (Start Up, Shut Down). Fatigue phenomena
- Heat Bridges, Heat Losses, Internal Lining
- Flow Effect: Vibrations, noise, pressure drop, turbulence
- Fitness for Service Assessment API 579
- Compressibility effects (gases)

CADE's approach

P R O C E S S VA L I D A T I O N / R E - D E S I G N
THERMO - HYDRAULIC
ANALYSIS Flow Distribution
CFD SIMUL ATION Heat Transfer Profiles
Steady State Temperature Profiles
Transient State Pressure Profiles
Velocity Profiles

MECHANICAL ANALYSIS M E C H A N I C A L D E S I G N / VA L I D A T I O N
FEA
Thermal - Structural FEM analysis
Fatigue analysis
Steady State Short and long term cycle perfomance
Transient State Temperature/stress distribution over solid model (metal)
Full dynamic response, spectrum, harmonic, modal analysis
Fitness for Service Assessment API 579

CFD (Computational Fluid Dynamics) FLUENT, CFX, OPENFOAM

software tools MATHCAD
ANSYS

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
 CAPABILITIES AND SERVICES
advanced mechanical engineering
1 - Process Engineering advanced energy, thermal and process engineering
1.1 - Process Simulation
1.2 - Upset Analysis
1.3 - Sensitive Analysis

2 - Process Equipment Engineering

2.1 - Thermal-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

- Transient heating of solid / fluid

key points - Tridimensional Heat Transfer inside solid / fluid
- Heat Transfer controlled by Heat Capacity of solid
- Phase change of solid / fluid
- Large thickness equipment under cycle operation
- Liquid/Gas circulation inside solid
- High mass ratio solid/fluid systems
- Heat transfer inside solid assumed as not negligible

CADE's approach

P R O C E S S D E S I G N / CFD VA L I D A T I O N

CONJUGATED HEAT TRANSFER Heat Transfer between fluid and solid

CFD Temperature Profiles (solid and fluid)
Exchanged Power Profiles Vs Time
Transient State Local Effects (extended surfaces)
Heating demand by solid (heating applications)
Heat recovered (heat recovery applications)

MECHANICAL ANALYSIS
FEA M E C H A N I C A L D E S I G N / VA L I D A T I O N
Thermal-Structural FEM analysis
Steady / Transient State
Short and long term cycle perfomance
Fatigue analysis
Full dynamic response, spectrum, harmonic, modal analysis
Fitness for Service Assessment API 579

CFD (Computational Fluid Dynamics) FLUENT, CFX, OPENFOAM

software tools ANSYS

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
 CAPABILITIES AND SERVICES
advanced mechanical engineering
1 - Process Engineering
advanced energy, thermal and process engineering
1.1 - Process Simulation
1.2 - Upset Analysis
1.3 - Sensitive Analysis

2 - Process Equipment Engineering

2.1 - Thermal-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

key points - Heat Transfer

- Air Cooler
- TEMA Heat Exchanger
- Hydraulic regimen influence - HRSG / Waste Heat Boiler
- Mass Transfer - Steam Drum
- Gas-Liquid Systems - Steam Dryer
- Solid-Fluid Systems - Deaerator
- Heat Recovery - Separation Equipment
- Reacting medium - Reactor
- Dynamic Mixer

CADE's approach
P RO C E S S D E S I G N
REFERENCE CASE
Main Dimensions
Internals
Design Case
Reference P&ID
Rating Case
Reference PFD (design and rating cases)
Process Data Sheet (design and rating cases)
S P A I N

MECHANICAL DESIGN M E C H A N I C A L D E S I G N / VA L I D A T I O N
Mechanical design
Piping stress analysis
-

Design according to codes

Static / Dynamic FEA Thermal - Structural analysis
E S P A Ñ A

Steady / Transient State FEA Short and long term cycle perfomance
Fatigue analysis
Full dynamic response, spectrum, harmonic, modal analysis
-
i n g e n i e r i a

THERMO-HYDRAULC
CFD SIMULATION
+
F E M A N A LY S I S CFD + FEA as per point 2.1
Fitness for Service Assessment API 579
Steady / Transient State
d e
s o l u c i o n e s

Mathcad
ASPEN ASME
Hysys AD2000
software tools HTFS (ASPEN) design codes EN
PVELITE CODAP
CAESAR II
CFD - FLUENT, CFX, OPENFOAM BS
ANSYS
C A D E
1 - Process Engineering
1.1 - Process Simulation
CASE STUDY
1.2 - Upset Analysis
1.3 - Sensitive Analysis
advanced mechanical engineering
advanced energy, thermal and process engineering
2 - Process Equipment Engineering
2.1 - Thermal-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

flare gas recovery system

objective
Thermal and Hydraulic simulation of exhaust gas pipe network (including relief valves behaviour) and flare stack.
Mechanical validation of pipes, KO Drum and flare stack.

Following issues were carried out:

- Simulation of relief valves

- Heat transfer simulation between gas and external ambient (hot case, cold case, rain, etc.)
- Friction pressure losses and vacuum simulation of pipe network
- CFD simulation for obtaining temperature and pressure profiles inside the flare stack in transient conditions.
- Mechanical validation of pipes and KO Drum under vacuum conditions.
- Mechanical validation of flare shaft considering temperature profile along the shaft for hot and cold cases.
- Upgrading mechanical proposal for KO Drum and Flare according to current corrosion status.

approach
- Thermal and Hydraulic simulation
- Mechanical pipe network validation under vacuum according to ASME B31.3
- FEA validation of KO Drum and shaft flare including temperature influence on guyed stack

results and conclusions

- Pressure and temperature profiles along pipe network
- Pressure and temperature profiles along flare shaft
- Upgrading mechanical proposal for vessels (KO Drum) and shaft flare

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
1 - Process Engineering
1.1 - Process Simulation
CASE STUDY
1.2 - Upset Analysis
1.3 - Sensitive Analysis
advanced mechanical engineering
advanced energy, thermal and process engineering
2 - Process Equipment Engineering
2.1 - Thermal-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

steam generator train in CSP (concentrated solar power) plants

objective
Thermal design of a Steam Generator Train for a CSP Power Plant
(Solar Parabolic Trough) unde steady state operational conditions
and transient simulation during Steam Turbine Start Up.

Following issues were carried out:

Transient Performance of Steam Generator Train (Steam
temperature, pressure and mass flow Vs time)
Solar field simulation Vs time (HTF temperatures and flow curves
Vs time)
Thermal design under steady state conditions
Redesign of Heat Exchanger Train to meet Steam Requirements
during turbine start up

approach
- Thermal steady state design
- Simulation of HTF System (Solar field, steam generation train
and steam turbine)
- Optimization of steam generator train to meet steam turbine
start up ramp (design)

results and conclusions

- Optimized geometry of Steam Generation Train
- Performance curves

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
1 - Process Engineering
1.1 - Process Simulation
CASE STUDY
1.2 - Upset Analysis
1.3 - Sensitive Analysis
advanced mechanical engineering
advanced energy, thermal and process engineering
2 - Process Equipment Engineering
2.1 - Thermal-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

HTF system sizing optimization in CSP plants

objective
Size optimization of HTF pipe network in Solar Parabolic Trough Power Plant according to real solar irradiation (DNI) on plant location.

Following issues were carried out.

- Simulation of solar irradiation

- Simulation of solar collectors performance within solar field
- Calculation of HTF temperature and mass flow curves withing solar field
- Hydraulic simulation of pipe network in order to determinate friction losses.
- Thermal simulation of pipe network in order to determinate heat losses.
- Size optimization of individual parts of pipe network from aneconomical and energetic point of view.

approach
- Simulation of solar field
- Thermal and Hydraulic simulation of HTF pipe network
- Optimization algorithm

results and conclusions

- Optimum size of individual parts of HTF pipe network

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
1 - Process Engineering
1.1 - Process Simulation
CASE STUDY
1.2 - Upset Analysis
1.3 - Sensitive Analysis
advanced mechanical engineering
advanced energy, thermal and process engineering
2 - Process Equipment Engineering
2.1 - Thermal-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

downstream treatment and combustion of a compressed Syngas

objective
Simulation of Downstream treatment and Combustion in a Gas Turbine of a compressed Syngas stream.

Following issues were carried out.

- Simulation of Downstream treatment (cooling, depressurization, solubility and gas-liquid separation)

- Gas turbine simulation
- Optimization of process variables in order to maximize electric power from turbine
- Hydraulic simulation of pipe network in order to determinate friction losses.
- Integration useful thermal energy of exhaust hot gases from turbine in actual process plant
- Feasibility

approach
- Simulation of Downstream Process
- Simulation of Gas Turbine
- Optimization algorithm

results and conclusions

- PFD
- P&ID
- Optimized Downstream Treatment variables
- Technical-Economical feasibility study

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
1 - Process Engineering
1.1 - Process Simulation
CASE STUDY
1.2 - Upset Analysis advanced mechanical engineering
1.3 - Sensitive Analysis
advanced energy, thermal and process engineering
2 - Process Equipment Engineering
2.1 - Thermal-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

advanced gasification processes (reacting medium)

objective
Optimization of Pressure and Temperature for a biomass gasification process in order to maximize Low Heating Value (LHV) of Syngas.
Following issues were carried out.

- Simulation of kinetic of Gasification Process

- Study of influence of Pressure and Temperature in kinetic and composition of Syngas
- Performance curves Vs pressure and temperature
- Optimization of process variables to maximize LHV of Syngas
- Proposal of gasification reactor dimensions
- Economical study for optimization case.

approach
- Simulation of process
- Optimization algorithm
- Feasibility study

results and conclusions

- Optimized process variables
- Performance of reactor for optimized variables
- Technical-Economical feasibility study for optimized cases
- Proposal of gasification reactor main dimensions

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
 1 - Process Engineering
1.1 - Process Simulation CASE STUDY
1.2 - Upset Analysis advanced mechanical engineering
1.3 - Sensitive Analysis
advanced energy, thermal and process engineering
2 - Process Equipment Engineering
2.1 - Thermal-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

heat recovery steam generator (HRSG)

objective
Influence evaluation of two upset conditions from a process and mechanical point of view
on HRSG (fired tube type).

Conditions to be evaluated: by-pass system failure and steam line depressurization.

Following issues were carried out:

- Thermal and Hydraulic simulation under upset conditions (tube side and shell side)
- Refractory lining performance (channels, tubesheet, and tubes)
- Temperature distribution of pressure parts by performing transient FEA
- Stress distribution of pressure parts by performing transient FEA
- Proposal to minimize effects of upset conditions under consideration

approach
- Thermal-Hydraulic simulation
- Transient Thermal and Mechanical FEA

results and conclusions

- Temperature and pressure distribution of cold and hot fluids
- Temperature and stress distribution of pressure parts
- Remediation and prevention process measures

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
1 - Process Engineering
1.1 - Process Simulation CASE STUDY
1.2 - Upset Analysis advanced mechanical engineering
1.3 - Sensitive Analysis
advanced energy, thermal and process engineering
2 - Process Equipment Engineering
2.1 - Thermal-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

water knock-out drum with internal tube heat exchanger

objective
Simulation of Water Knock-Out (3-phase configuration) under failure of temperature control valve of steam
supply line for internal coil.

Following issues were carried out:

- Maximum steam flow through control valve

- Temperature and evaporation rate of water under maximum steam flow
- Turbulence inside vessel
- Performance of separator (composition of each phase)
- Performance of demister under upset conditions (flow temperature, pressure and gas composition)

approach
- Heat transfer simulation between internal tube exchanger and fluid)
- Hydrodynamic simulation of liquids under evaporation conditions
- Thermodynamic equilibrium of phases

results and conclusions

- Separation Efficiency for each phase
- Composition of each phase
- Maximum temperature of each phase

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
1 - Process Engineering
1.1 - Process Simulation CASE STUDY
1.2 - Upset Analysis advanced mechanical engineering
1.3 - Sensitive Analysis
advanced energy, thermal and process engineering
2 - Process Equipment Engineering
2.1 - Thermal-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

biogas line

objective
Simulation of influence of failure in Methane composition Control Loop on biogas line
equipment (H 2 S removal, gas turbine, flare and related equipment )

Following issues were carried out:

- Calculation of maximum flow and composition of biogas under uncontrolled captation.

- Simulation of effect over hydraulic seals of biogas line (biogas leak to atmosphere)
- Response simulation of H2S removal system under biogas peak flow (peak of H2S
content in outlet stream)
- Composition of combustion gases under H2S peak
- Dew point for acid components of combustion gases and risk of corrosion in cold
points

approach
- Hydraulic simulation on biogas pipe network
- Process simulation of equipment (desulphuration scrubber, gas turbine and flare)
- Emissions and corrosion study

results and conclusions

- Flow and compositon of emissions
- Cold points to be checked to prevent local corrosion
- Re-design of lines and drain points

Friction losses

Length

Header 1 Header 2

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
1 - Process Engineering
1.1 - Process Simulation
1.2 - Upset Analysis
CASE STUDY
1.3 - Sensitive Analysis advanced mechanical engineering
advanced energy, thermal and process engineering
2 - Process Equipment Engineering
2.1 - Thermo-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

exothermic reactor

objective
Thermal and Kinetic Simulation of Exothermic Reactor in order to define
cooling system and control loop.

Following issues were carried out:

- Kinetic simulation
- Heat transfer simulation between reacting medium and internal cooling coil
- Calculation of steady steates Vs cooling fluid temperature
- Stability Phase Diagrams
- Definition of stable operation conditions

approach
- Kinetic and thermal model
- Transient simulation and steady state calculations Vs operational conditions

results and conclusions

- Operational conditions (reacting medium and cooling system) in order to
achieve stable steady states.
- Sensitive diagrams for main operational variables
- Temperature control loop proposal

Diagram phase (unstable steady state)

Diagram phase (stable steady state)

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
1 - Process Engineering
1.1 - Process Simulation
1.2 - Upset Analysis
CASE STUDY
1.3 - Sensitive Analysis advanced mechanical engineering
advanced energy, thermal and process engineering
2 - Process Equipment Engineering
2.1 - Thermo-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

biological reactor (Fermenter)

objective
Kinetic Simulation of Fermenter in order to determinate stable conditions for
start-up and operation as well as prediction of effects of changes in biomass
inlet flow.

Following issues were carried out:

- Kinetic simulation
- Calculation of steady states Vs initial biological substrate concentration
- Effect of changes in inlet biomass flow on each steady state
- Recirculation effect

approach
- Kinetic simulation
- Transient simulation and steady states calculation
- Methane production optimization

results and conclusions

- Operational conditions to achieve steady state with maximum methane
production
- Recirculation rate
- Control loop proposal based on methane concentration

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
1 - Process Engineering

1.1 - Process Simulation CASE STUDY

1.2 - Upset Analysis
1.3 - Sensitive Analysis advanced mechanical engineering
advanced energy, thermal and process engineering
2 - Process Equipment Engineering
2.1 - Thermal-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

lp bog after cooler (air cooled heat exchanger)

objective
Thermal-Hydraulic and mechanical validation of air cooler (ACHE) working
as after cooler in gas compression line during start-up (recycled and
opened flow)

Following issues were carried out:

- ACHE thermal rating for each point of start-up ramp
- Thermal-hydraulic simulation of tubeside during start-up ramp
- Dynamic stress analysis Air side film coefficient Vs time
- Fatigue analysis and evaluation

approach
- Performance of ACHE during start-up ramp
- CFD of tubeside during start-up
- FEM analysis of nozzles, headers, finned tubes and tubesheets
during start-up. Input data extracted from previous CFD output.

results and conclusions Inlet flow rate Vs time

- Mass flow rate which allows a safety and stable start-up of

line, in order to avoid excessive pressure losses, local absolute
pressures and velocities.
- Detail thermal performance of ACHE during start-up.
- Maximum stress of pressure parts
- Maximum allowable number of cycles
- Design modifications and aumented inspections proposal for
bundle tube supports

Tube side Mach number

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
1 - Process Engineering

1.1 - Process Simulation CASE STUDY

1.2 - Upset Analysis
1.3 - Sensitive Analysis advanced mechanical engineering
advanced energy, thermal and process engineering
2 - Process Equipment Engineering
2.1 - Thermal-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

HTF expansion vessel

objective
Mechanical design of nozzles and saddles of HTF system equipment
(expanssion vessels, buffer tanks, etc.).
Thermal shock evaluation under transiend conditions.

Following issues were carried out:

- Transient thermal calculation of fluid bulk temperature inside

based on initial temperature, inlet temperature and flow
curves
- Inside heat transfer coefficient for gas and liquid
- FEA of nozzles (inlet liquid part)
- FEA of saddles
- Fatigue analysis and evaluation

approach
- Transient thermal simulation (inputs required for FEA)
- FEA for pressure parts (shell, heads, nozzles) and saddles

results and conclusions

- Nozzles reinforcement
- Saddles geometry
- Maximum number of allowable cycles for operating life

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
1 - Process Engineering

1.1 - Process Simulation CASE STUDY

1.2 - Upset Analysis
1.3 - Sensitive Analysis advanced mechanical engineering
advanced energy, thermal and process engineering
2 - Process Equipment Engineering
2.1 - Thermal-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

WHB - waste heat boiler

objective
Validation of conventional thermal and mechanical design
of two Waste Heat Boiler (WHB) of a Desulphuration Plant
by means of Finite Element Analysis (FEA) in order to study
local effects from a thermal and mechanical point of view,
considering process requirements.

Following issues were carried out:

- Thermal-Hydraulic design (full) including steam risers
and downcomers
- Definition of internal refractory lining for channels
to meet minimum and maximum wall temperature
limits for cold and hot process cases.
- Validation of tubesheet lining and ferrules of tubes
(Max. tube-tubesheet temperature)
- FEA of channels, forged ring/Knucle and tubesheet
- FEA of risers and downcomers

approach
- Static thermal simulation to determinate tube
side and shell side bulk temperatures and heat
transfer coefficients.
- FEA to determinate temperature distribution
within solids
- FEA to determinate stress of pressure parts

results and conclusions

- Full mechanical design
- Channels and tubesheet linning
- Forged ring knuckle geometry
- Tubesheet thickness
- Risers and downcomers stress analysis

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
1 - Process Engineering

1.1 - Process Simulation CASE STUDY

1.2 - Upset Analysis
1.3 - Sensitive Analysis advanced mechanical engineering
advanced energy, thermal and process engineering
2 - Process Equipment Engineering
2.1 - Thermal-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

flue gas system

objective
Validation of conventional thermal and mechanical design
of two Waste Heat Boiler (WHB) of a Desulphuration Plant
by means of Finite Element Analysis (FEA) in order to study
local effects from a thermal and mechanical point of view,
considering process requirements.

Following issues were carried out:

- Definition of internal refractory lining for channels
to meet minimum and maximum wall temperature
limits for cold and hot process cases.
- Validation of tubesheet lining and ferrules of tubes
(Max. tube-tubesheet temperature)
- FEA of channels, forged ring/Knucle and tubesheet
- FEA of risers and downcomers

approach
- Static thermal simulation to determinate tube
side and shell side bulk temperatures and heat
transfer coefficients.
- FEA to determinate temperature distribution
within solids
- FEA to determinate stress of pressure parts

results and conclusions

- Channels and tubesheet linning
- Forged ring knuckle geometry
- Tubesheet thickness
- Risers and downcomers stress analysis

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
1 - Process Engineering

1.1 - Process Simulation CASE STUDY

1.2 - Upset Analysis
1.3 - Sensitive Analysis advanced mechanical engineering
advanced energy, thermal and process engineering
2 - Process Equipment Engineering
2.1 - Thermal-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

melting zinc furnace

objective approach
Optimization of Zinc Melting Furnace (thermal duty, recirculation - Transient conjugated heat transfer of system solid ingot-liquid
rate and geometry) by CFD/CHT zinc (Fluent)
- Optimization of process and geometry parameters
Following issues were carried out:

- Transient Ingot Heating simulation during specified melting time

- Thermal-Hydraulic simulation of surrounding heating fluid (liquid zinc) results and conclusions
- Effect of recirculation rate and chambers geometry - Chambers geometry
- Effect of solid ingot in flow profiles during melting process - Recirculation mass flow
- Transient study of trayectories of slag inside melting chamber - Thermal duty and position of burners

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
1 - Process Engineering

1.1 - Process Simulation

1.2 - Upset Analysis
CASE STUDY
1.3 - Sensitive Analysis advanced mechanical engineering
advanced energy, thermal and process engineering
2 - Process Equipment Engineering
2.1 - Thermal-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

thermal energy storage

objective
Design of thermal storage system based on concrete with
thermal oil acting as heating/cooling fluid by CFD/CHT

System is able to storage excess energy and to recover it

adapted to demand with thermal oil as heating / cooling fluid

Following issues were carried out:

- Definition of tubes geometry and pitch

- Thermal-Hydraulic simulation of tubeside (HTF side)
- Tridimensional conduction heat transfer inside solid based
on thermal properties (conductivity and heat capacity)
- Definition of external isolation in order to minimize heat
losses

approach
- Transient conjugated heat transfer of concrete system (Fluent)
- Optimization of geometry in order to meet process requirements
(heating and cooling ramps)

results and conclusions

- Heat Exchanger geometry (concrete section and tubes)
- Charging and discharging curves Vs time

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
1 - Process Engineering

1.1 - Process Simulation CASE STUDY

1.2 - Upset Analysis
1.3 - Sensitive Analysis advanced mechanical engineering
advanced energy, thermal and process engineering
2 - Process Equipment Engineering
2.1 - Thermal-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

finned tubes (recovery heat exchanger)

objective
Determination of effect of finned tube (thermal inertia based
on heat capacity) on gas temperature during transient periods
in an Air Cooler Heat Exchanger.
Definition of temperature control loop and winterization
strategies.

Following issues were carried out:

- Thermal air side / tube side simulation
- Calculation of heat exchanged based on inlet tube side
temperature and flow curves.
- Performance of finned tube Vs time
- Tube side outlet temperature Vs time

approach
- Transient Conjugated Heat Transfer of air - finned tube
-gas system
- Calculation of effect on outlet gas temperature of heat
capacity of finned tube Vs time

results and conclusions

- Process gas outlet temperature considering thermal
inertia of finned tubes
- Proposal for "tunning" temperature control loop based
on an adapting fuzzy control loop
- Proposal for new set pont for recirculation air temperature
during winterization strategy

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
1 - Process Engineering

1.1 - Process Simulation CASE STUDY

1.2 - Upset Analysis
1.3 - Sensitive Analysis advanced mechanical engineering
advanced energy, thermal and process engineering
2 - Process Equipment Engineering
2.1 - Thermal-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

waste heat boiler (WHB)

objective
Thermal, Hydraulic and Mechanical design of Waste Heat Boiler
(fired tube type) for a Sulphur Recovery Plant.

Following issues were carried out:

- Thermal design of Shell and Tube Heat Exchanger (fired

tube)
- Hydraulic design of riser, downcomers and steam drum
- Mechanical design of pressure parts based on design
conditions
- Thermal and Mechanical evaluation of rating cases

approach
- Process design (Thermal and Hydraulic)
- Mechanical design of pressure parts

results and conclusions

- Thermal and hydraulic design (TEMA Process Data Sheet)
- Mechanical Calculation report
- Risers and downcomers Stress report

This scope was complemented with a Thermal-Hydraulic

+ FEA analysis for detailed study of local effects as per
case study described in section 2.1

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
1 - Process Engineering

1.1 - Process Simulation CASE STUDY

1.2 - Upset Analysis
1.3 - Sensitive Analysis advanced mechanical engineering
advanced energy, thermal and process engineering
2 - Process Equipment Engineering
2.1 - Thermal-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

heat exchangers
(biflux, feedwater heaters, closed cooling water, steam
superheater, Shell and Tube, etc.)

objective
Thermal, Hydraulic and Mechanical design of Biflux Heat
Exchanger (bayonet type)

Following issues were carried out:

- Thermal and Hydraulic design

- Material selection
- Mechanical design of pressure parts based on design
conditions
- Thermal and Mechanical evaluation of rating case

approach
- Process design (Thermal and Hydraulic)
- Mechanical design of pressure parts

results and conclusions

- Thermal and hydraulic design (TEMA Process Data Sheet)
- Mechanical calculation report

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
1 - Process Engineering

1.1 - Process Simulation CASE STUDY

1.2 - Upset Analysis
1.3 - Sensitive Analysis advanced mechanical engineering
advanced energy, thermal and process engineering
2 - Process Equipment Engineering
2.1 - Thermal-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

spray dryer

objective
Design of Spray Dryer (drying chamber and cyclon chamber)
for lixiviates effluent from landfill.

Following issues were carried out:

- Atomization system design
- Air heating supply design
- Volute air inlet design
- Drying chamber and cyclon design
- Instrumentation and control
- Mechanical design of pressure parts and auxiliary
structures

approach
- Fluid-dynamics design of drying chamber and cyclon by
means of CFD simulation
- Static Mechanical design of pressure parts
- Mechanical design of auxiliary structures

results and conclusions

- P&ID
- Dimensional drawings of drying chamber and cyclon
- Atomization system specification
- Specification Data Sheet of commercial components
- Instrumentation and control strategy

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
1 - Process Engineering

1.1 - Process Simulation CASE STUDY

1.2 - Upset Analysis
1.3 - Sensitive Analysis advanced mechanical engineering
advanced energy, thermal and process engineering
2 - Process Equipment Engineering
2.1 - Thermal-Hydraulic and FEM Analysis
2.2 - CHT - Conjugated Heat - Transfer
2.3 - Process Equipment Design

air coolers

objective
Thermal, Hydraulic and Mechanical design of Air Coolers
according to API 661.

Following issues were carried out:

- Thermal design
- Rating evaluation
- Mechanical design of pressure parts
- Instruments and control loop proposal

approach
- Thermal design according to API 661
- Static Mechanical design of pressure parts

results and conclusions

- P&ID
- API 661 Process Data Sheet
- Control loops

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
 CSP - Concentrated Solar Power
CASE STUDY
advanced mechanical engineering
advanced energy, thermal and process engineering

CSP Pilot Plant

Basic and Detail engineering of molten salt Loop

objective
Complete basic and detail engineering of CSP pilot plant based on molten
salt as heat transfer fluid.

Following tasks were carried out:

- Basic and detail engineering including:

- Process design
- Design of main process equipment
- Mechanical/Structural/Civil Works/Electric engineering

results and conclusions

- Molten Salt loop process simulation
- Thermal and Hydrodynamic simulation: HTF mass flow optimization (mmin / mmax)
- Temperature profile inside receiver
- Piping Stress and flexibility analysis
- Impedance heating
- Materials selection (piping, valves, etc.)

C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N
C A D E s o l u c i o n e s d e i n g e n i e r i a - E S P A Ñ A - S P A I N