We recognise the dynamic nature of refinery units and have developed a range of chemicals and application techniques to decontaminate columns, vessels, exchangers and piping removing hydrocarbons from heavy asphaltenes to light ends and benzene. Each system is individually assessed by our engineers to determine the most efficient means of decontamination, considering the system design, operational history and client expectations. From rapid vapour phase decontamination in just 8-12 hours to liquid circulations and full unit decontamination, ProDecon has the right chemistry, the right equipment and the right people to deliver your turnaround.

ProDecon’s V-Purge™ and Decon-88™ family of chemicals are highly effective in vapour phase decontamination.  The chemistry is introduced into the steam flow through specially designed manifolds and is carried throughout the system effectively contacting all surfaces.

The chemistry works to free the hydrocarbons and release gaseous contaminants.  The V-Purge™ chemistry works simultaneously to oxidise pyrophoric iron sulphide leaving the columns and vessels safe for man entry with zero LEL, Zero H2S and zero benzene in just 8-12 hours.  With minimal invasive set up and effluent generation, our vapour phase decontamination is a cost effective and rapid option across all fractionation columns.

ProDecon provide full service liquid phase decontamination service including circuit design, temporary piping, pumps and effluent handling. The process is designed taking into consideration the target areas of heavy fouling, flow distribution and hydraulic loading.

This process is particularly effective in minimising the need for hydrojetting in columns, vessels and heat exchangers removing heavy deposits, residues, sludges and insoluble materials. This process is commonly combined with the vapour phase decontamination for use in column and overhead systems quickly achieving gas free conditions and vessel cleaning, allowing maintenance to proceed immediately on handover and reducing the overall turnaround schedule.

Fouling from asphaltenes, waxes and tars in heavy hydrocarbons on vis breakers, vacuum residues, cokers and slurry circuits cause stubborn hard deposits in columns bottoms and heat exchangers causing a loss in efficiency and presenting a challenge for mechanical cleaning. ProDecon’s Pro-FlowTM and Pro-SolveTM products are especially designed to help alleviate this issue.

Working in the wash oil phase during the turnaround Pro-FlowTM acts to break down the heavy asphaltenes, improving sludge removal and accelerating handover and improving the effectiveness of the wash oil circulation.

Pro-SolveTM and Pro-FlowTM can both be applied to heat exchangers in-situ to help restore performance providing energy savings and increase productivity.

ProDecon specialises in the engineering of full unit decontamination, integrating fully with the refinery shutdown and de-inventory procedure, to provide a completely hydrocarbon free unit.

Where traditional decontamination processes focus on the column and overhead systems, this complex process operates from the battery limit feed through all piping, exchangers, vessels and columns including product run downs, flare and closed blow down systems.  Handover from operations to turnaround team with a completely hydrocarbon and H2S free unit, provides the maximum level of safety for the maintenance on the unit.  With all vessels, piping and exchangers cleaned, blinding requirements and mechanical cleaning needs are minimized, reducing overall turnaround schedule and costs.

Chemistry is selected according to the foulant and are available for use in an aqueous phase or using a hydrocarbon carrier allowing for operation at higher temperatures and often directly in process. ProDecon have a range of proprietary chemicals specifically for removing heavy hydrocarbon deposition in-situ without the need for bundle removal and the associated mechanical requirements.

Inorganic deposits from ineffective water treatment programs or corrosion are removed using reactive chemistry. The process is designed specifically for the given foulant taking into account the metallurgy and design limitations of the entire system to ensure compatibility.  ProDecon’s R&D function can help to identify suitable cleaning methods for other forms of process fouling from a wide range of industries.

ProDecon provide a complete service with chemical circulation and dosing pumps to achieve the required flow characteristics within the exchanger. Mobile heat exchangers are provided to ensure the correct temperature conditions are achieved and controlled.  The system is circulated with a flow reversal manifold to ensure maximum physical impact.  All parameters are monitored using our on-site testing facilities to monitor and control the chemical reaction and determine an accurate end point to the process.

With our full range of capabilities we are able to provide effective heat exchanger cleaning to meet your individual needs, from full heat trains to individual equipment.  Our performance restoration service can help return your plant quickly to efficient operation saving costs and increasing production.

Annual cleaning programmes offer many benefits:

Unlike aggressive methods such as water blasting this presents no risk of damaging the fin fans.  Our operators can clean the fans from the bottom-up meaning that there is no need for scaffolding or other temporary platforms. This has two major benefits, as the operators can work underneath the fans where there is no chance of them damaging the delicate fins by standing on them. Secondly, our operators do not need to access to the plenum chamber and this reduces the hazards faced by workers.

The method is non-hazardous, REACH compliant, compatible with all metallurgies and environmentally safe. The levels of performance restoration gained over previously employed water jetting methods mean we see repeat orders year after year from customers.

Combustion side fouling of heat transfer surfaces occurs as a result of incomplete combustion which leads to the formation of carbon deposits. Some degree of incomplete combustion is inevitable no matter what type of fuel is being used (coal, heavy residual oil or gas).

Thermal cracking of the fuel is taking place in the combustion chamber because the fuel in the form of fine particles is exposed to high temperatures without adequate air. Cracking in vapour phase results in relatively softer carbonaceous deposits like soot. Cracking in liquid phase results in more sticky carbonaceous deposits. These deposits adhere to heat transfer surfaces especially at areas with flow constrictions. Apart from the unburnt carbon, sulphates and vanadates are other common substances that are found in fouling deposits.

The location of the fouling can be determined by observing the bridge walls, the convection outlet and stack temperatures, the pressure drop across convection areas and across air heaters. The improvements in efficiency are quickly evident and regular use of Polarchem can significantly extend the run time and negate the need for water washing during shutdown.

The process can be applied to all types of box or cylindrical furnaces, with natural or forced draught, firing fuel oil alone or in combination with gas. Applied as a one off solution for performance restoration or as part of a continued preventative maintenance programme the Polarchem process reduces fuel consumption, corrosion, air pollution, soot blowing and increases the intervals between shutdown.

The chemical cleaning usually consists of a combination of the following stages:

For further improvements in efficiency, ProDecon are able to provide an on-line cleaning service to remove tube fouling and avoid the formation of future fouling. This extends run time, improves heat transfer and minimise’ s corrosion.

Starting with the flow modelling to determine the required characteristic to meet Cleaning Force required (CFR) in relation to the Maximum Continuous Rating (MCR) conditions, throughout the system network, quality engineering is at the heart of this critical activity.  Exit piping and silencing requirements are taken into consideration and incorporated into the overall design.  We can provide acoustic silencers and quench attemperator systems to ensure this high energy activity can be executed safely within the congested construction environment.

Our engineers monitor the steam blowing conditions to ensure the design parameters are met and the results are proven using pneumatically inserted target plates.

One of the initial steps in the pre-commissioning process is to pig the line to remove construction debris, scale and standing water.

ProDecon has extensive experience in pipeline de-watering utilising foam and wire pigs until all standing water and scale is removed. The line is then dried to the required dew point (-40°C) utilising oil free compressors, desiccant dryers or nitrogen.

During the final phase of pipeline pre-commissioning, ProDecon can support and provide a comprehensive hydrostatic testing service to ensure a pipeline's integrity and to establish its maximum allowable operating pressure.

ACF products react preferentially with strong acids such as hydrochloric acid (HCl). Already precipitated corrosive ammonium salts can be dissolved and removed during operation. Liquid ACF salts are formed with a neutral pH and very low corrosion potential.

Applied On-Line the ACF technology optimizes your process operation by:

• Prevention of salt fouling and corrosion.
• Formation of ACF salts with a neutral pH.
• High moisture absorption characteristics; ACF salts are highly hygroscopic and fully soluble in water.
• Very low corrosivity of formed ACF salts.
• Easy handling of liquid ACF products.
• Removal of the ammonia salts without re-deposition downstream.
• Restores performance without the need for expensive shutdowns.
  
  

Specialising in hazardous hydrocarbon and chemical environments, we often experience complex one-off projects that require specialist technical expertise to resolve critical challenges through our unrivalled market leading expertise across decontamination, sludge processing and chemical cleaning. We’re able to engineer bespoke industrial cleaning solutions to tackle unique projects that combines our in-house R&D and engineering capability to address complex challenges in any industrial environment.