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Doctor Edward Ishiyama

Doctor Edward Ishiyama

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Office Phone: 330144

Research Interests

Research description

Fouling in crude refinery preheat trains (IHS, London)

Crude oil refinery preheat trains are network of heat exchangers that are designed to reduce energy consumption but their operation can be hampered by fouling. Fouling behaviour vary between refineries. Effective management of preheat operation requires inspection of historical plant performance data to determine fouling behaviours, and the exploitation of that knowledge in turn to predict future performance.

Fouling results in major economic and environmental penalties. A state-of-the art preheat train fouling analysis and mitigation simulator, SmartPM (smart predictive maintenance), is developed. The simulator takes plant monitoring data to evaluate past performance and predict future refinery throughput, energy use, emissions and optimum heat exchanger maintenance/cleaning schedules. The smart technology then allows “what if” scenario planning, for example to assess economic benefits of better heat exchanger design; the use of anti-foulant chemicals, or to assess cost and operational penalties through refining new crude blends.

Deposit ageing (with Ian Wilson and Bill Paterson)

The effect of fouling in heat-transfer devices is complicated by ageing of the fouling deposits. Ageing is, like deposition, often sensitive to temperature, so that heat transfer, deposition, and ageing are coupled phenomena. We investigate methods to quantify thermal ageing of deposits. The model is extended to scheduling cleaning algorithms; aim is to generate guidelines in ‘when’ to use ‘which’ cleaning methods, where different degree of ageing results in different degree of cleaning.

Past projects

Carbon Brainprint (with Cranfield University)

The Carbon Brainprint concept is introduced as the prospect of assessing the global impact of research and teaching in the Higher Education sector in mitigating global warming. The subproject at Cambridge, focuses on quantifying the impact of research done in the area of scheduling cleaning on refinery preheat trains on reducing carbon emissions.

Fouling in sugar refineries (with Sebastien Sors, Polytech Nantes, France)

On a sugar beet refinery, raw sugar juice is preheated using a network of heat exchangers before entering a series of evaporators which concentrate it prior to crystallisation. These heat exchangers undergo severe fouling due to the crystallization of sulphates and carbonates present in raw sugar beet juice and wash water. The preheating is performed by recovering heat from crystallizer and evaporator vapours and condensates. This work describes mitigating fouling in the sugar refinery preheat train through scheduling of heat exchanger cleaning based on a heuristic algorithm described by Ishiyama et al. (2009). The objective is to minimise the use of a valuable heating utility stream by the judicious use of cleaning actions. A case study based on a British Sugar refinery, published by Smaïli et al. (1999), is  revisited. The results are compared with those obtained by Smaïli et al. employing an MINLP/NLP formulation. Both approaches demonstrate the economic benefit and technical feasibility of fouling mitigation by manipulating cleaning.
Ref: Smaïli, F., Angadi, D. K., Hatch, C. M., Herbert, O., Vassiliadis, V. S. and Wilson, D. I. 1999. Optimization of scheduling of cleaning in heat exchanger networks subject to fouling: Sugar industry case study. Food & Bioproducts Processing, 77, 159–164.

A techno-economic analysis of the performance of antifouling coatings in food industry heat exchangers (with Leonardo Gomes Da Cruz, University of São Paulo)

Coatings for reducing the rate of fouling on heat transfer surfaces are often promoted as a viable mitigation option in the food sector. The financial attractiveness of such coatings for retrofit applications is considered, where an uncoated exchanger is replaced by a coated one. The replacement unit may be larger owing to the extra thermal resistance introduced by the coating. The annualised operating costs are calculated, based on optimised, regular fouling and cleaning cycles as well as the annualised cost of the replacement unit. Fouling rates based on literature values are used. The attractiveness of the coating is very sensitive to the reduction in fouling rate if this can be achieved over the lifetime of the unit. The marginal benefit, which must include the additional cost of the coating, can then be estimated.

Keywords

  • crude oil
  • Carbon Brainprint
  • network simulation
  • fouling
  • ageing
  • process control
  • heat exchanger

Key Publications

Journal Publications

Ishiyama E.M. and Pugh S.J. (2015) Considering in-tube crude oil boiling in assessing performance of preheat trains subject to fouling, Heat Transfer Engineering, 36(7-8), 632-641.

Gomes da Cruz L., Ishiyama E.M., Boxler C., Augustin W. and Wilson D.I. (2015). Value pricing of surface coatings for mitigating heat exchanger fouling, Food and Bioprocess Engineering, 93, 343–363.

Ishiyama E.M., Paterson W.R. and Wilson D.I. (2014) Aging is important: closing the fouling-cleaning loop, Heat Transfer Engineering, 35(3), 311-326.

Ishiyama E.M., Pugh S.J., Paterson W.R., Kennedy J., Polley G.T. and Wilson D.I. (2013). Management of crude preheat train subject to fouling, Heat Transfer Engineering, Special Edition, 34(9), 692-701.

Polley G.T., Tamakloe E., Wilson D.I. and Ishiyama E.M. (2013). Applying thermo-hydraulic simulation and heat exchanger analysis to the retrofit of pre-heat trains, Applied Thermal Engineering, 51(1-2).

Pogiatzis T., Ishiyama E.M., Paterson W.R., Vassiliadis, V.I. and Wilson D.I. (2012). Identifying optimal cleaning cycles for heat exchangers subject to fouling and ageing, Applied Energy, 89(1), 60-66.

Ishiyama E.M., Paterson W.R. and Wilson D.I. (2011). Exploration of alternative models for the ageing of fouling deposits, AIChE J, 57(11), 3199-3209.

Ishiyama E.M., Paterson W.R. and Wilson D.I. (2011). Optimum cleaning cycles for heat transfer equipment undergoing fouling and ageing, Chemical Engineering Science, 66(13), 604-612.

Ishiyama E.M., Paterson W.R., Wilson D.I., Heins, A.V. and Spinelli L. (2010). Scheduling cleaning in a crude oil preheat train subject to fouling: incorporating desalter control, Applied Thermal Engineering, 30(13), 1852-1862.

Ishiyama E.M., Coletti F., Machietto S., Paterson W.R. and Wilson D.I. (2010). Impact of deposit ageing on thermal fouling: Lumped parameter model, AIChEJ, 56(2), 531-545.

Coletti F., Ishiyama E.M., Machietto S., Paterson W.R. and Wilson D.I. (2010). Impact of deposit ageing and surface roughness on thermal fouling: distributed model, AIChEJ, 56(12), 3257-3273.

Ishiyama E.M., Paterson W.R. and Wilson D.I. (2009). The effect of fouling on heat transfer, pressure drop and throughput in refinery preheat trains: Optimisation of cleaning schedules, Heat Transfer Engineering, 30(10-11), 1-10.

Ishiyama E.M., Paterson W.R. and Wilson D.I. (2009). Platform for techno-economic analysis of fouling mitigation options in refinery preheat trains, Energy & Fuels, 23(3), 1323-1337.

Ishiyama E.M., Paterson W.R. and Wilson D.I. (2008). Thermo-hydraulic channelling in parallel heat exchangers subject to fouling, Chemical Engineering Science, 63(13), 3400-3410.

  

Conference Publications

AIChE meetings

Ishiyama E.M., Kennedy J., Pugh S.J. (2014). Scopes of improvements on refinery preheat trains subject to crude oil fouling, in conference proceedings of the AIChE Spring Meeting, New Orleans, LA.

Ishiyama E.M., Pugh S.J., Kennedy J., Wilson D.I., Ogden-Quin A. and Birch G. (2013). How to get the best from your preheat train – A UK refinery based case study, Paper 31, AIChE Meeting, San Antonio, Texas.

Ishiyama E.M., Polley G.T. and Pugh S.J. (2012). Recent experiences on modelling fouling of crude refinery preheat trains handling complex and heavy crude slates, Paper 31(a), AIChE Spring National Meeting, Huston.

Ishiyama E.M., Pugh S.J. and Wilson D.I. (2012). Industrial experience in handling cleaning of crude refinery preheat trains, Paper 31(e), AIChE Spring National Meeting, Huston.

Ishiyama E.M., Pugh S.J., Wilson D.I., Paterson W.R. and Polley G.T. (2011). Importance of data reconciliation on improving performances of crude refinery preheat trains, paper 22d, AIChE Spring National Meeting, Chicago.

Polley G.T., Tamakloe E., Ishiyama E.M. and Pugh S.J. (2011). Analysis of plant data, paper 94d, AIChE Spring National Meeting, Chicago.

Polley G.T., Wilson D.I. and Ishiyama E.M. (2011). Mitigation of fouling in preheat trains, paper 94e, AIChE Spring National Meeting, Chicago.

Polley G.T., Tamakloe E., Wilson D.I. and Ishiyama E.M. (2011). Thermo-hydraulic simulation of preheat train behaviour, paper 94f, AIChE Spring National Meeting, Chicago.

Kumana J.D., Polley G.T., Pugh S.J., Ishiyama E.M. (2010). Improved energy efficiency in CDUs through fouling control, 2010 AIChE Spring Meeting and 6th Global Congress on Process Safety, paper 99a.


International Conference on Fouling and Cleaning in Food Processing

Gomes da Cruz L., Ishiyama E.M., Boxler C., Augustin W. and Wilson D.I. (2014). Value pricing of surface coatings for mitigating heat exchanger fouling, Cambridge, UK.

Sors S., Ishiyama E.M. and Wilson D.I. (2014). Management of beet sugar refinery preheat trains, Cambridge, UK.

Ishiyama E.M., Paterson W.R. and Wilson D.I. (2010). The effect of ageing of fouling-cleaning symbiosis, Cambridge, UK, 128-135.


International Conference on Heat Exchanger Fouling and Cleaning (HEFC)

Ishiyama E.M., Pugh S.J. , Kennedy J., Wilson D.I., Ogden-Quin A. and Birch G. (2013). An industrial case study on retrofitting heat exchangers and revamping preheat trains subject to fouling, in conference proceedings of the 10th HEFC conference, Budapest, Hungary.

Ishiyama E.M., Pugh S.J. and Wilson D.I. (2013). Importance of considering uncertainties in heat exchanger plant data during data reconciliation, in conference proceedings of the 10th HEFC conference, Budapest, Hungary.

Ishiyama E.M. and Pugh S.J. (2013). Considering in-tube boiling in assessing performance of crude refinery preheat trains subject to fouling, in conference proceedings of the 10th HEFC conference, Budapest, Hungary.

Ishiyama E.M., Pugh S.J., Paterson W.R., Kennedy J., Polley G.T. and Wilson D.I. (2011). Management of crude preheat train subject to fouling, in conference proceedings of the 9th HEFC conference, Crete, Greece.

Ishiyama E.M., Paterson W.R. and Wilson D.I. (2011). The impact of ageing on fouling and cleaning: closing the fouling-cleaning loop, in conference proceedings of the 9th HEFC conference, Crete, Greece.

Fuentes M., Polley G.T., Picon-Nunez M. and Ishiyama E.M. (2011). Fuel efficiency of fired heaters: Influence of preheat train performance and fired heater design, in conference proceedings of the 9th HEFC conference, Crete, Greece.

Ishiyama E.M., Paterson W.R., Wilson D.I., Heins, A.V. and Spinelli L. (2009). Importance of control considerations in refinery preheat trains – a case study, in conference proceedings of the 8th HEFC conference, Schladming, Austria.

Wilson D.I., Ishiyama E.M., Paterson W.R. and Watkinson A.P. (2009). Ageing: Looking back and looking forward, in conference proceedings of the 8th HEFC conference, Schladming, Austria.

Ishiyama E.M., Paterson W.R. and Wilson D.I. (2007). Simulating operation of refinery preheat trains for assessing fouling mitigation strategies, in conference proceedings of the 7th HEFC conference, Tomar, Portugal.


Other contributions to literature

Polley G.T., Tamakloe E., Picon-Nunez M., Ishiyama E.M. and Wilson D. I. (2011). Applying thermo-hydraulic simulation and heat exchanger analysis to the retrofit of heat recovery systems, 12th UK National Heat Transfer Conference, September, Leeds.

Ishiyama E.M., Pugh S.J. and Polley G.T. (2011). Use of fouling rate models in performance analysis and retrofit proposal of crude refinery preheat trains, in conference proceedings of the 12th International Conference on Petroleum Phase Behaviour and fouling, London, UK.

Pogiatzis T., Ishiyama E.M., Paterson W.R., Vassiliadis, V.I. and Wilson D.I. (2010). Identifying optimal cleaning cycles for heat exchangers subject to fouling and ageing, in conference proceedings of the PRO-TEM network, Sustainable Thermal Energy Management Conference, Newcastle, UK.

Ishiyama E.M., Paterson W.R. and Wilson D.I. (2008). Platform for techno-economic analysis of fouling mitigation options in refinery preheat trains, in conference proceedings of the 10th International Conference on Petroleum Phase Behaviour and Fouling, Vancouver, Canada.

Polley G.T., Ishiyama E.M. and Pugh S.J. (2012). Using dynamic crude oil fouling models to improve refinery preheat train performance, Hydrocarbon World, 6(2), 48-50.

Pugh S.J. and Ishiyama E.M. (2011), Effective use of refinery data for fouling reduction, Emerson Global Users Exchange, Gaylord Opryland Resort & Convention Center in Nashville, Tennessee, 24-28th October.

Kumana J.D., Pugh S.J. and Ishiyama E.M. (2011). Maintain peak HEN performance under fouling conditions, AIChE Regional Technology Conference, Galveston, Texas, 6-7 October.

Parson D., Chatterton J., Clements-Croome D., Elmulim A, Darby H., Yearly T., Wilson D.I., Ishiyama E.M., (2011). Carbon Brainprint – Final report, HEFCE project LSDHE 43.

Pugh S.J. and Ishiyama E.M. (2011). Next generation software for management of fouling in crude oil preheat trains, Westminster, London, Heat Transfer Society London Forum, 5th July.

Gibbard I., Pugh S.J., Ishiyama E.M., Kennedy J., Polley G.T., Veillet M. and Xu F. (2011). Techniques for the minimization of CDU operating costs, 8th Annual Conference on Oil Refining, Transportation and Trading in the CIS and Baltic States, Odessa, Ukraine.

Pugh S.J. and Ishiyama E.M. (2011). Energy, Emissions, and Efficiency: How to address heat exchanger fouling to reduce energy and maintenance costs while improving plant performance, Penn Energy Webcast, 31st March.

Wilson D.I., Ishiyama E.M., Paterson W.R., Polley G.T. and Pugh S.J. (2011). Management of fouling in crude oil preheat trains, Hydrocarbon World, 6(1), 16-21.

Wilson D.I., Ishiyama E.M. and Paterson W.R. (2008). Minimising the carbon footprint of oil refinery preheat trains: Optimising operation, cleaning and design, Process modelling to reduce carbon footprint, IChemE Process Engineering SG, 27th November.

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