I am currently a visitor in the Paste, Particle and Polymer Processing group (P4G) and a research engineer at HTRI. My research interest is in solving problems associated with the formation of unwanted deposits (fouling) in heat exchangers and associated networks.
Research
Past projects
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 was 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.
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, focused 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.
Publications
Journal Publications
2018
Ishiyama E.M. and Pugh S.J. Effect on flow distribution in parallel heat exchanger networks: Use of thermo-hydraulic channelling model in data reconciliation, Heat Transfer Engineering, https://doi.org/10.1080/01457632.2018.1522098.
Ishiyama E.M., Falkeman E., Wilson D.I. and Pugh S.J. Quantifying implications of deposit ageing from crude refinery preheat train data, Heat Transfer Engineering, https://doi.org/10.1080/01457632.2018.1522072.
2017
Ishiyama E.M., Kennedy J. and Pugh S.J. Fouling management of thermal cracking units, Heat Transfer Engineering, 38(7-8), 694-702.
Wilson D.I., Ishiyama E.M. and Polley G.T. Twenty years of Ebert and Panchal – What next?, Heat Transfer Engineering, 38(7-8), 669-680.
2016
Magens O.M., Ishiyama E.M. and Wilson D.I. Quantifying the ‘Implementation Gap’ for Antifouling Coatings, Applied Thermal Engineering, 99, 683-689.
2015
Ishiyama E.M. and Pugh S.J. 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. Value pricing of surface coatings for mitigating heat exchanger fouling, Food and Bioprocess Engineering, 93, 343–363.
Chatterton J., Parsons D., Nicholls J., Longhurst P., Bernon M., Palmer A., Brennan F., Kolios A., Wilson D.I., Ishiyama E.M., Clements-Croome D., Elmualim A., Darby H., Yearley T., Davies G., Carbon brainprint – An estimate of the intellectual contribution of research institutions to reducing greenhouse gas emissions, Process Safety and Environmental Protection, 96, 74-81.
2014
Ishiyama E.M., Paterson W.R. and Wilson D.I. Aging is important: closing the fouling-cleaning loop, Heat Transfer Engineering, 35(3), 311-326.
2013
Ishiyama E.M., Pugh S.J., Paterson W.R., Kennedy J., Polley G.T. and Wilson D.I. Management of crude preheat train subject to fouling, Heat Transfer Engineering, 34(9), 692-701.
Polley G.T., Tamakloe E., Wilson D.I. and Ishiyama E.M. Applying thermo-hydraulic simulation and heat exchanger analysis to the retrofit of pre-heat trains, Applied Thermal Engineering, 51(1-2), 137-143.
2012
Pogiatzis T., Ishiyama E.M., Paterson W.R., Vassiliadis, V.I. and Wilson D.I. Identifying optimal cleaning cycles for heat exchangers subject to fouling and ageing, Applied Energy, 89(1), 60-66.
2011
Ishiyama E.M., Paterson W.R. and Wilson D.I. 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. Optimum cleaning cycles for heat transfer equipment undergoing fouling and ageing, Chemical Engineering Science, 66(13), 604-612.
2010
Ishiyama E.M., Paterson W.R., Wilson D.I., Heins, A.V. and Spinelli L. 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. 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. Impact of deposit ageing and surface roughness on thermal fouling: distributed model, AIChEJ, 56(12), 3257-3273.
2009
Ishiyama E.M., Paterson W.R. and Wilson D.I. 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. Platform for techno-economic analysis of fouling mitigation options in refinery preheat trains, Energy & Fuels, 23(3), 1323-1337.
2008
Ishiyama E.M., Paterson W.R. and Wilson D.I. Thermo-hydraulic channelling in parallel heat exchangers subject to fouling, Chemical Engineering Science, 63(13), 3400-3410.
Conference Publications
2019
Ishiyama E.M., Juhel C., Aquino B., Hagi, H., Pugh S.J. and Zettler, H.U., Advanced fouling management through use of HTRI SmartPM: Case study on TOTAL Normandy refinery CDU preheat train, in proceedings of the Heat Exchange Engineering conference, Prague, Czech Republic.
Ishiyama E.M., Pugh S.J., and Joshi H.M., Discussion of using fouling rig analysis to model industrial fouling data, in proceedings of the 13th HEFC conference, Warsaw, Poland.
Ishiyama E.M., and Pugh S.J. Modelling fouling in hydrodesulfurization unit heat exchangers, in proceedings of the 13th HEFC conference, Warsaw, Poland.
Ishiyama E.M., Juhel C., Aquino B., Hagi, H., Pugh S.J. and Zettler, H.U., Advanced fouling management through use of HTRI SmartPM: case studies from total refinery CDU preheat trains, in proceedings of the 13th HEFC conference, Warsaw, Poland.
2018
Ishiyama E.M, Pugh S.J., Melo C., and Segeur F., Benefits of optimizing the cleaning schedule in crude preheat trains, 5th Latin American and Caribbean Refining Congress, Mendoza, Argentina (27 – 30 August 2018).
2017
Ishiyama E.M. and Pugh S.J. Effect on flow distribution in parallel heat exchanger networks: Use of thermo-hydraulic channelling model in data reconciliation, in proceedings of the 12th HEFC conference, Madrid, Spain.
Ishiyama E.M., Falkeman E., Wilson D.I. and Pugh S.J. Quantifying implications of deposit ageing from crude refinery preheat train data, in proceedings of the 12th HEFC conference, Madrid, Spain.
Smith A.D., Ishiyama E.M., Harris J.S. and Lane M.R. Translating crude oil fouling testing rig data to the field: a road map for future research, in proceedings of the 12th HEFC conference, Madrid, Spain.
2016
Pugh S.J., Ishiyama E.M. and Brigone M. Heat exchanger selection improves the performance of refinery preheat trains: Industrial case study, AIChE Spring Meeting, Houston.
2015
Pugh S.J. and Ishiyama E.M. SmartPM for effective management of crude oil refinery preheat trains and other networks subject to fouling, AFPM Annual Meeting, San Antonio, Texas.
Ishiyama E.M., Pugh S.J., Kennedy J. and Wilson D.I. Effect of scheduling cleaning of crude preheat train exchangers on the operation of fired heaters, in proceedings of the 11th HEFC conference, Enfield, Dublin.
Perrone F., Brigone M., Rottoli M., Pugh S.J. and Ishiyama E.M. EMBaffle in refinery service. On-field study and data validation through SmartPM, in proceedings of the 11th HEFC conference, Enfield, Dublin.
Ishiyama E.M., Kennedy J. and Pugh S.J. Fouling management of thermal cracking units, in proceedings of the 11th HEFC conference, Enfield, Dublin.
Wilson D.I., Ishiyama E.M. and Polley G.T. Twenty years of Ebert and Panchal – What next?, in proceedings of the 11th HEFC conference, Enfield, Dublin.
Ishiyama E.M., Pugh S.J., Kennedy J. and Wilson D.I. Optimizing operations of crude preheat train and furnace: Influence of preheat train management on furnace operation, in proceedings of the 3rd Sustainable Thermal Energy conference, Newcastle, UK.
Magens O.M., Ishiyama E.M. and Wilson D.I. Quantifying the ‘Implementation Gap’ for Antifouling Coatings, in proceedings of the 3rd Sustainable Thermal Energy conference, Newcastle, UK.
2014
Ishiyama E.M., Kennedy J., Pugh S.J. Scopes of improvements on refinery preheat trains subject to crude oil fouling, in conference proceedings of the AIChE Spring Meeting, New Orleans, LA.
Gomes da Cruz L., Ishiyama E.M., Boxler C., Augustin W. and Wilson D.I. Value pricing of surface coatings for mitigating heat exchanger fouling, International Conference on Fouling and Cleaning in Food Processing, Cambridge, UK.
Sors S., Ishiyama E.M. and Wilson D.I. Management of beet sugar refinery preheat trains, International Conference on Fouling and Cleaning in Food Processing, Cambridge, UK.
Ishiyama E.M. and Pugh S.J. Effective management of crude preheat train fouling, Heat Exchange Engineering Middle East, Bahrain.
2013
Ishiyama E.M., Pugh S.J., Kennedy J., Wilson D.I., Ogden-Quin A. and Birch G. 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., Pugh S.J. , Kennedy J., Wilson D.I., Ogden-Quin A. and Birch G. 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. 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. 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.
2012
Ishiyama E.M., Polley G.T. and Pugh S.J. 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. Industrial experience in handling cleaning of crude refinery preheat trains, Paper 31(e), AIChE Spring National Meeting, Huston.
Polley G.T., Ishiyama E.M. and Pugh S.J. Using dynamic crude oil fouling models to improve refinery preheat train performance, Hydrocarbon World, 6(2), 48-50.
2011
Ishiyama E.M., Pugh S.J., Wilson D.I., Paterson W.R. and Polley G.T. 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. Analysis of plant data, paper 94d, AIChE Spring National Meeting, Chicago.
Polley G.T., Wilson D.I. and Ishiyama E.M. 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. Thermo-hydraulic simulation of preheat train behaviour, paper 94f, AIChE Spring National Meeting, Chicago.
Ishiyama E.M., Pugh S.J., Paterson W.R., Kennedy J., Polley G.T. and Wilson D.I. 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. 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. 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., Pugh S.J. and Polley G.T. 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.
Wilson D.I., Ishiyama E.M., Paterson W.R., Polley G.T. and Pugh S.J. Management of fouling in crude oil preheat trains, Hydrocarbon World, 6(1), 16-21.
Kumana J.D., Pugh S.J. and Ishiyama E.M. 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., Carbon Brainprint – Final report, HEFCE project LSDHE 43.
2010
Kumana J.D., Polley G.T., Pugh S.J., Ishiyama E.M. Improved energy efficiency in CDUs through fouling control, 2010 AIChE Spring Meeting and 6th Global Congress on Process Safety, paper 99a.
Ishiyama E.M., Paterson W.R. and Wilson D.I. The effect of ageing of fouling-cleaning symbiosis, International Conference on Fouling and Cleaning in Food Processing, Cambridge, UK, 128-135.
Pogiatzis T., Ishiyama E.M., Paterson W.R., Vassiliadis, V.I. and Wilson D.I. 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.
2009
Ishiyama E.M., Paterson W.R., Wilson D.I., Heins, A.V. and Spinelli L. 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. Ageing: Looking back and looking forward, in conference proceedings of the 8th HEFC conference, Schladming, Austria.
2008
Ishiyama E.M., Paterson W.R. and Wilson D.I. 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.
Wilson D.I., Ishiyama E.M. and Paterson W.R. 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.
2007
Ishiyama E.M., Paterson W.R. and Wilson D.I. Simulating operation of refinery preheat trains for assessing fouling mitigation strategies, in conference proceedings of the 7th HEFC conference, Tomar, Portugal.
HEFC = International Conference on Heat Exchanger Fouling and Cleaning
