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Advanced Analytics for Industrial Thermal Systems

Over the years, Hexxcell has developed specialised algorithm to analyse process data of thermal systems. Hexxcell Dynamic Data Analysis™, Fouling Propensity Analysis™ and Crude Slate Design™ provide unprecedented insights and actionable information to improve long-term energy efficiency performance, reduce downtime and decarbonise thermal processes.

Dynamic Data Analysis™

Hexxcell Dynamic Data Analysis™ is a detailed analysis, powered by Hexxcell Studio™, that uses historical plant data to provide deeper insight into the thermo-hydraulic and fouling behaviour of heat exchangers than previously possible.


It allows unveiling key correlations between operating parameters, crude slates and fouling behaviour.​

Key benefits

  1. Assessment of:

    • Measurements quality

    • Thermo-hydraulic performance

    • Economic impact of fouling

    • Efficiency of cleaning action

  2. Identification of:

    • Key HEXs for performance improvement

    • Opportunities for improvement

  3. Diagnostics of fouling causes and detection of changes in behaviour (e.g. inorganic breakthrough)

  4. Impact of operations on fouling rates:

    • Antifoulants

    • Bypasses

    • Flow splits

    • Revamps

Fouling Propensity Analysis™

Hexxcell Fouling Propensity Analysis™ uses advanced data analytics to provide a detailed analysis of the correlation between oils processed, fouling rates and operating conditions.

Crude Slate Design™

Hexxcell Crude Slate Design™, is add-on module to Hexxcell Studio™ dedicated to oil refineries. It provides a data-driven, predictive approach to evaluating the effect that the selection of oils have on fouling behaviour on the crude distillation unit. As a result, oil planners can use this tool to assess, in a simple way and ahead of time how their blending decisions are going to impact operations (e.g. hitting furnace or hydraulic limits etc.) and to quantify the costs of processing specific slates both in economic and environmental terms. This information can also be fed back to operators and used to further optimise plant performance and maintenance actions.

Key benefits

  1. Identification of:

    • Correlation between fouling rates, oil/blend physical properties and basic chemistry

    • Problematic oils (i.e. related to high fouling rates)

    • Beneficial oils (i.e. related to negative fouling rates)

  2. Diagnosis of past acute fouling episodes:

    • Oil slate vs. conditions

    • HEXs in which oils are problematic

    • Operating conditions at which oils are problematic

  3. Recommendations on:

    • Development of blending guidelines with plant data

    • Future processing

    • Further lab-testing


See also:

Equipment Design: Dynamic Retrofit Test™


A predictive approach to test performance of a proposed retrofit design

Advanced Monitoring and Predictive Maintenance

  • Assessment of fouling costs

  • Monitor heat exchanger network performance

  • Identify best cleaning scheduling

  • Optimise flow splits

  • Bypass management

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