Lucas Olson

Nanocoating technologies offer promising opportunities for the oil and gas industry to greatly improve efficiencies and reduce greenhouse gas emissions. This article focuses on the development and application of nanocomposite protective layers (NPLs) on water cooling heat exchangers in downstream refineries to reduce biofouling and increase heat transfer. These exchangers are known for biofouling that reduces thermal efficiency and requires significant downtime and maintenance. Internal coatings are well known to address these issues, but most studies focus on epoxy or ceramic coatings, while the technical and economic benefits of nanocoatings are less established. This study presents results from a case study of the R&D process of an innovative NPL as well as results from field pilots in downstream oil refineries, such as shell-and-tube and plate heat exchangers. In addition to insights into expected efficiency gains, these pilots provide takeaways into associated cost savings in preventative and corrective maintenance, delayed replacement costs, and reduced downtime. These results are supplemented by expert interviews that provide insights into innovative forms of financing for the R&D process of these NPLs as well as streamlining the commercialization and technology adoption process for downstream refineries. The results of this study demonstrate the potential of nanotechnology to provide significant increases in efficiencies for downstream refineries, helping to reduce the carbon footprint of these facilities. They also present a blueprint for commercializing cutting-edge technologies in heavily regulated industrial processes.