Total Site Integration of Light Hydrocarbons Separation Process

Ukraine is the largest consumer of hydrocarbons per unit of production in Europe (Ukraine policy review, 2006). The most important point is a reduction of energy consumption in chemical and metallurgical industries as a biggest consumer. This paper deals with energy savings potential of light hydrocarbons separation process. Energy consumption of light hydrocarbons separation process processes typical of Eastern European countries were analysed. Process Integration (PI) was used to perform a preliminary analysis of different units and fulfil the retrofit project of Total Site Integration (TSI). A new heat exchanger network (HEN) were developed and the equipment was calculated with use of the Pinch principles. A complex method was developed and applied to integrate several units at the enterprise site demonstrating the possibility to use heat pumps. Heat pump integration increases heat recovery and offers a solution in order to increase energy savings and project profitability. The heat transfer area and number of heat exchangers for a retrofitted heat exchanger network have been identified. The estimated payback period for integration Heat Pump of Gas Separation Enterprise is about 127 days and the pathways of plant modernization have been also proposed

Targeting Minimum Heat Transfer Area for Heat Recovery on Total Sites

This paper upgrades the Total Site integration methodology, when accounting for a trade-off between capital and heat recovery by selection of optimal temperature levels for intermediate utilities and therefore, decrease capital cost. Heat transfer area for recuperation in Total Site is a two-fold problem and it depends on the Sink Profile on one side and on the Source Profile on another. The resulting temperature of intermediate utility is a result of a trade-off since the heat transfer area on Source side is decreasing, when temperature of IM is decreasing, however increased on Sink side. In the opposite higher intermediate utility temperature leads to higher area on the Source side and lower on Sink side. The temperature of each intermediate utility may be varied between specified lower and upper bounds subject to serving the Sink and Source Profiles

Heat pump integration for total site waste heat recovery

Total Site Heat Integration (TSHI) promotes energy recovery between processes to enhance overall energy efficiency of an industrial complex. Various industrial waste heat utilisation technologies have been studied to improve the energy efficiency of energy system. Vapour compression as an open loop heat pump system has good potential to be used to upgrade the waste heat to useful heat in Total Site systems. Vapour compression systems upgrade low grade waste heat by supplying a low quantity of high pressure steam (thermocompressor) or mechanical work (mechanical-compressor) to generate higher pressure steam, as is common with evaporation systems. The vapour compression system recovers the latent heat content of the industrial waste heat, which reduces cooling demand, decreasing the demand for high quality steam and reducing boiler load. This paper introduces an effective Total Site targeting methodology to integrate open cycle heat pump systems, i.e. vapour compression technologies, into an integrated industrial energy system for enhancing overall site energy efficiency. Industrial waste heat and high quality steam demand are able to be reduced simultaneously though this integration. The energy reduction and cost-benefit of thermo-compressor and mechanical-compressor installations are compared through a literature case study. The case study showed a deficit of heat at the MPS and a surplus of heat the LPS, which was identified as a candidate for compression according to the appropriate placement principle for heat pumps. For the case study, a four-stage mechanical vapour compression system and two-stage thermal vapour compression system resulted in an energy cost reductions of 343,859 USD/y and 168,829 USD/y

An integrated pinch analysis framework for low carbon industrial site planning

Reduction of CO2 emissions from energy generation and utilization has received growing attention in recent years due to the potential negative environmental impacts arising from CO2 emissions, and the need to address the global sustainability challenges. Many of the previous published papers have only focussed on application of the various Pinch Analysis methods in isolation. Furthermore, with the rapid advancement in Pinch Technology, industries and practitioners face the challenge of keeping up-to-date with the Pinch Technology advancement, let alone implement them in industries. There is the need to develop a guide for industrial site planners to use and benefit from the suite of Pinch Analysis tools in an integrated manner towards systematically planning a low carbon emission site. The main objective of this study is to establish a systematic framework for low carbon industrial site planning, by using an integrated set of Pinch Analysis techniques. The framework consists of five main stages. The first stage is the data collection of resources. Second stage is the analysis of Total Site Heat Integration, followed by Stage 3 analysis of cogeneration potential. Stage 4 is the Power Pinch Analysis and finally Stage 5 is the Carbon Pinch Analysis. The new framework is demonstrated by using an illustrative case study, and has contributed significantly in addressing low carbon emission for industrial site, resulting an overall reduction about 64.7% of steam, 74.28% of power, and 99.8% of carbon emission. In summary, this new framework for low carbon industrial site planning is available for designers, planners or industrial site owner to optimise integrated energy and carbon emission for an industrial site

A resilience indicator for Eco-Industrial Parks

An Eco-Industrial Park (EIP) is a community of businesses that seeks to reduce the global impact by sharing material. The connections among the industrial participants within this park improve the environmental performance of the industrial network. However, the connectivity also propagates failures. This risk is an important point of criticism and a barrier to industrial plants when evaluate their integration to an EIP. This paper proposes an indicator to follow the resilience of an EIP so as to improve the security of the whole system, considering the dynamic of the participants to endure a disruptive event. This metric could be used by decision-makers in order to include the resilience in the design phase of an EIP. Solving these security problems would expand the set of experiences of cleaner production, facilitating the integration of industrial processes. The proposed resilience indicator is based on two main characteristics of an industrial network: the number of connections among participants, and the capacity of each flow to change its magnitude when a participant suddenly stops sharing flows within the park. A network is separated in independent layers to quantify its flexibility when substituting flows. Each layer includes a single shared material. The resilience of a multi-layer park is then calculated as a weighted summation. This indicator is applied over two illustrative cases to study: Kalundborg, in Denmark; and Ulsan, in South Korea. These applications show consistent results when compared with reality. Although the proposed resilience indicator has been developed for material networks, it can be adapted to heat integration networks. In this case, special attention should be payed to physical constraints as minimal temperature gradients

Centralised utility system planning for a total site heat integration network

Total Site Heat Integration (TSHI) is a technique of exchanging heat among multiple processes via a centralised utility system. An analysis of the integrated multiple processes, also known as the Total Site (TS) system sensitivity, is needed to characterise the effects of a plant maintenance shutdown, to determine the operational changes needed for the utility production and to plan mitigation actions. This paper presents an improved Total Site Sensitivity Table (TSST) to be used as a systematic tool for this purpose. The TSST can be used to consider various ‘what if’ scenarios. This tool can be used to determine the optimum size of a utility generation system, to design the backup generators and piping needed in the system and to assess the external utilities that might need to be bought and stored. The methodology is demonstrated by using an Illustrated Case Study consisting of three processes. During the TS normal operation, the Total Site Problem Table Algorithm (TS-PTA) shows that the system requires 1065 kW of High Pressure Steam and 645.5 kW of Medium Pressure Steam as the heating utility, while for the cooling utility, 553.5 kW of Low Pressure Steam and 3085 kW of cooling water are required. The results of the modified TSST proposed that a boiler and a cooling tower with the system design requiring a maximum capacity of 2.172 MW of steam and 4.1865 MW of cooling water are needed to ensure an operational flexibility between the three integrated processes

Unified Total Site Heat Integration: Targeting, Optimisation and Network Design

Process industries in New Zealand use 214.3 PJ of process heat, of which approximately 65 % is fossil fuels. Despite increasing energy demands, depleting fossil fuel resources, and pressure to reduce Greenhouse Gas emissions, low grade heat in large-scale processing sites is still not fully utilised. This thesis presents methods to target, optimise and design more practical heat recovery systems for large industrial sites, i.e. Total Sites, and overcome technical limitations of current methods. Original contributions of this thesis to literature include novel developments and applications in six areas: i) a new Total Site Heat Integration (TSHI) targeting method – Unified Total Site Targeting (UTST) – which sets realistic targets for isothermal and non-isothermal utilities and heat recovery via the utility system; ii) a new TSHI optimisation and utility temperature selection method to optimise Total Cost of the utility system; iii) a new Utility Exchanger Network synthesis and design method based on the targets achieved by the UTST method and optimal temperatures from optimisation method; iv) a new method for calculating assisted heat transfer and shaft work to further improve TSHI cogeneration and performance; v) examination of heat transfer enhancement techniques in TSHI to achieve higher heat recovery and lower required area by substituting conventional utility mediums by nanofluids in the utility system; and vi) a spreadsheet software tool called Unified Total Site Integration to apply the developed methods to real industrial cases. The developed methods have been applied to three large industrial case studies. Results confirm that heat recovery and utility targets obtained from the UTST method were lower but more realistic to achieve in practice when compared to conventional TSHI methods. The three industrial case studies represent a wide variety of processing industries. In summary, the over-estimation of TSHI targets for the three case studies from using the conventional method compared to the new method are 0.2 % for the Södra Cell Värö Kraft Pulp Mill, 22 % for a New Zealand Dairy Factory, and 0.1 % for Petrochemical Complex. The Total Annualised Costs (TAC) for the three case studies are minimised using a new derivative based approach. Results show TAC reductions 4.6 % for Kraft Pulp Mill, 0.6 % for Dairy Factory, and 3.4 % for Petrochemical Complex case studies. In addition, sensitivity analysis for the optimisation is undertaken. The UTST method with its modified targeting procedure is demonstrated to generate simpler Utility Exchanger Network designs compared to conventional methods, which confirm the original targets are realistic and achievable. A new method for calculating assisted heat integration targets applied to an example Total Site problem increased heat recovery by 1,737 kW, which is a 21% increase in Total Site heat recovery, and increased shaft work by 80 kW. Lastly, the addition of nanoparticles to create a closed nanofluid heat recovery systems shows heat recovery from liquid-liquid heat exchangers increases of 5 % to 9 % using an intermediate fluid with 1.5 vol. % CuO/water

Systematic approaches for synthesis, design and operation of biomass-based energy systems

A biomass-based energy system (BES) is a utility facility which produces cooling, heat and power simultaneously from biomass. By having a BES installed on-site, industrial processes can reduce energy costs by locally producing heat, cooling and power for process and work place requirements. However, several barriers have hindered development of BESs in the energy industry. These barriers include doubts over its operational uncertainties (e.g., seasonal biomass supply, equipment reliability, etc.), the misconception that generating energy from biomass is only a marginal business and the lack of successful cooperative partnerships within the industry. According to literature, such barriers are due to the lack of frameworks that address design aspects and demonstrate the economic viability of a BES. This thesis presents systematic approaches and frameworks to design a BES. These approaches emphasise on integrating synthesis, design and operation decision making for a BES during its preliminary design phase. Firstly, a systematic approach is presented to synthesise a BES considering seasonal variations in biomass supply and energy demand. In this approach, a multi-period optimisation model is formulated to perform technology and design capacity selection by considering seasonal variations in biomass supply and energy demand profiles. This approach is then extended to systematically allocate equipment redundancy within the BES in order to maintain a reliable supply of energy. In this approach, k-out-of-m system modelling and the principles of chance-constrained programming are integrated in a multi-period optimisation model to simultaneously screen technologies based on their respective equipment reliability, capital and operating costs. The model also determines equipment capacities, along with the total number of operating (and stand-by) equipment based on various anticipated scenarios in a computationally efficient manner. Following this, a systematic approach is developed to simultaneously screen, size and allocate redundancy within a BES considering its operational strategies (e.g., following electrical load or following thermal load). Subsequently, a systematic framework on Design Operability Analysis (DOA) is developed to analyse BES designs in instances of failure. This framework provides a stepwise procedure to evaluate proposed BES designs under scenarios of disruption and analyse their true feasible operating range. Knowledge of the feasible operating range enables designers to determine and validate if a BES design is capable of meeting its intended operations. Following this, a systematic Design Retrofit Analysis (DRA) framework is presented to debottleneck and retrofit existing BES designs in cases where energy demands are expected to vary in the future. The presented framework re-evaluates an existing BES design under disruption scenarios and determines its real-time feasible operating range. The real-time feasible operating range will allow designers to determine whether debottlenecking is required. If debottlenecking is required, the framework provides systematic debottlenecking and retrofit guidelines for BES designs. The design of a BES is then extended further to consider its interaction in an eco-industrial park (EIP). Since heat, cooling and power are essentially required in most industrial processes, a BES can be more economically attractive if synthesised for an EIP. As such, an optimisation-based negotiation framework is developed to analyse the potential cost savings allocation between participating plants in an EIP coalition. This framework combines the principles of rational allocation of benefits with the consideration of stability and robustness of an EIP coalition to changes in cost assumptions. Lastly, possible extensions and future opportunities for this research work are highlighted at the end of this thesis

Systematic approaches for synthesis, design and operation of biomass-based energy systems

A biomass-based energy system (BES) is a utility facility which produces cooling, heat and power simultaneously from biomass. By having a BES installed on-site, industrial processes can reduce energy costs by locally producing heat, cooling and power for process and work place requirements. However, several barriers have hindered development of BESs in the energy industry. These barriers include doubts over its operational uncertainties (e.g., seasonal biomass supply, equipment reliability, etc.), the misconception that generating energy from biomass is only a marginal business and the lack of successful cooperative partnerships within the industry. According to literature, such barriers are due to the lack of frameworks that address design aspects and demonstrate the economic viability of a BES. This thesis presents systematic approaches and frameworks to design a BES. These approaches emphasise on integrating synthesis, design and operation decision making for a BES during its preliminary design phase. Firstly, a systematic approach is presented to synthesise a BES considering seasonal variations in biomass supply and energy demand. In this approach, a multi-period optimisation model is formulated to perform technology and design capacity selection by considering seasonal variations in biomass supply and energy demand profiles. This approach is then extended to systematically allocate equipment redundancy within the BES in order to maintain a reliable supply of energy. In this approach, k-out-of-m system modelling and the principles of chance-constrained programming are integrated in a multi-period optimisation model to simultaneously screen technologies based on their respective equipment reliability, capital and operating costs. The model also determines equipment capacities, along with the total number of operating (and stand-by) equipment based on various anticipated scenarios in a computationally efficient manner. Following this, a systematic approach is developed to simultaneously screen, size and allocate redundancy within a BES considering its operational strategies (e.g., following electrical load or following thermal load). Subsequently, a systematic framework on Design Operability Analysis (DOA) is developed to analyse BES designs in instances of failure. This framework provides a stepwise procedure to evaluate proposed BES designs under scenarios of disruption and analyse their true feasible operating range. Knowledge of the feasible operating range enables designers to determine and validate if a BES design is capable of meeting its intended operations. Following this, a systematic Design Retrofit Analysis (DRA) framework is presented to debottleneck and retrofit existing BES designs in cases where energy demands are expected to vary in the future. The presented framework re-evaluates an existing BES design under disruption scenarios and determines its real-time feasible operating range. The real-time feasible operating range will allow designers to determine whether debottlenecking is required. If debottlenecking is required, the framework provides systematic debottlenecking and retrofit guidelines for BES designs. The design of a BES is then extended further to consider its interaction in an eco-industrial park (EIP). Since heat, cooling and power are essentially required in most industrial processes, a BES can be more economically attractive if synthesised for an EIP. As such, an optimisation-based negotiation framework is developed to analyse the potential cost savings allocation between participating plants in an EIP coalition. This framework combines the principles of rational allocation of benefits with the consideration of stability and robustness of an EIP coalition to changes in cost assumptions. Lastly, possible extensions and future opportunities for this research work are highlighted at the end of this thesis