Ensuring cost-effective heat exchanger network design for non-continuous processes

The variation in stream conditions over time inevitably adds significant complexity to the task of integrating non-continuous processes. The Time Averaging Method (TAM), where stream conditions are simply averaged across the entire time cycle, leads to unrealistic energy targets for direct heat recovery and consequently to Heat Exchanger Network (HEN) designs that are in fact suboptimal. This realisation led to the development of the Time Slice Method (TSM) that instead considers each time interval separately, and can be used to reach accurate targets and to design the appropriate HEN to maximise heat recovery. However, in practise the HENs often require excessive exchanger surface area, which renders them unfeasible when capital costs are taken in to account. An extension of the TSM that reduces the required overall exchanger surface area and systematically distributes it across the stream matches is proposed. The methodology is summarised with the help of a simple case study and further improvement opportunities are discusse

Carbon Emissions Pinch Analysis (CEPA) for emissions reduction in the New Zealand electricity sector

Carbon Emissions Pinch Analysis (CEPA) is a recent extension of traditional thermal and mass pinch analysis to the area of emissions targeting and planning on a macro-scale (i.e. economy wide). This paper presents an extension to the current methodology that accounts for increased demand and a carbon pinch analysis of the New Zealand electricity industry while illustrating some of the issues with realising meaningful emissions reductions. The current large proportion of renewable generation (67% in 2007) complicates extensive reduction of carbon emissions from electricity generation. The largest growth in renewable generation is expected to come from geothermal generation followed by wind and hydro. A four fold increase in geothermal generation capacity is needed in addition to large amounts of new wind generation to reduce emissions to around 1990 levels and also meet projected demand. The expected expansion of geothermal generation in New Zealand raises issues of GHG emissions from the geothermal fields. The emissions factors between fields can vary by almost two orders of magnitude making predictions of total emissions highly site specific

WinGEMS modelling and pinch analysis of a paper machine for utility reduction

A multi-ply paper machine process model was developed using WinGEMS and the stream data produced was used to conduct a pinch analysis. The product stream was excluded from the analysis and the composite curves display the enthalpy contained only in the inputs and outputs to the various sections of the paper machine. The pinch point for the overall paper machine was 55.9 C while the minimum hot utility target was 170 MW. Occurrences of cross pinch heat transfer were identified and discussed. Heat recovery options for heating of the fresh water showers, using waste heat streams were investigated. Steam savings of over 14 MW could be achieved by recovering heat from two waste streams that currently go directly to drain with no heat recovery taking place. The use of pinch analysis for utilities targeting under non-continuous conditions was examined. Finally, the feasibility of integrating non-conventional technologies, such as heat storage, is discussed

Carbon emissions pinch analysis (CEPA) for emissions reduction in the New Zealand electricity sector

Carbon Emissions Pinch Analysis (CEPA) is a recent extension of traditional thermal and mass pinch analysis to the area of emissions targeting and planning on a macroscale (i.e. economy wide). This paper presents a carbon pinch analysis of the New Zealand electricity industry and illustrates some of the issues with realising meaningful emissions reductions. The current large proportion of renewable generation sources (~67% in 2007) complicates wholesale emissions reductions. The biggest growth in renewable generation is expected to come from geothermal energy followed by wind and hydro. A four fold increase in geothermal generation capacity is needed in addition to large amounts of new wind generation to reduce emissions to around 1990 levels and also meet projected demand. The expected expansion of geothermal generation in New Zealand raises issues of GHG emissions from the geothermal fields. The emissions factors between fields can vary by almost two orders of magnitude making predictions of total emissions highly site specific

Importance of understanding variable and transient energy demand in large multi-product industrial plants for process integration

There have been some news releases claiming that Professor Henle in Germany has found the chemical identity of UMF, and that in future chemical analysis will be used instead of assays of antibacterial activity to indicate the level of UMF in manuka honey. Both of these claims are misleading. Because the level of active substance in manuka honey is an unreliable indication of the level of antibacterial activity and can be very misleading, it is hard to see any commercial advantage for it to be used to indicate antibacterial activity other than if someone wanted to fool the consumer into thinking that the higher numbers are giving them a level of antibacterial activity that is far higher than they are really getting

Non-continuous and variable rate processes: Optimisation for energy use

The need to develop new and improved ways of reducing energy use and increasing energy intensity in industrial processes is currently a major issue in New Zealand. Little attention has been given to optimisation of non-continuous processes in the past, due to their complexity, yet they remain an essential and often energy intensive component of many industrial sites. Novel models based on pinch analysis that aid in minimising utility usage have been constructed here through the adaptation of proven continuous techniques. The knowledge has been integrated into a user friendly software package, and allows the optimisation of processes under variable operating rates and batch conditions. An example problem demonstrates the improvements in energy use that can be gained when using these techniques to analyse non-continuous data. A comparison with results achieved using a pseudo-continuous method show that the method described can provide simultaneous reductions in capital and operating costs

A derivative method for minimising total cost in heat exchanger networks through optimal area allocation

This paper presents a novel Cost Derivative Method (CDM) for finding the optimal area allocation for a defined Heat Exchanger Network (HEN) structure and stream data, without any stream splits to achieve minimum total cost. Using the Pinch Design Method (PDM) to determine the HEN structure, the approach attempts to add, remove and shift area to exchangers where economic benefits are returned. From the derivation of the method, it is found that the slope of the ε-NTU relationship for the specific heat exchanger type, in combination with the difference in exchanger inlet temperatures and the overall heat transfer coefficient, are critical to calculating the extra overall duty each incremental area element returns. The approach is able to account for differences in film coefficients, heat exchanger types, flow arrangements, exchanger cost functions, and utility pricing. Incorporated into the method is the newly defined “utility cost savings flow-on” factor, θ, which evaluates downstream effects on utility use and cost that are caused by changing the area of one exchanger. To illustrate the method, the CDM is applied to the distillation example of Gundersen (2000). After applying the new CDM, the total annual cost was reduced by 7.1 % mainly due to 24 % less HEN area for similar heat recovery. Area reduction resulted from one exchanger having a minimum approach temperature (ΔTmin) of 7.7 °C while the other recovery exchangers had larger ΔTmin values. The optimum ΔTmin for the PDM was 12.5 °C. The CDM solution was found to give a comparable minimum total area and cost to two recently published programming HEN synthesis solutions for the same problem without requiring the increased network complexity through multiple stream splits

Triggered memory-based swarm optimization in dynamic environments

This is a post-print version of this article - Copyright @ 2007 Springer-VerlagIn recent years, there has been an increasing concern from the evolutionary computation community on dynamic optimization problems since many real-world optimization problems are time-varying. In this paper, a triggered memory scheme is introduced into the particle swarm optimization to deal with dynamic environments. The triggered memory scheme enhances traditional memory scheme with a triggered memory generator. Experimental study over a benchmark dynamic problem shows that the triggered memory-based particle swarm optimization algorithm has stronger robustness and adaptability than traditional particle swarm optimization algorithms, both with and without traditional memory scheme, for dynamic optimization problems

Process integration in pulp and paper mills for energy and water reduction - A review

Process integration (including pinch analysis) is a holistic or systems approach to process design and optimisation, which considers the interactions and interdependences between individual unit operations or process elements. Large reductions in both energy and water use in pulp and paper mills has been demonstrated using process integration techniques. A review of the current process integration techniques for energy and water reduction, with a focus on application to the pulp and paper industry is presented in this paper. The concurrent application of heat integration and water/mass integration analysis is discussed. Particular focus is given to published case studies. The integration of biorefineries into existing mills and the energy and water use implications is also receiving much attention and this development is also reviewed

Cost Optimal Area Allocation in Heat Exchanger Networks

This paper discusses the cost optimal area allocation in heat exchanger networks