TEP 4215 - Plan for Assignments with Guidance Ass. Topic - - PowerPoint PPT Presentation

Department of Energy and Process Engineering

Truls Gundersen 10.01.10

TEP 4215 - Energy Utilization and Process Integration in Industrial Plants, or for short: “Energy and Process”

• The Objective is to convey

u Systems Thinking and Systematic Methods for:

§ Analysis and Design (and partly Operation) of § Processes and Utility Systems, with focus on § Efficient Use of Energy while considering § Economy, Operation and (to some extent) Environment

• Requirements to be able to join the Course

u None (meaning previous courses), but it is an advantage to

have some basic knowledge about the following:

§ heat exchangers, distillation columns, evaporators § turbines, heat pumps and “simple” thermodynamics

u Fall 98: 100 students from 8 departments in 4 faculties !! u From Spring 2009: Compulsory for the “PuP” Program

Truls Gundersen 10.01.10

• The Course Content is primarily

u System based Strategy for Design of integrated

Process Plants with corresponding Utility Systems

u Systematic Methods for Analysis and Design of

§ Reactor Systems (very limited and not in depth) § Thermally driven Separation Systems, such as (primarily) Distillation and (to a much less extent) Evaporation § Heat Exchanger Networks and Correct Heat Integration § Utility Systems (heating, cooling and power)

u The Thermodynamically based Pinch Analysis u Brief Introduction to the use of Optimization u Environmental Issues related to Energy Usage u New Design and Retrofit of Existing Plants

TEP 4215 - Energy and Process

Department of Energy and Process Engineering

Truls Gundersen 01.01.10

• The Curriculum for the Course is:

u R. Smith: “Chemical Process Design and Integration”, 2nd ed., John

Wiley & Sons, January 2005. Alternative Text Book:

u I.C. Kemp: “Pinch Analysis and Process Integration”, Elsevier,

Butterworth Heinemann, December 2006.

u T. Gundersen: “Basic Concepts for Heat Recovery in Retrofit

Design of Continuous Processes”, Ch. 6 in “A Process Integration Primer”, IEA, 2000 (18 pages).

u Lectures and Assignments. u Assignments are Examination oriented (most are previous Ex Q’s) u Examination will test Understanding through Calculation Examples.

This requires Training established by working with Assignments.

• Home Page: http://www.ivt.ntnu.no/ept/fag/tep4215/

TEP 4215 - Energy and Process

Department of Energy and Process Engineering

Truls Gundersen 12.01.13

Ass. Topic Supervised Deadline 1 Sequence of Distillation Columns 22.01 29.01 2 Minimum Energy Requirements and Pinch 29.01 05.02 3 Design of Heat Exchanger Networks (1) 05.02 12.02 4 Optimization of Heat Exchanger Networks 12.02 26.02 5 Retrofit Design of Heat Exchanger Networks 26.02 05.03 6 Indirect Integration of Plants using Steam 05.03 12.03 7 Integration of Distillation Columns 12.03 09.04 8 Optimal Use of Heat Pump 09.04 16.04 9 Area in Heat Exchanger Networks 16.04 23.04 10 Heat Integration and Forbidden Matches 23.04 30.04 11 Design of Heat Exchanger Networks (2) 30.04 none

Guidance: One Ph.D. Student (?), 6 Student Assistants and the Lecturer

TEP 4215 - Plan for Assignments with Guidance

Department of Energy and Process Engineering

Introduction and Background

E-stat 1

• T. Gundersen

Process, Energy and System

Russia USA Canada Iran Norway Algerie UK Others

20.7% 18.6% 6.2% 3.8% 2.8% 2.5% 42.4% ”others”

Norway as an Energy Nation Natural Gas Production (GSm3)

Norway: 1997: 43.0 (1.9%) − 2007: 89.7 (3.1%) World Production (2007): 2940 GSm3

3.1%

Saudi Arabia Russia USA Iran China Mexico Norway Others

Introduction and Background

• T. Gundersen

Process, Energy and System

Norway as an Energy Nation Oil Production (mill. tonnes)

Norway: 1997: 156.2 (4.6%) − 2007: 118.8 (3.0%)

World Production (2007): 3905.9 mill. tonnes

12.6% 12.6% 8% 5.4% 4.8% 49.1% 3.0%

E-stat 2

Introduction and Background

• T. Gundersen

Process, Energy and System

Energy Production (PJ) in Norway in 2007

(Total: 9 512.7 PJ − Export: 8 474.6 PJ (89.1%)

Crude Oil Natural Gas Hydro Power LNG Gasoline Coal Bio Energy

38.8% + 48.4% = 87.2% 6.0%

E-stat 3

P(eta) = 1015

Introduction and Background

• T. Gundersen

Process, Energy and System

Energy Consumption in Norway by Sector in 2007 (Total: 813.5 PJ)

Industry & Mining Transportation Other Sectors

Other Sectors: Private household (20.0%), Community Consumption (13.7%) and Fishing/Agriculture (3.6%) 37.3% 35.1% 27.6%

 The Course “Energy & Process” makes Sense !!

E-stat 4

T(erra) = 1012

Introduction and Background

• T. Gundersen

Process, Energy and System

Aluminum Chemical Pulp & Paper Petrochemical Food Industry Iron & Steel Minerals Wood Ware Mining Others

Energy Consumption (TWh) in Norwegian Industry in 2007 (Total: 80.66 TWh)

29.6% 17.6% 13.6% 12.0%

E-stat 5

Introduction and Background

• T. Gundersen

Process, Energy and System

Energy Consumption, Fossil Fuels and the Impacts on the Environmental

E-stat 6

• Emissions include:

u Greenhouse Gases u Acid Gases u Particles

• Options to mitigate:

u Carbon Capture and

Storage (CCS)

u Fuel Switch u Renewables u Energy Efficiency

• The Cleanest Energy?

"Systematic and General Methods for Designing Integrated Production Systems, ranging from Individual Processes to Total Sites, with special emphasis on the Efficient Use of Energy and reducing Environmental Effects"

Definitions and Relations

Intro 1

• T. Gundersen

Process, Energy and System

P R O C E S S I N T E G R A T I O N

IEA OECD

The IEA Definition

• f Process Integration

From an Expert Meeting in Berlin, October 1993

Intro 2

• T. Gundersen

Process Synthesis - Definition

“Process Synthesis is a Systematic approach to the selection and interconnection of unit operations and to the specification of their operating conditions, in order to develop a conceptual flowsheet that produces desired products from available raw materials, in a safe and environmentally acceptable way, with maximum profit, while the plant exhibits flexibility, operability and controllability”

Definitions and Relations Process, Energy and System

Intro 3

• T. Gundersen

Systems Engineering (SE) (Cybernetics) Process Systems Engineering (PSE) (SE applied to Process Systems) IPD - Integrated Process Design (disciplines) (software) LCA - Life Cycle Analysis (time) Process Integration and Synthesis (space)

Process Integration & Systems Engineering

Definitions and Relations Process, Energy and System

• T. Gundersen

Terms in Perspective

Process Integration Energy Conservation Heat Integration Process Synthesis

Intro 4

Definitions and Relations Process, Energy and System

• T. Gundersen

Process as a “Converter”

Energy Material

Com Exp Raw Material(s) Product(s) Byproduct(s) Steam HP MP LP Cooling Steam HP MP LP Cooling Mechanical Energy

Intro 5

Introduction to Process Design Process, Energy and System

• T. Gundersen

A “Generic” Process

Feed Gas Recycle Liquid Recycle Feed Treatment Reactor Separation System Purge Product Byproduct Intro 6

Process, Energy and System Introduction to Process Design

• T. Gundersen

Conseptual Design and the “Onion”

R S H U R = Reactor System S = Separation System H = Heat Integration U = Utility System

Decomposition

R S H U

Interactions

Intro 7

Process, Energy and System Introduction to Process Design

• T. Gundersen

Process Example with elements of R/S/H/U

Intro 8 REACTOR TOLUENE COL. BENZENE COL. STABILIZER

Diphenyl Benzene Fuel Gas Toluene Feed Toluene Recycle H2 Feed Flash Drum Purge Compressor Gas Recycle

Process, Energy and System Introduction to Process Design

• T. Gundersen

4-way Trade-off in Process Design

Energy

Steam, Cooling water Refrigeration, etc.

Capital

Investment in Equipment, Interest

Raw Materials

Conversion, Losses Selectivity, Yield

Operation

Flexibility, Safety and Controllability

Topology

Process parameters Ex.: ΔTmin

Intro 9

Process, Energy and System Introduction to Process Design

• T. Gundersen

Project Life Cycle

Idea Commercial Justification Technology Definition Commercial Endorsement Process Package Detailed Design Plant Completion Process Redesign Plant Operation and Maintenance Plant Dis- assembling

Engineering Research Operation

Process Process Functional Detailed Plant Conception Simulation Design Design Construction w Laboratory w Rigorous w PFD + P&ID w Equipment w Project Control w Pilot Plant Simulation w Functional Design Time w Synthesis w Parameter Performance w Piping Materials w Structural Optimization Specs w Layout Labor Optimization w Stream w Major Equipm. w Isometrics Schedule w Flowsheeting Compositions w Costing w Structural Density w Costing Conditions w Instrumentation w Electrical w Cost Control w Duty Sizing Performance w Civil Specifications w Mechanical Phases and corresponding Technical Activities

Intro 10

Process, Energy and System Introduction to Process Design

• T. Gundersen

Motivating Example

Traditional Design

Feed Product Reactor ST ST CW Recycle Sepa- rator

QST = 1722 kW QCW = 654 kW Area = 629 m2 Units = 6 stk.

Process, Energy and System Motivation

Intro 11

• T. Gundersen

Motivating Example

Systematic Design

QST = 1068 kW QCW = 0 kW Area = 533 m2 Units = 4 stk.

Feed Product Reactor ST Recycle Sepa- rator

Intro 12

Process, Energy and System Motivation

• T. Gundersen

Motivating Example

Comparison

Tradi- Syste- tional matic design design QST (kW) 1722 1068 QCW (kW) 654 Area (m2) 629 533 Units 6 4 A QST

Tradi- tional Syste- matic 1722 629 1068 533

Intro 13

Process, Energy and System Motivation

Dual Pressure Nitric Acid Plant

• T. Gundersen

Intro 14

Process, Energy and System Motivation

• T. Gundersen

Methods for Process Integration

• Pinch Analysis

§ Graphical Thermodynamic Diagrams § “Best performance” Targets ahead of design § Systematic Design Methods

• Exergy Analysis

§ Components and the Systems Level § “Sound” Design, but at what Price ?

• Mathematical Programming

§ Constrained Optimization § Discrete and Continuous Variables

PI Methods

Intro 15

Process, Energy and System

• T. Gundersen

Areas of Application – Process Tasks

• Optimal Level of Heat Recovery

§ Trade-off Investment and Operating Cost

• Design of Heat Exchanger Networks
• Design, Sequence and Heat Integration of

thermally driven Separation Systems

§ Distillation, Evaporation and Drying

• Design of Utility Systems

§ Boilers, Fired Heaters, Refrigeration Cycles § Integration of Heat Pumps and Turbines

• Design of Operable Plants

§ Flexibility, Controllability, Startup, Shutdown

Intro 16

Application Areas Process, Energy and System

• T. Gundersen

Areas of Application – Industrial Branches

• Chemical and Petrochemical Industry

§ Ethylene, Methanol, Ammonia § Nitric Acid, Fertilizer, etc., etc.

• Oil Refineries
• Oil & Gas (including Offshore)
• Thermal Power Plants
• Pulp and Paper Industry
• Metal Industry
• Food and Drink Industry

§ Breweries, Dairies

• Pharmaceutical Industry

Intro 17

Process, Energy and System Application Areas

Why Process Integration ?

• T. Gundersen

Nordisk Energi Forsknings Program

Diagnosis (analysis) “Global” considerations Smart Solutions Economy Innovation

Why PI ? We cannot afford not to

Intro 18

Motivation Process, Energy and System

• T. Gundersen

Summary of the Introduction

• PI aims at the Conceptual Phase

§ Critical Decisions are made § The Creative Part of Process Design

• PI offers a Design Philosophy with

Focus on the System (total Plant)

• Process Structure (flowsheet/topology)

more important than Process Parameters

• PI provides Systematic and General

Methods for Integrated Design Solutions

• PI is heavily used in many Industrial

Companies and Industrial Branches

Intro 19

Process, Energy and System Summary of Intro

• T. Gundersen

Challenges in Process Design and Integration

• “Open-ended” è Can “always” be improved
• Discrete Decisions è Combinatorial Explosion
• Non-Linear Relations è Numerical Problems
• Uncertainty in Cost Calculations

§ Energy: Price of Oil (10 to 150 to 60 to 110 $/bbl) § Equipment: Bid, Future, Installation, etc.

Intro 20

Process, Energy and System Summary of Intro