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Abstract
Chemical process industry has been facing increasing cost of energy, growing
competition driven by rapid globalization, rising public concern for the environment,
and increasing regulatory efforts of governments concerning the environment, health,
and safety. In response to these conditions and with regard to the capital intensive nature
of chemical process industries, constant optimization through redesign of existing
production plants has emerged as a key strategy. In this study a typical process plant for
production of benzene via hydrodealkylation of toluene is considered. Pinch analysis
was carried out, energy flows and requirements were determined. Composite curve was
generated. The results of the study show that the net temperature rise required by the
heat exchangers collectively is 675 oC and the temperature of process streams collectively
was in excess by 2587.3 oC which shows energy is wasted in the plant.
Keywords: Composite curve, Heat Exchangers, hydrodealkylation of toluene, Pinch
Analysis.
1.0 Introduction
The increasing cost of energy and stringent environmental regulations force chemical
process industries to search for possible ways of reducing energy consumption for its
operations (Piagbo and Dagde, 2013). Energy saving in plant design has essentially been
a trial-and-error procedure between changes in structure and simulation until
satisfactory reductions are achieved. A step by step system-oriented, thermodynamics-
based, integrated approach to the analysis, synthesis and retrofit of process plants is
desired. Over the past two decades, the design tools of process integration has been
developed to achieve process improvement, conservation in mass and energy resources,
productivity enhancement, and reductions in the operating and capital costs of chemical
processes using pinch analysis which is a very well recognized and proven technique for
analysis of hydrogen, water and energy usage in industries such as chemicals,
petrochemical, pulp and paper, oil refining and steel and metallurgy. The use of capable
software is usually applied for analyzing large amount of data contained in pinch
analysis. The application of software in the analysis offers many advantages like speedy
design and modification of heat exchanger networks, eliminates avoidable errors from
manual calculations, increase accuracy of results among others.
Process revamp came into existence as the result of quest for energy savings and
efficiency in production process. Retrofitting includes division of a process system into
three subsystems: separation, heat exchange, and utility subsystems for proper heat
integration within each subsystem and subsequent coordination between each
subsystem. To carry out retrofitting of a process system, firstly there is need to perform
Seminar Series Volume 6, 2015 Page 73
Idriss et al., Pinch Analysis of Benzene Production Process via the Hydrodealkylation
of Toluene
heat exchanger network (HEN) analysis starting by finding out the Pinch temperature of
the HEN according to the relative position of the endothermic and exothermic
temperatures with the Pinch temperature, different retrofit strategies for separators will
be used (Feng and Liang, 2013).
By observing the PFD of the process we can highlight a significant enthalpic content of
outlet stream from the reactor. Such stream is quenched to block any further side
conversion of toluene to biphenyl and its enthalpic content is exploited to preheat the
inlet stream to the reaction section (although it is not sufficient and some further heating
is provided in the furnace to comply with the process specification).
Table 1: Cold and Hot Streams data for production of benzene via Hydrodealkylation
of Toluene (Turton et al. 2012).
Stream 1 2 3 4 5 6 7 8 9 10
Temp(oC) 25 59 25 225 41 600 41 38 654 90
Hydrogen(kmol/h) 0.0 0.0 286 735.4 449 735.4 25.2 651.9 652.6 0.02
Methane(kmol/h) 0.0 0.0 15 317.3 302.2 317.3 16.95 438.3 442.3 0.88
Benzene(kmol/h) 0.0 1.0 0.0 7.6 6.6 7.6 0.37 9.55 116.0 106.3
Toluene(kmol/h) 108 143.2 0.0 144 0.7 144 0.04 1.05 36.0 35.0
5.0 Conclusion
The results show that there is excess heat emitted from the system, this can be seen from
table table 2 and the plot in figure 2 as well. This shows that the analysis has established
that that some energy streams are wasted. The cumulative temperature requirement of
the process streams was 675 oC and the total outlet temperature attained by the entire
References
1. Deepa and Ravishankar (2013) Reducing Hot and Cold Utility Requirements for
Finishing Column Section Using Pinch Analysis Techniques, International Journal of
Engineering Research and Applications. 3(4), 587-1592 .
2. Feng X. and Liang C. (2013) Strategy for Total Energy System Retrofit of a Chemical
Plant,Chemical Engineering Transactions, 35, 145-150.
8. Turton R., Bailie R. C., Whiting W. B., Shaeiwitz J. A. and Bhattacharyya D. (2012)
Analysis, Synthesis and Design of Chemical Processes, Fourth Edition,
Prentice Hall International Series in the Physical and Chemical Engineering Series.