Chapter 11. Methodologies Developed and Applied in Process Integration Studies For The Swedish Kraft Pulp and Paper Industry

11
Methodologies Developed and Applied in Process

Integration Studies for the Swedish Kraft Pulp
andPaper Industry: A Review
Maryam Mahmoudkhani and Thore Berntsson
CONTENTS
11.1 Introduction......................................................................................................................... 349
11.2 Process Integration Studies............................................................................................... 351
11.2.1 PI Studies: Thermodynamics-Based Methods................................................... 352
11.2.1.1 Pinch Analysis.......................................................................................... 352
11.2.1.2 Exergy Analysis........................................................................................ 352
11.2.1.3 Mathematical Programming Methods................................................. 353
11.3 Energy-Efficiency Measures Based on Newly Developed Methods........................... 353
11.3.1 Pinch-Analysis-Based Advanced Composite Curves........................................354
11.3.2 Matrix Method for Economical Retrofit of a Heat-Exchanger Network..... 356
11.3.3 Combined Water and Energy Reduction Analysis............................................ 358
11.4 Examples of Application of New Methods..................................................................... 359
11.4.1 Use of Advanced Curves and Background/Foreground Analysis
forBiorefinery Concepts........................................................................................ 359
11.5 Assessing Profitability and Carbon Balances of Energy Investments........................ 363
11.6 Conclusions.......................................................................................................................... 365
Acknowledgments....................................................................................................................... 366
References...................................................................................................................................... 366
11.1Introduction
Improved energy management, process integration, and water reduction are among the
measures that have been proposed to improve energy efficiency in the pulp and paper
industry. This industry differs from industrial chemical plants in terms of its raw mate-
rial and its water consumption as well as the layout of its processes. In the pulp and
paper industry, wood is the main raw material, but this material, in addition to its
chemical value, has a tremendous potential to be used for its energy content. The water
system in the pulp industry is highly complex, due mainly to high water demand for
both utilities and the process (the so-called process water); therefore, the utility system
(also called the secondary heat system or the hot- and warm-water production system)
is not as s traightforward as in other industries. Moreover, the piping distances in pulp
and paper mills are usually longer than in typical chemical industries. Taken together,
349
350 Integrated Biorefineries
these issues make the analysis of energy systems for pulp processes a highly complex
task. This fact emphasizes the importance of process integration for efficient use of
energy in the process.
Process integration tools and methods have been used to analyze the use of energy and
other resources in the pulp and paper industry and to identify ways to increase productivity,
decrease costs, and address environmental issues. These tools have been used to perform
process-integration case studies of pulp mills from 1990 onward in various locations,
including the United States, Canada, Finland, and Sweden. Projects in North America
have focused primarily on possibilities to improve resource use in the short and medium
terms, while studies in Sweden have been more strategic in nature and have had a more
long-term implementation perspective (for strategic decision-making under energy-market
uncertainties in future) (IEA, 2004). Depending on technical, geographical, and legal
parameters, mill specifications differ in terms of the degree of modernization of equip-
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ment, water and energy systems, fuel consumption, carbon dioxide emissions, and taxation
and policy instruments. In this chapter, the interaction between various Kraft pulp
specifications and the choice of an appropriate process integration method is described,
because the heat and water systems in Kraft pulping are more complex than those in other
mills such as thermomechanical pulp (TMP) mills.
Available data on energy use in the pulp and paper sector indicate an ~30% higher
energy consumption per product unit in North America, which is mainly due to the
aggressive modernization and expansion programs undertaken in Scandinavian mills
and the energy optimization strategies undertaken in response to high fuel prices
(Mnnist and Mnnist 1999). For an average Swedish nonintegrated market pulp mill,
a steam demand of 1517 GJ/ADt has been reported (KAM 2003). Mnnist and Mnnist
(2006) stated that CO2 emissions are lower in Sweden than in Finland and Canada due to
differences in energy efficiency, degree of integration, mill size, in-house power genera-
tion, and the types of fossil fuel used for energy supply. Mnnist and Smith (2006) also
reported that NOx emissions are higher from Kraft pulp mills in the United States and
Canada than in Sweden, mainly because of higher energy use in the former mills. North
American bleached Kraft pulp mills have a total water consumption in the range of
5070m3/adt pulp and use 7276% solids firing in the recovery boiler (Bruce 2000). For
Swedish bleached Kraft pulp mills firing black liquor with 7280% dry solids, total water
consumption is reported to range from 30 to 60m3/adt pulp (of which process water*
accounts for ~50% of the total) (Environmental Database 2008). For corresponding model
mills, process water consumption has been calculated to range from 17 to 35m3/adt pulp
(FRAM 2005). Moreover, in older mills, the pinch temperature is lower than in modern
mills (well below 100C, compared to 120140C). Therefore, to improve mill energy per-
formance, different process integration methods must be considered due to differences in
the specifications of each mill.
In the literature, numerous studies have described various methods and tools for p rocess
integration in the pulp and paper industry. However, a summary of the methods developed
and their applications in the Kraft pulp and paper industry has not yet been published.
This chapter aims to provide an overview of the available methods and tools which have
been used for process integration in the Swedish Kraft pulp and paper industry. Different
methods are described and discussed, and the results of applying these methods to mill
energy analysis are presented.
* In general, the water intake to the mill is divided into process water and utility water.
Methodologies Developed and Applied in Process Integration 351
11.2 Process Integration Studies

The term process integration refers to a system-oriented and integrated approach, meaning
that rather than optimizing process units separately, the interaction between different
parts of the process is considered, and the system as a whole is optimized. Figure 11.1
sketches a typical sequence of systematic steps taken to perform a process integration
study. These steps do not necessarily need to be taken consecutively, but in general all
steps are included. A fundamental step before performing any process integration study
is to develop an overall mass and energy balance for the process. Process simulation can
provide the data required to extract the appropriate streams in a process and to identify
their potential for process integration. Various process simulation programs have been
used, ranging from BALAS* to WinGEMS, with more focus in the pulp and paper industry
on broad-spectrum application software like CADSim Plus. The stream specifications can
then be identified and set in the flowsheets generated by one of these simulation software
packages.
Process integration studies can be based on mathematical methods, thermodynamic
methods, economic methods, or a combination of these. Examples of these methods include
mathematical programming, pinch analysis, and hierarchical analysis. The most w idespread
methods for process integration in the pulp and paper industries are pinch analysis, math-
ematical programming, and to a certain extent exergy analysis, among which pinch analy-
sis methods are well proven and established and the most commonly used in commercial
projects (IEA 2004).
An existing concept based on pinch technology for performing any retrofit or for
integrating new energy technologies is the grand composite curve (GCC). Pinch analysis
tools are used to construct GCCs which can then be used to analyze the mills energy sys-
tems. Early examples such as TARGET (written at UMIST) and PROTAB (developed by ICI)
have been developed into highly sophisticated programs such as SUPERTARGET (Linnhoff
March) and Advent/Aspen Pinch (Aspen Tech). Later, Hyprotech developed HX-NET,
which became the main Aspen specialized pinch software module. These programs use
complex targeting procedures and are relatively costly to purchase or license (Kemp 2007).
Tools such as Pro-Pi have therefore been developed to perform the essential calculations
of energy and cost targets and to generate GCCs without including the network design.
Process PI studies: Process Energy Process Assessing

simulation thermodynamic- integration efficiency integration profitability
tools based method targeting measures of new and carbon
analysis technologies balances on
energy
investments
FIGURE 11.1
Example sequence of systematic steps for process integration studies based on thermodynamic methods.
* A steady-state simulation package for chemical processes with emphasis on pulp and paper, developed by
VTT (Technical Research Center of Finland).
A Microsoft Windows-based software package for studying pulp and paper production processes.
Pro-Pi is an add-in module in MS Excel developed by CIT (Chalmers Industriteknik).
Pro-Pi has been used for research purposes and in applied industrial studies in Sweden
and Finland. Canmet ENERGY* recently developed and tested a process integration
software tool called INTEGRATION in Quebec. The tool aims to make process integra-
tion studies easier, faster, and cheaper and focuses on thermal energy usage (i.e., energy
performance, quantity and quality of waste heat, and opportunities for heat recovery). The
INTEGRATION tool is not yet completely documented, but as a continuation of the
research work reported here, it could be interesting to study the possibilities of combining
this tool with the recently developed methods presented in this chapter.
11.2.1 PI Studies: Thermodynamics-Based Methods

11.2.1.1 Pinch Analysis
Pinch analysis is a well-proven and established thermodynamics-based method with a

structured approach which is used to design energy-efficient systems, that is, to maximize
internal heat recovery within a process and to minimize process demands for the hot and
cold duties supplied by utilities (Linnhoff 1993; Smith 1995; Kemp 2007). Pinch analysis
aims to minimize the heat demand of the process. By knowing the heat content of all
streams and their start and target temperatures, a heat-exchanger network (HEN) can be
designed in which the external heat demand is minimized. It has, however, been reported
that the traditional pinch method is not well suited to tackle certain problems. For example,
pinch curves are not well suited for retrofit situations because no information on the exist-
ing heat-exchanger network (HEN) design can be extracted from these curves (Nordman
and Berntsson 2001). Many efforts have therefore been made to develop new methods based
on pinch analysis to extract information on existing HEN designs and to identify and eval-
uate opportunities for increasing energy efficiency. In addition to the lack of information on
the existing HEN in traditional pinch analysis, neither the direct relation between energy
and water reduction, nor the relation between the use and production of utilities, is
considered. Because water handling in the pulp and paper industry is complex and closely
related to both energy use and the environmental impacts of the mill, other approaches
have been developed to tackle these issues. In the literature, various kinds of systematic
methodologies combined with thermal pinch analysis have been presented. Examples of
such methodologies are the combined method used in the NRCan optimization software
package used by VTT in Finland and the SDMTM software package (IEA 2004).
11.2.1.2 Exergy Analysis

In general, exergy analysis is used when there is a large pressure difference in a process
unit or for electricity production units, particularly when electricity and heat production
interact. Exergy analysis has, however, been used sporadically in the pulp and paper
industry because electricity and heat are always treated separately in energy balances. If
the transport and exchange of thermal energy is a dominant part of the energy system,
then pinch analysis is preferable, because exergy analysis does not necessarily add further
information beyond that provided by thermal pinch analysis (Grip etal. 2011). As for the
energy content of the flows, in this case, temperature is suitable as a measure of energy
* http://canmetenergy-canmetenergie.nrcan-rncan.gc.ca.
NRCan: Natural Resources Canada.
SDMTM: Successive Design Methodology, developed by American Process, Inc., provides a systematic
approach for simultaneous application of water and energy conservation in practical mill situations.
quality. There are, however, certain process units, for example, the recovery boiler and the
electricity production units, to which exergy analysis can be applied. Although it has been
shown that the recovery boiler has the lowest exergy efficiency in the mill, analysis of such
process units is probably more useful for the unit manufacturer than for the pulp mill
(A. sblad 2011, personal communication). Exergy analysis has, however, been used in
combination with pinch analysis to provide a new perspective for identification of process
enhancement opportunities involving energy upgrading and conversion in the pulp and
paper industry. The method has, for example, been used to estimate exergy losses in the
heat-exchanger network in a TMP mill (Hippinen etal. 2010) or in a black-liquor evapora-
tion plant in a Kraft pulp mill (Marinova etal. 2009). In this method, exergy analysis is
combined with pinch analysis by replacing temperature on the y-axis with Carnot
efficiency.*The sequence of processes by which heat is produced and supplied to the end
receptor is represented in this diagram. The area between the balanced hot and cold com-
posite curves represents the exergy loss of the system (Marinova et al. 2009). Hippinen
et al. (2010) studied the heat-exchanger network of a pulp and paper (TMP) mill using
combined pinch and exergy analysis and concluded that no advantages could be obtained
from this c ombination of techniques.
11.2.1.3 Mathematical Programming Methods

Mathematical programming is a tool by which mathematical relations can be identified in
the system under analysis. The MIND (Method for analysis of INDustrial energy systems)
tool developed in the Department of Management and Engineering in Linkping
University is an example of a tool based on mathematical programming methods which
has been applied to the analysis and optimization of industrial energy systems as well as
to industries in cooperation with other players such as district heating systems. The opti-
mization is carried out using mixed-integer linear programming (MILP) (Bengtsson etal.
2002; Karlsson 2011). To apply these mathematical methods in process integration studies,
they should be combined with pinch analysis. Marechal and Kalitventzeff (1997) presented
a methodology for a combined energy and environment synthesis of industrial processes
in which the EMO (Effect Modeling and Optimization) mathematical formulation approach
was used to combine numerical optimization involving MILP with process thermody-
namic analysis. To the authors knowledge, there exist very few studies dealing with the
application of mathematical programming methods to energy analysis of Kraft pulp mills
(Jnsson et al. 2008; Cakembergh-Mas et al. 2010; Karlsson 2011). No details of these
methods are therefore discussed in this chapter.
11.3 Energy-Efficiency Measures Based on Newly Developed Methods

There are numerous ways to decrease energy usage in pulp and paper processes. Overviews
of various measures to save both thermal and electrical energy can be found in Browne etal.
(2001), Bruce (2000), and Loutfi and Ruzicka (2006). In this chapter, the focus is on measures
applied for thermal energy savings, such as steam savings and excess heat utilization. The
main method described in this chapter is process integration (the so-called heat integration)
* Carnot efficiency is defined as 1 (To /T ).

which can be achieved with or without major changes in process equipment. Several
energy-efficiency measures for reducing steam consumption in pulp and paper mills can be
found in the literature. The most frequently mentioned are internal heat recovery, conden-
sate recovery, redesign of the hot- and warm-water systems (HWWS), and water reuse, as
well as energy conversion and upgrading (Nordman and Berntsson 2001; Wising et al.
2002a,b, 2005; IEA 2004; Axelsson etal. 2006; Marinova etal. 2009; Mateos-Espejel etal. 2010a).
It is important to note that when performing energy analysis in a mill, the best approach
is not always to eliminate or reduce the pinch violations first and then to use the r emaining
excess heat to reduce energy consumption. In many cases, efforts to eliminate or reduce
pinch violations may encounter practical constraints, may be economically unattractive, or
both. The most cost-effective solution with respect to how many, and which, pinch viola-
tions to resolve is actually an optimization problem. The target function is the net profit of
the mill. For strict mathematical optimization, conditions such as the mill layout and
piping distances are needed. Moreover, economic conditions such as energy prices and the
annuity factor are also needed to find the best solution (Axelsson, 2008). To evaluate energy
export potential from a mill in the future, both energy prices and the CO2 emissions impact
of energy exports and imports would be needed. Therefore, the need to develop new
methods to provide the required information is obvious. This topic is discussed further in
detail later in this chapter.
11.3.1 Pinch-Analysis-Based Advanced Composite Curves

An existing concept based on pinch technology for integrating new energy technologies is
the grand composite curve (GCC). However, this curve is not well suited for retrofit
situations, in which two problems occur with the GCC. First, the temperatures are not
estimated correctly in existing systems having a heat demand that is large in relation to
what could be achieved by enhanced heat recovery. Second, the GCC does not provide any
information about the existing heat-exchanger network (HEN), which means that no
indication of the changes needed in the HEN to approach theoretical levels can be given.
To cope with these problems, novel composite curves developed in the Heat and Power
Department, Chalmers University of Technology, are proposed in this chapter. They are
based on pinch technology and permit accurate representation of existing loads as well as
possible improvements that could be obtained by retrofitting. As emphasized above, the
current status and existing design of the energy systems in a plant influence considerably
the available opportunities for improvement.
With the aid of four different composite curves above the pinch and four below in a
temperatureheat load diagram, important information on such opportunities for a num-
ber of different measures can be extracted. The measures in question are improved heat
exchange, introduction of a heat pump or a CHP plant, and the consequences of various
process changes. These curves can therefore be used to assess possible heating-system
improvements. The four types of curves above the pinch (see Figure 11.2) are
Hot utility curve (HUC). This curve simply shows a composite of the hot utility as
a temperature versus heat load diagram (e.g., for water, steam, or oil distribution
systems).
Actual heat load curve (AHLC). This curve shows a composite of all the cold
streams or cold stream segments constituting the cold side of the heaters in the
heat distribution system(s) in a temperature versus heat load diagram.
400
THLC AHLC
350
EHLC HUC
300
250
T (C)
200
150
100
50
0
0 2000 4000 6000 8000 10000 12000 14000 16000
Q (kW)
FIGURE 11.2
Temperature vs. heat load diagram above the pinch, showing the HUC, THLC, AHLC, and EHLC curves.
Theoretical heat load curve (THLC). This curve shows the theoretically lowest
temperature versus heat load at which heat can be introduced to the system when
all thermodynamically correct opportunities for heat exchanger enlargement and
introduction of new heat exchangers have been implemented at the existing external
heat demand.
Extreme heat load curve (EHLC). The EHLC curve shows the heat load vs.
temperature level when the heat exchange is carried out with a minimum heat-
exchanger area. This is the same as performing the heat exchange vertically in the
composite curves. It also means that the externally supplied heat is transferred to
the cold streams as high a temperature as theoretically possible.
In principle, the same four types of curves should also be constructed below the pinch
and are called the cold utility curve (CUC), the actual cooling load curve (ACLC), the
theoretical cooling load curve (TCLC), and the extreme cooling load curve (EHLC).
With the aid of these curves, three levels of complexity of changes in heating, cooling,
and process systems can be identified and evaluated. These are
Improvements involving only the HUC/CUC. Only the utility system is involved.
In principle, these have no influence on the flexibility, controllability, or operability
of the plant. Little or no investment cost in the heating/cooling/process system is
required.
Improvements involving AHLC/ACLC. Changes in the heating and cooling
distribution systems are needed (e.g., adding one or more temperature level(s) to
the heating or cooling system). No changes in the process heat-exchanger network
(HEN). Relatively minor influence on flexibility, controllability, and operability.
Moderate investment cost in the heating/cooling/process system.
Improvements involving THLC/TCLC. Changes in the HEN are needed (new
units or enlargements of existing units). Risk of major influence on flexibility,
controllability, and operability. Risk of considerable investment cost in the h eating/
cooling/process system.
Generally speaking, with any improvement measure, there is a tradeoff between the
ossible magnitude of the energy improvement (normally influenced favorably by greater
p
complexity of heating/cooling/process system changes) on the one hand and investment
cost, flexibility, controllability, and operability on the other. Therefore, it is of high
importance to identify opportunities for improvements as a function of their level of
complexity.
The AHLC curve should lie between the THLC and EHLC curves. If any part of the
AHLC lies below the THLC, then either that part is violating the pinch rules by heating
below the pinch, or the actual Tmin,HX is less than specified. It should not be possible for
the AHLC to lie above the EHLC curve because of the definition of the EHLC curve. An
AHLC close to the EHLC curve means that the existing HEN has a good fundamental
design with a small installed heat-exchanger area. This can, however, be a poor solution in
a retrofit situation in which additional area must be installed to increase process-to-process
heat exchange. The heaters that are to be freed or relieved are placed high in temperature,
which leads to small Ts for the new or enhanced heat exchangers. A relatively large area
must then be inserted for a given saving in external heating.
On the other hand, an AHLC close to the THLC means that the heaters in the existing
HEN are placed low in temperature. More heat-exchanger area is then required to transfer
the same amount of heat as in the previous case. This is therefore a poor design from a
greenfield design viewpoint. However, this area has potential for better utilization. By
increasing the internal heat exchange, heaters can be released or relieved at a lower tem-
perature compared to the previous case. Intelligent matching using criss-cross heat
exchange then leads to inserts of smaller area than in the previous case. From this discus-
sion, it can be concluded that the cost of additional heat-exchanger area in an HEN retrofit
should be relatively small when the AHLC is close to the THLC. When it lies close to the
EHLC curve, the cost should be larger and should increase as the AHLC approaches the
EHLC curve.
The base cost, that is, the area-independent part, for a new heat exchanger is far from
negligible. If the AHLC is close to the THLC, this cost should also normally be smaller
than when it is close to the EHLC. The reason is that with the original heaters placed low,
the number of possible combinations between these and the hot streams is greater, and
therefore the likelihood of finding matches with large streams reduces the number of
matches needed. A third important cost is the cost of piping. The curves do not provide
any information about how to reduce the length of piping, but fewer units generally mean
less piping. Therefore, the consequences for piping cost can, at least partly, be studied, and
once again, a situation with the AHCL close to the THLC is favorable.
The same discussion as above can also be held below the pinch with the four curves
CUC, ACLC, TCLC, and ECLC. A more comprehensive description of the method can be
found elsewhere (Nordman and Berntsson 2009a,b).
11.3.2 Matrix Method for Economical Retrofit of a Heat-Exchanger Network

When retrofitting an HEN using the traditional pinch method, many important parameters
such as heat-exchanger area, number and type of heat exchangers, physical distance
between the streams, piping, annual pressure-drop costs, and others are not considered in
the analysis. An approach is desirable which would be suited for heat-exchanger networks
that include many possible heat-exchanger alternatives. However, it is important that the
area cost not be the only cost considered, because in practice it accounts for only a fraction
of the total retrofit cost. A proposed method which systematically and rigorously solves
the problem of determining retrofit solutions is the matrix method (Carlsson, 1996). The
method was developed to make it possible to consider all the parameters that influence the
final design. The main parameters taken into account in the matrix method are: area cost
(size, heat-exchanger type, and material), piping cost (the distance between streams, pipe
materials, and diameter), pressure-drop cost, and maintenance cost. In this method, the
complex heat-exchanger network design has been simplified using certain heuristics such
as temperature differences in the heat exchangers, tick-off matches, and stream splitting.
The rearrangement of heat exchangers and thus the identification of profitable solutions
are carried out in a simpler way in this method than in more advanced mathematics-based
methods (e.g., MILP and MINLP as presented by Yee and Grossmann (1987) and Ciric and
Floudas (1990)), and the final solution is found by comparing the alternatives identified. In
the basic approach, certain general principles of retrofit analysis are applied, such as
retaining existing heat exchangers in their original positions (matches) as much as possible,
installing as few new heat exchangers as possible, maintaining a minimum heat-exchanger
area, and repiping no more than necessary.
The matrix method is an interactive method in which the user decides which heat-
exchanger combinations will be included in the solution. A computer program calculates
the consequences of the various heat-exchanger alternatives. A heat-exchanger design
consists of a combination of matches, each of which contributes an individual annual cost
to the total cost of retrofitting the heat-exchanger network. The combination of matches
that yields the lowest cost is the solution to the retrofit problem at each global Tmin
(Nordman and Berntsson, 2001). The method has been used successfully to find an
economically feasible heat-exchanger network retrofit for the release of excess heat

discovered using the curves (Bengtsson etal. 2002).
In the matrix method, a matrix is developed in which hot streams run vertically and cold
streams horizontally. For each thermodynamically possible match, the cost of implement-
ing the match is calculated at a given level of energy recovery (i.e., Tmin), using all costs
discussed above. In each match, at least one stream is ticked off. For piping, the geographi-
cal distances between all streams are included as input data. The user picks one match, for
example, the one having the lowest cost (except for existing ones which have zero cost),
and the matrix is fully recalculated with the ticked-off stream(s) in the chosen match
omitted. This goes on until all matches have been chosen and the given energy recovery
has been achieved. This procedure must be repeated once or twice until the sequence with
the lowest total cost has been found.
The whole procedure described above can be carried out also with other Tmin values.
This will lead to a graph of total investment cost versus energy recovery level, from which
the optimal level of energy recovery for a given energy cost can be determined.
One characteristic of this method is its simple way of dealing with existing and new
matches. Existing matches are regarded as new installations, but are given an appropriate
value (normally zero) by means of the cost equation.
From the matrices, one can easily obtain much information about the nature of the
network, such as
Identification of which streams are difficult to match and how different streams
interact with each other
Identification of matches that are economically feasible to terminate before heat
load tick-off
Information about the need for stream splitting and the possibility of creating a
network with the minimum number of units
The influence of the global Tmin on the complexity of the network, concerning, for
example, the need for stream splitting and extra units
Identification of the parameters having the greatest impact on the solution (i.e.,
heat-exchanger costs and others)
A number of rules and algorithms have been developed to determine in which order the
matches should be chosen. However, only a few iterations normally are necessary.
11.3.3 Combined Water and Energy Reduction Analysis

Classical water-pinch methodologies have proved difficult to use in the pulp and paper
industry because there are too many contaminants in the water streams and because water
is both a utility and process stream in the pulp and paper industry (Koufos and Retsina
2001; Savulescu at al. 2005a). Approaches for combining heat and water reduction tech-
niques have therefore been developed in which modified water-pinch approaches have
been used (Bedard et al. 2001; Koufos and Retsina 2001; Bengtsson etal. 2002; Savulescu
etal. 2005b; Mateos-Espejel etal. 2010a). Methodologies based on the interaction of water
and energy using process integration approaches such as the water-thermal composite
curve and the water source-and-sink curve have therefore been developed. Some of these
studies deal in addition with the complex problem of combining reductions in energy and
water usage in an efficient way based on the interactions of water and energy in a mill.
Heavy optimization efforts are required to consider water, not only as a source in a water
balance, but as a heat source in an energy balance, and then to combine it with contami-
nant concentrations and temperatures (Savulescu etal. 2001; Mateos-Espejel etal. 2010a,b).
Mills evaluated using these methods have had high water consumption and a low degree
of backpressure electric production. Modern energy-efficient mills, however, often have
low water consumption, and t raditional heat-recovery projects suggested mostly for ear-
lier mills are often not applicable to m
odern mills (Wising 2003).
In general, the water that is used as a hot or a cold utility in a mill is stored in tanks,
normally at three to five different temperature levels. The water stream normally does not
have the same temperature as the overall tank; this means that a mixing of waters at
different temperatures occurs in tanks. For modern pulp mills for which the water

consumption is low and the pinch temperature is already at 100C or above, mixing of
water streams at different temperatures in tanks is not considered as a pinch violation
(temperature levels are below the pinch temperature), and various solutions are required
principally for improving energy efficiency. The tank curves method was therefore
developed to maximize the usable excess heat potential at high temperature in the HWWS
which can be used for other processes or saved as primary heat (Nordman and Berntsson
2006). In this method, the system boundary encloses the HWWS, and making changes in
the HWWS would then leave the remaining process without any changes at all. Therefore,
no complex simultaneous optimization and analysis of water consumption, water con-
tamination, number of tanks, temperature levels in tanks, and tank size is performed in
this method. Instead, the number of tanks and their temperature levels are optimized for
a given mill water demand. The method can be applied in mills with either high or low
water consumption.
11.4 Examples of Application of New Methods

When steam is saved and excess heat is released using one or more of the energy-efficiency
measures mentioned earlier, the saved steam and released heat can be used in various
ways in the mill. It can be used internally to increase the level of efficiency in the mill, for
example, upgrading the evaporation plant, or externally, for example by the installation of
new equipment like heat pumps, or in the implementation of new biorefinery concepts, for
example, precipitation of lignin from black liquor. Common uses of saved steam and
released heat in Kraft pulp mills which have been studied and reported in the literature
are described briefly in the following section. Examples of methodologies for integrating
new concepts in Kraft pulp mills based on newly developed methods for energy-efficiency
improvement will be summarized.
11.4.1Use of Advanced Curves and Background/Foreground Analysis

forBiorefineryConcepts
When analyzing the energy consequences when a subprocess, for example, a distillation
plant, is changed or when a new subprocess is introduced into an existing process, the
concept of background/foreground analysis is useful. It should be seen mostly as a guide
for finding the integration possibilities between processes. In this analysis, the existing
process and its GCC are called the background process and the background curve, respectively.
Correspondingly, the subprocess and its GCC are called the foreground process and the fore-
ground curve. If the temperature levels match, the two processes can be integrated so that
the cooling demand of one process is used as heat in the other. The possibilities can then
be analyzed and approximately quantified with the aid of the background and foreground
curves. One example of how these advanced curves can be used is shown in Figure 11.3. It
is taken from a project on how to convert a Kraft pulp mill into an ethanol plant (Fornell
and Berntsson 2011).
One integration problem is how to integrate the distillation and evaporation parts into
the background process, which includes the pretreatment, the ethanol line (except for
distillation), and the units in the chemical recovery cycle. When assessing the use of heat
in a lignocellulosic ethanol process, the most important unit is the pretreatment of the raw
material. According to previous studies (Fornell and Berntsson 2011), advanced pinch
curves can be used to advantage in process integration studies (shown in Figure 11.4). The
background process studied here is in part a retrofit (the reused pulp-mill unit operations)
and in part a greenfield design (the ethanol line). The base case for comparison in this
study is a background process design in which no energy-efficiency improvements have
been made in the repurposed pulp mill.
In Figure 11.4, the AHLC (actual heat load curve) and the ACLC (actual cooling load
curve) show at what temperatures hot and cold utilities are needed in the base-case pro-
cess. As can be seen from the ACLC, there is not much excess heat available for integration
of the thermal-separation units in the original design (~3.4 MW above 90C). If a GCC were
constructed for the process at the Tmin corresponding to the same utility demand, it would
appear that the excess heat available would be 13.7 MW (above 90C). This excess heat can,
however, be made available in the process only if a retrofit of the heat-exchanger network
is done. The demand for low-temperature hot utility (below 110C) is 13.5 MW, and because
the THLC and the AHLC are almost completely superimposed, the supply temperature
Steam addition Steam withdrawal
Live steam
Surface
1 2 3 4 5 6 7 condenser
Heavy liquor
Condensates
Live steam cond

Intermediate liquor Mixing

Weak liquor
tank
Condensates
CO2
Lignin separation plant
Filtration Washing Lignin

3045% (6570%)
Precipitation
Lignin lean filtrate Wash filtrate
FIGURE 11.3
Evaporation plant (seven effects) with heat integration and lignin separation. (From Fornell, R. and Berntsson, T.,
2011. Process integration study of a kraft pulp mill converted to an ethanol production plantPotential for heat
integration of thermal separation units. Submitted for publication.)
200
TCLC AHLC
ACLC THLC
150
T (C)
100
50
0
0 10 20 30 40
Q (MW)
FIGURE 11.4
Advanced pinch curves for the background process. (From Fornell, R. and Berntsson, T., 2011. Process i ntegration
study of a kraft pulp mill converted to an ethanol production plantPotential for heat integration of thermal
separation units. Submitted for publication.)
cannot be decreased further without violating the pinch conditions. The THLC and the
utility demand in the GCC are at the same temperature.
There are two ways of studying the possibilities for steam savings in this process; either
the background process could be improved by increasing internal heat recovery (i.e.,
resolving the pinch violations), or the heat-exchanger network could be redesigned to
increase the possibilities for external heat integration with distillation and evaporation.
From Figure 11.4, it can be seen that resolving pinch violations will decrease the hot utility
to 15MW (where the THLC and the TCLC cross). It can also be seen that ~17MW of excess
heat at a high temperature (above 100C) can be freed without changing the hot-utility
demand (TCLC). The theoretical cooling load curve (TCLC) shows the highest tempera-
tures at which coolers can be placed in the process for a specific THX (set to 7K in this
study) while maintaining the base-case hot-utility demand. The THLC gives the same
information as the TCLC, but for heaters above the pinch temperature [36]. The figure also
indicates that there is a pinch violation of ~2 MW which can be resolved with the excess
heat existing in the process today (to the left of where the ACLC and AHLC cross). This
pinch violation actually represents the use of 4-bar steam for building heating. The total of
the pinch violations that can be resolved is therefore 17 MW. From Figure 11.4, it can also
be seen that the amount of excess heat that can be made available to meet the original util-
ity demand is greater than the amount of excess heat available in the GCC (Figure 11.5)
(18 MW above 90C in TCLC compared to 13.7 MW in the GCC).
Another example of results obtained using the advanced curves is shown in Figure 11.5.
The results in the figure have been calculated using the matrix method as in Nordman
(2005). From this curve, it can be seen that the cost of saving energy is substantially lower
in the case in which heaters are placed close to the pinch, and the more energy that is
saved, the more the relative cost of the retrofit increases among the cases. The number of
new or rearranged units is also lower in the case in which heaters are placed close to the
pinch, indicating that the expected cost of piping is also lower in this case. Note that
resolving one pinch violation can affect more than one heat exchanger. In Figure 11.5, the
4 K as global T
4000
Heaters far away from pinch (17)
3500
Heaters close to pinch
(17)
3000
Investment cost (kS)
(15)
2500
(13)
2000
(8)
1500
(11)
1000 (7)
(4)
500 (2) (3)
(1)
0
0 1000 2000 3000 4000 5000 6000 7000
Qsave (kW)
FIGURE 11.5
Cost-efficiency curve with number of new or rearranged units presented within brackets.
number of new or rearranged units is indicated within brackets for each pinch violation
that is resolved. The unit cost (i.e., the area-independent part) is ~40% of the total cost in
the case in which the heaters are placed close to the pinch, whereas it is only ~20% in the
case in which the heaters are placed high in temperature, although there are many more
units in the latter case. This can be explained by the fact that much more area needs to be
introduced to perform the heat exchange when the heaters are placed high in temperature
because the T values serving as a driving force are low.
An example of the tank curve method is described and illustrated below.
As already mentioned, this method is based on traditional composite curves. In addition
to the hot and the cold CCs, a third curve is introduced, called the tank curve. The steps in
the method are listed below:
1. Identify the HWWS hot streams and construct the hot CC.
2. Identify the HWWS cold streams.

3. Identify the process demands and the cooling demands from the cold streams.
4. Construct the cold CC from the cold streams for the process demands.
5. Calculate the theoretical target for the maximum excess heat at a given Tmin
(Figure 11.6b).
6. Replace the cold CC with the tank curve (Figure 11.7).
7. Vary the number of tanks and their temperature levels to maximize the amount of
usable excess heat.
The main idea of the tank curve is that fresh water for process needs is taken at the fresh-
water inlet temperature and is heated successively until it reaches the tank temperature.
(a) (b)
Excess heat of
high temperature
Excess heat
Excess heat of
Tmin
T (C)
low temperature
T (C)
Q (kW) Q (kW)
Qxs
FIGURE 11.6
(a) Composite curves show how the temperature of the cooling demands, which could be used for Qxs, varies.
(b) Shifting the tank curve to the left until reaching the HWWS Tmin yields the maximum usable Qxs.
90
T = 85C
The tank curve for
80 TTL 2,
one tank level (at 85C)
curve 1 and 2
70
60
50 TTL 1, curve 2
T (C)
40
TTL 1, curve 1
30
20
Two tank curves
10 The original cold curve from the with two tank levels
demands of the final users
0
0 5000 10000 15000 20000 25000 30000 35000
Q (kW)
FIGURE 11.7
Tank curves are constructed from knowledge of the original cold composite curve and look different depending
on the number of tanks and their placement with respect to temperature.
Process demands are then met either by direct tapping from a suitable tank (tank tempera-
ture is the same as process demand) or by mixing tank water with fresh water until the
desired temperature is reached.
In a greenfield design, this method could be used to minimize the number of water
storage tanks needed. In the case of a retrofit, a number of tanks are already installed. In
this case, there are two options:
Maximize the usable heat using the current number of tanks.

Maximize the usable excess heat using fewer than the current number of tanks.
The second option makes it possible to reduce control complexity. Installing more than
the current number of tanks would in most cases not be necessary because the method has
shown that most systems could operate with only two tanks.
11.5 Assessing Profitability and Carbon Balances of Energy Investments

Energy systems are complex sociotechnical systems with many actors connected in an
infrastructural network, including social and industrial sectors, production systems, and
system operators. Besides obvious important parameters such as investment costs and
performance, system culture plays a very important role. Government measures aimed at
implementing new technology should therefore be characterized not only by the level of
economic support provided, but also by the compatibility of that economic support with
the established system cultures within the energy system (Marbe 2005). Political measures
aimed at saving energy, such as green certificates, long-term agreements between the
government and industry c oncerning energy investments, and CO2 trading may help mills
to choose the alternative which provides the largest reduction in CO2 emissions, but could
just as well have the opposite effect (Algehed 2002). The issue of CO2 emission is important
from a strategic perspective for the pulp and paper industry. Because energy use in the
pulp and paper industry is high, energy savings in this sector can have a large impact on
national CO2 emission levels (Wising 2003). The profitability and the net CO2 emissions
reduction potential of energy investments in this sector must therefore be assessed by
quantifying their implications within a future energy-market context. To carry out
decision-making s ubject to uncertainty about future energy-market conditions, various
strategies can be considered.
Over more than a decade, research on strategic methods for evaluating candidate
investments, using different scenarios that include future fuel prices, energy carrier prices,
and CO2 emissions and policy instruments, has been conducted in the Department of Heat
and Power Technology at Chalmers University of Technology (dahl et al. 2000; dahl
and Harvey 2007; Axelsson et al. 2009; Axelsson and Harvey 2010). To obtain reliable
benchmarks, these scenarios need to be consistent. A calculation aid or a tool can be helpful
for creating scenarios adapted for this energy-intensive industry (Axelsson 2008). A
methodology has therefore been developed which includes blocks with different sets of
coherent energy-market prices. These blocks were initially intended to be used to con-
struct scenarios for evaluation of industrial energy projects. These so-called energy-market
scenarios were then upgraded by constructing a tool,* ENPAC, to enable the creation of
consistent scenarios.
The ENPAC tool calculates energy prices for a large-volume customer based on forecasted
world-market fossil-fuel prices and relevant policy instruments (e.g., costs associated with
emitting CO2, various subsidies favoring renewable energy sources in the electricity mar-
ket or the transportation-fuel market) and on key characteristics of energy-conversion
technologies in the district-heating and electric-power sectors. An overview of the proce-
dure and purpose of the ENPAC tool for evaluation of energy-efficiency investments in
energy-intensive industries is shown in Figure 11.8. For further details, the reader is
referred to the report by Axelsson and Harvey (2010).
A systematic approach which trades off CO2 emission reductions against investments
in process-integration measures in industry while optimizing these investments under
economic uncertainty has also been presented in the literature (Svensson etal. 2009b;
Svensson and Berntsson 2010). The methodology proposed by Svensson and Berntsson
(2010) is based on the assumption that investment decisions must be made before the
values of uncertain parameters can be known. An example of an uncertain parameter
is the availability of carbon capture and sequestration (CCS) to an extent such that coal-
power plants with CCS can be assumed to be the marginal electricity producer. Many
of the uncertainties affecting investment decisions are related to future CO2 emission
targets and policies. The optimization should therefore consider not only economic
criteria, but also greenhouse-gas reductions. Svensson and Berntsson (2010) used a
model to optimize decisions on energy-efficiency investments under uncertainty. As
the decision problem became a multiobjective programming problem, the method pro-
posed by Svensson and Berntsson attempted to provide a good framework for deci-
sion-making about energy-efficiency m easures when considerations of greenhouse-gas
reductions are influencing these d ecisions. In the Swedish case, for example, in addi-
tion to the question of future CCS availability, electricity price is also a time-dependent
* ENPAC, Energy Price and Carbon Balance Scenarios, developed by Erik Axelsson and Simon Harvey at
Chalmers University of Technology and Profu (www.profu.se).
Fossil fuel prices on the European

commodity market
Policy Different optional energy projects
instruments
Electricity price
The ENPAC tool
(for constructing Fuel prices Robust investment
energy market options
scenarios) CO2 emissions Energy
Energyintensive
intensive
industry Consequences for
associated with industry
global CO2 emissions
marginal energy
Construction of... ...consistent energy ...evaluation of energy ...to identify robust solutions
market scenarios for... projects in industry... with low CO2 emissions.
FIGURE 11.8
Overview of the purpose of energy-market scenarios for evaluation of energy-efficiency investments in energy-
intensive industries when the ENPAC tools are used to construct the scenarios. (Adapted from Axelsson and
Harvey 2010. Scenarios for Assessing Profitability and Carbon Balances of Energy Investments in Industry. AGS
Pathways Report: EU1, Sweden.)
parameter. Depending on which market is setting the electricity price (e.g., a common
Nordic electricity market or a North European one), different scenario building blocks
will result. This method has been applied to the case of energy-efficiency investments
at a chemical pulp mill (Svensson etal. 2009a). The results showed that the proposed
methodology could handle both time dependence and parameter uncertainties and
found a robust solution which turned out to be a combination of two opposing invest-
ment strategies. The obvious effect of policy instruments aimed at decreasing CO2
emissions was also found to be an increased profitability for all energy-efficiency
investments.
11.6Conclusions
This chapter was intended to provide an overview of the available thermodynamics-
based methods and tools that have been used to perform process integration studies for
Kraft pulp and paper mills in Sweden. This overview could provide a basis for building
a platform for further development of process integration tools and methods, including
consideration of the implementation of new biorefinery concepts. In this context, a num-
ber of various approaches which tackle the complex issue of process integration with
regards to energy and water systems, appropriate efficiency measures, and evaluation of
the chosen integration measures under an uncertain future energy market have been
presented. Depending on the operating history of the mill under study (modern vs. old
mill) and the degree of existing integration, different methods can be used to optimize
process energy consumption. In general, it can be said that energy savings can enable
energy exports from the mill or can be used to integrate new technologies or concepts
into the mill. To decide which measures to choose, a method for assessing profitability
and CO2 balance has been presented.
Acknowledgments
The work presented here has been performed within the Technology Impact Assessment:
System Perspectives on the Biorefinery project in the research area of Energy Combines*
within Chalmers Energy Initiatives, a strategic, governmentally funded program. The
author acknowledges Anders sblad (CIT-Industriell Energianalys) for his valuable
insights and contributions to this work.
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11

Methodologies Developed and Applied in Process

Maryam Mahmoudkhani and Thore Berntsson

11.2 Process Integration Studies

Process PI studies: Process Energy Process Assessing

11.2.1 PI Studies: Thermodynamics-Based Methods

Pinch analysis is a well-proven and established thermodynamics-based method with a

11.2.1.2 Exergy Analysis

11.2.1.3 Mathematical Programming Methods

11.3 Energy-Efficiency Measures Based on Newly Developed Methods

* Carnot efficiency is defined as 1 (To /T ).

11.3.1 Pinch-Analysis-Based Advanced Composite Curves

11.3.2 Matrix Method for Economical Retrofit of a Heat-Exchanger Network

11.3.3 Combined Water and Energy Reduction Analysis

11.4 Examples of Application of New Methods

11.4.1Use of Advanced Curves and Background/Foreground Analysis

Steam addition Steam withdrawal

Live steam cond

Intermediate liquor Mixing

Filtration Washing Lignin

Lignin lean filtrate Wash filtrate

2. Identify the HWWS cold streams.

Maximize the usable heat using the current number of tanks.

11.5 Assessing Profitability and Carbon Balances of Energy Investments

Fossil fuel prices on the European

market scenarios for... projects in industry... with low CO2 emissions.

Engineering Transactions 21, 349354.

Technical-Association-of-Canada, Montreal, January 2001.

Das könnte Ihnen auch gefallen

11.4.1Use of Advanced Curves and Background/Foreground Analysis