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SABP-A-005 28 December 2005 Quick Energy Assessment Methodology for Energy Efficiency Optimization Document Responsibility: Energy Systems Unit/ESD/CSD
Previous Issue: None Next Planned Update: 1 January 2009 Primary Contact: nourelmm@aramco.com, phone +966 (3) 873-6045
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
Table of Contents
Page 1.0 Introduction 1.1 1.2 1.3 1.4 2.0 Definition Purpose and Scope Intended Users Initial Assessment Objectives 3 3 3 4 4 4 4 5 3 Energy Flow Diagrams Steam and Power Diagram Fuel Diagram Energy Saving Housekeeping List Energy Saving Generic Checklist 7 11 12 13 14 16 16 18 52 54
Quick Energy Assessment Overview 2.1 2.2 Energy Efficiency Optimization Task Description Solution Method Using Decomposition Approach
3.0
4A.0 Appendices for Short-cut Calculations and HGP Energy Study 4A.1 4A.2 4A.3 4A.4 Basic Steam Mass Balance Basic Energy Utility Targeting Using Pinch Method Basic Formulas for Some Quick Savings Estimation HGP Detailed Energy Assessment Study
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
1.0
Introduction
Energy conservation in Saudi Aramco became everyones business. It is mandatory for each process facility to find cost effective solutions to save energy and achieve more with less in their facilities. Saudi Aramco has constituted a committee called EMSC Energy Management Steering Committee to direct and manage a sustainable process for energy conservation. A vital contribution towards the success of the company wide energy conservation policy comes through documenting the company best practices in methodology, tools and applications in the field of energy conservation and distributing such knowledge among our facilities. Hence, a consistent effort has been exerted in Saudi Aramco to produce Best Practices to help Saudi Aramco plants achieve their energy conservation targets and disseminate energy conservation knowledge. This particular Best Practice document for initial energy assessment is a contribution towards this goal. It is expected to draw the line in conducting energy assessments through a user-friendly methodology. The theme of this quick energy assessment methodology for energy efficiency optimization is, Big Picture First, Details Later. Energy assessments, also called energy audits, may be primitive or comprehensive and detailed. A variety of approaches, methods and tools are available to conduct such energy assessments to improve the energy efficiency of industrial processes.
1.1
Definition
The term Energy Assessment refers to the methodology of collecting and analyzing available energy utilities related data in order to establish the big picture of the breakdown of energy consumption for a particular facility and identify componentbased-energy saving opportunities within the facility.
1.2
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
1.3
Intended Users
This Best Practice manual is intended for use by the energy engineers working in Saudi Aramco plants, who are responsible for efficient operation of their facility. This particular document will enable them to conduct quick energy assessments systematically.
1.4
2.0
2.1
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
1. Minimum disruption in the energy utility supply 2. Minimum consumption of energy utility.
Given an industrial facility that consists of several processes and utility plants, define; at minimum deficiency in energy utility systems supply to the process; near-optimal targets for energy consumption minimization, find a list of possible operational and design modifications to achieve desired target(s) and conduct the engineered solutions
2.2
3.0
Methodology
There are four essential tasks that can be conducted by a small energy focus group of three engineers: 1. 2. 3. 4. Data, Models and Targets Insights, Opportunities and Estimated savings potential Screen and Formulate Strategy Document, Report and Present
These tasks are exhibited in the 10-Steps procedures below. 1. Site survey through templates, checklists and interviewing of process owners/proponents to gather the right amount of data that enable the energy team build the plants big picture and understand the goals and the constraints of the facility( What to look for and what to ask)
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
2. 3.
Define the criteria for focusing on potential areas of interest (when to be rigorous and get to the second level of details) Develop site energy/utility nominal design/normal operation models with the appropriate level of details in a high level generic path diagrams for, power, fuel, H2, steam, water, nitrogen and air. Preliminary purpose of these models will be to understand what is going on in the energy utility system, locate the energy consumption elephants (ECEs) in both process and utility plants and generate insights for energy saving opportunities Add more depth in the level of details of the energy utility model for each ECE and/or other criterion of focus Define the effect of disturbances and uncertainty on the energy utility system models a. b. c. d. Sources of disturbances Site energy utility balance under disturbances Nominal and dynamic targeting of energy utility systems (Check that the big picture depicted for the process and the utility plants is correct with enough degree of confidence before you proceed) _ Identify main processing issues that affect utility utilization _ Link utility-utility interactions _ Integrate and qualitatively optimize site utilities (If we do not coordinate between steam and fuel systems we may stop flaring steam but flaring fuel) for energy utility saving
4. 5.
6.
7. 8.
Integrate core processes among themselves and with utilities Develop a comprehensive initiatives list via identifying and estimating energy utility savings opportunities a. b. c. d. Housekeeping list Checklists (generic and process specific) Waste energy recovery (pinch method and others) In-process Modification (pinch method and others)
9.
Champion a cross-fertilizing discussion among plant disciplines to prioritize, screen the initiatives and writing a project sheet, for each initiative, including a description of the opportunity and energy utility savings estimate Develop word strategies for realizing savings from facility goals, analysis of the results and the mapping of the opportunities onto the facility strategy (remember, 50% of something is better than 100% of nothing). Then report and present results.
10.
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
3.1
3.1.1
Fuel
Energy Sources
Energy Generation
Boilers & Cogeneration Steam Electricity
Energy Distribution
Energy Utilization
The task now is to look for the Elephants in the energy-process system. The graphs below will enable the Energy Engineer to find the Elephants to focus his/her efforts and decide where to start and insist on accurate data collection to further proceed with the analysis. Money-based graphs will help quickly to pinpoint the areas of focus. Furthermore, the BTU-based graphs will double check the pre-defined priority list, direct the study towards the process reasons behind certain energy elephant and find more efficient ways to satisfy the process target(s).
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
3.1.2
$ 0.5 MM
Process Purchase
$ 0.9 MM
Other users
$ 24.4 MM $ 0.0 MM
Steam
$ 52.4 MM $ 45.9 MM
$ 21.5 MM $ 20.70 MM
Fuel
Flare
furnaces
$ 16.9 MM
power
$ 2.2 MM
refrigeration
Motors
$ 37.6 MM
$ 0.0 MM
Export
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
Purchase
SA Fuel Gas
Export
Flare Area
Inlet Area
$ 56.1 MM/yr
power Total Purchased
$1.72MM/yr $2.8 MM/yr Utility Area $0.244MM/yr $ 0.4 MM/yr Sulfur Recovery Area $0.221MM/yr $16.6MM/yr Gas Treat $3.25 MM/yr Area $0.335MM/yr
Gas Comp.
$18.08 MM/yrArea $ 56.1 MM/yr 200 MW $0.609MM/yrLiquid Recovery $29.04 MM/yr Area
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
3.1.3
8.38 TBtu
0.18 TBtu
Electricity
0.39 TBtu 1.8 TBtu Process -0.19 TBtu Boilers steam cogen 0.0 TBtu
Fuel
steam
Building
5.46 TBtu 0.12 TBtu - 5.4 TBtu 2.11 TBtu 5.77 TBtu Boilers Boilers Process Process Building steam steam cogen cogen 5.59 TBtu 0.18 TBtu -5.4 TBtu 0.0 TBtu Conventional Electricity
-0.19 TBtu
Boiler Fuel
Conventional Electricity
Boiler Fuel
Conventional Electricity
Boiler Fuel
Area #1
#N
Area #1
#N
Area #1
#N
Unit #1
#N
Unit #1
#N
Unit #1
#N
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
3.2
Steam Targets
103 t/h
Consider replacing turbines with motors Enhance the recovery of Steam from condensate
HP Boiler
98 t/h
HP
68 t/h 21 t/h 8 t/h
Proc. #1
0.0 t/h
0.0 t/h
6.28 MW
Reduce it via operating at lower pressure
Proc. #2
4 t/h
MP Boiler
1 t/h
HP Process Condensate
chemicals
Eliminate vent
0.0 t/h
MP
2 t/h
Vent
MP Process Condensate
Vent
Proc. #4
1 t/h 4 t/h
Proc. #3
0.0 t/h
LP
LP Process Condensate
Effluent
5 t/h
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
3.3
Fuel Diagram
Fuel big picture shall exhibit at least fuel sources, pressure levels, mass balance, let down valves and compressors and main users. Hydrogen composition should also be considered to define the opportunities for recycles.
Hydrogen
400 psig 380 psig
PSA
Off-Gas
Fuel Gas
350 psig
180 psig
NG
150 psig
150 psig
52 psig
50 psig
boilers 15 psig
furnaces
5 psig
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
3.4
2. 3. 4. 5. 6. 7.
8. 9.
10. Optimize BFW pumps load allocation 11. Energy monitoring and indices/ energy management system 12. Shut down compressors at low feed rate (load management) 13. Steam trap management (consider self regulating electrical tracing) 14. Booster, shipper and condensate pumps load management 15. Compressors load management 16. Consider the use of Economizers and Pre-heater in the boilers 17. Compressed air leaks (maintenance) 18. Minimize boilers and water coolers blow downs 19. Utilize boiler blow-down 20. Turbines load management 21. Upgrade sluggish response control valves since the delay might result in extra
flaring
22. Enhance the efficiency of boilers and furnaces through tight control 23. Enhance boilers and furnaces insulation 24. Optimize the CHP system
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
25. Maintain plant steam reserve 26. Minimize/Eliminate the use of steam reducing stations and vents 27. Consider the reuse of turbo-expander to generate power in the HP/LP pressure
control valves
28. Enhance the combustion process in boilers and furnaces via using full additives
as a catalyst
3.5
10. Re-use the flue gases in process heating 11. Optimize your waste heat boilers 12. Recover valuable gases from your fuel gases 13. Reduce the H2 wheel in your plant 14. Cool down the inlet temperature to compressors 15. Reduce cooling medium return temperature in refrigeration cycles 16. Upgrade, regenerate and replace your catalyst 17. Optimize let down stations and steam turbine operation 18. Use highest efficiency turbines 19. Maintain your steam turbines to reduce steam consumption 20. Give frequent attention to steam traps and leaks 21. Replace turbine drives with electric motors if more economical since they are more efficient
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
22. Boilers and furnaces efficiency enhancement through advanced process control, on-line performance monitoring and optimization 23. Recover condensate 24. Thermal Heat and power integration (CHP) 25. Better control for dispersion steam to flare stacks 26. Optimize steam use in strippers 27. Minimize live steam utilization 28. Mechanical energy integration 29. Reduce natural gas consumption by understanding fuel gas sinks and constraints 30. Reduce fuel gas use with energy integration 31. Keep H2 separate from fuel gas system 32. Measure the composition of off-gas streams and recover C2 and C3+ 33. Avoid unnecessary processing of off-gas 34. Avoid unnecessary processing of wastes and inert 35. Minimize the unnecessary production of off-gas 36. Use on-line monitoring and APC for furnaces and other control sensitive fuel users 37. Avoid unnecessary recycles 38. Avoid leaks in the pressure relieve valves to the fuel system 39. Adjust operating pressures and optimize process interaction 40. Clean and maintain pipelines and valves to minimize pressure drops 41. Clean and maintain Boiler tubes from deposits & scale for better operations 42. Treat and recycle blow down to force lower cycles of concentration in cooling towers and boilers 43. Use lowest quality water 44. Maximize use of stripped sour water 45. Minimize generation of wastewater 46. Seek out and repair all hydrocarbon leaks 47. Eliminate direct water injection for cooling purposes 48. Eliminate live steam used for re-boiling and stripping where it is only used for BTU value 49. Minimize or eliminate live steam consumption in sour water strippers by replacing it with re-boilers
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
50. Boiler blow-down could be considered for cooling tower make-up 51. Extract the low pressure steam from the boiler blowdown 52. Consider re-using the boiler blowdown for reserving the boiler 53. Use process water effluent as a source on the next lower water quality level 54. Eliminate live steam usage since it becomes water and follows an energy path through the plant consuming more energy to process it 55. Should live steam becomes necessary optimize the amount used through pressure manipulation 56. Use lowest quality water possible for desalter operation 57. Minimize water used in desalter 58. Automate desalter operation, avoid water slipping through with crude during desalting/maximize the separation of free water upstream of the crude desalting (each Ib of water will require roughly Ib steam for processing) 59. Minimize the water-wheel in the plant 60. Maximize utilization of treated oily-water from the waste-water treatment plant 61. Install low NOX burners 62. Consider the use of Cogeneration 63. Adjustable speed motors/devices for pumps, compressors, etc. 64. Increase waste heat steam generation 65. Insulate condensate return lines, valves, flanges, etc. 66. Cooling- tower blow-down should not be treated but segregated to sewer 67. Boiler blow-down should not be sent to wastewater treatment but segregate to sewer.
28 December 2005
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
98+5 t/h
HP Boiler
98 t/h
HP
68 t/h 21 t/h 8 t/h
Proc. #1
0.0 t/h
6.28 MW
Proc. #2
HP Process Condensate
0.0 t/h
MP
2 t/h
Vent
MP Process Condensate
18 t/h 38 t/h
Deaerator
1 t/h
0.0 t/h
BFW
(42+5) t/h
Effluent
LP
4 t/h
Proc. #3
LP Process Condensate
5 t/h
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
Feed
PROCESS
Product
120
HOT UTILITY
100
80
60
40
20
0 0
COLD UTILITY
10
20
30
40
50
60
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
Moving the cold stream to the left on the enthalpy axis without changing its supply and target temperatures till we have small vertical distance between the hot stream and the cold stream we obtain some overlap between the two streams that result in heat integration between the hot and the cold and less hot and cold utilities. As been depicted in the graph below with shrinkage in the hot and cold lines span.
Feed
PROCESS
Product
120
HOT UTILITY
100
80
HEAT RECOVERY
60
Pinch
(MAT)
40
20
0 0
COLD UTILITY
10
20
30
40
50
60
For demonstration, all hot streams will be represented in the process by one long hot stream to be called the hot composite curve. Same thing be done for all cold streams in the process.
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
The next step will be drawing the two composite curves/lines on the same page in Temperature (T)-Enthalpy diagram with two conditions: 1- The cold composite curve should be completely below the hot composite curve, and 2- The vertical distance between the two lines/curves in terms of temperature should be greater than or equal to a selected minimum approach temperature called global Tmin The resulting graph is depicted below and known as thermal pinch diagram:
Opportunity for heat recovery Net Heat Source Below the Pinch
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
1. Constructing the composite curves (step-by-step) The above mentioned process can proceed as follows:
Stream Type 1-Hot 2-Hot 3-Cold 4-Cold Supply Temperature (C) 170 120 50 20 Target Temperature (C) 70 30 90 110 FCp (kW/ C) 10 20 40 18
1- Draw the hot composite curve and the cold composite curve via developing the following tables. Note: The tables list all the hot and cold streams temperatures in an ascending order with the cumulative enthalpy corresponding to the lowest hot temperature and lowest cold temperature respectively equal to zero. 2- In every temperature interval the cumulative hot load is calculated using the following formula: H= FCp * (Tsupply Ttarget) 3- In every temperature interval the cumulative cold load is calculated using the following formula: H= FCp * (Ttarget Tsupply)
Hot streams temperature list T0=30 T1=70 T2=120 T3=170 Cumulative Enthalpy (H) H0=0.0 H1=800 H2=2300 H3=2800
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
30 20 Cold composite curve is not completely below the hot composite curve
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
As we mentioned before the cold composite curve shall lie completely below the hot composite curve and this can be done via dragging the cold composite curve to the right on the enthalpy axis (H). This process shall stop at a vertical distance between the cold and the hot composite curve for a temperature equal to the minimum temperature approach selected earlier.
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
Algebraic Method: Information needed Explained via another example Given a unit with a list of hot streams to be cooled and cold streams to be heated
Stream ID Type Flowrate*Average Specific heat (FCp) Supply temperature Target Temperature
1 2 3 4
10 5 19 2
1. Constructing temperature interval diagram 1.1_ Draw two temperature scales one for the hot streams and another for the cold streams 1.2_ Select reasonable minimum temperature approach between the hot streams and the cold stream (for instance, 10C) 1.3_ Draw all the hot streams (in the table hot section) to be cooled according to the hot steam scale as arrows that start at the supply temperatures and end at the target temperatures 1.4_ Repeat step 1.3 for all cold streams in the cold section of the table 1.5_ Start at the highest temperature of any hot stream in the hot section and draw a horizontal line that span along the two sections of the table, the hot and the cold. 1.6_ Draw horizontal lines again at the start and the end of any arrow representing the hot streams in the hot section of the table 1.7_ Repeat step 1.6 for any arrow representing cold stream in the cold section (at the start and the end of any arrow) 1.8_ Count the number of segments generated and number them starting at the highest temperature (they are called temperature intervals) 1.9_ Make sure that each temperature interval has now temperature value on both the hot temperature scale and cold temperature scale. The difference is the desired minimum temperature approach (for instance the 10C used in this example)
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
These procedures are depicted in the figure below: Note: This structure means that within any temperature interval it is thermodynamically feasible to transfer heat from the hot streams to cold streams. It is also feasible to transfer heat from a hot stream in an interval x to any cold stream which lies in an interval below.
T minimum = 10 K
T*
555 515
Interval
2 385 375 310 305 295 3 4 5 6 H2 390 380 330 310 300 380 370 320 300 290 C1 C2
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
Note: The temperature symbol T* is interval inlet temperature used later on selecting the suitable energy utility after calculating the targets using what is known as grand composite curve. To calculate T* we take the average interval inlet temperature of the hot and cold temperature scale. 2. Constructing tables of exchangeable heat loads and cooling capacities 2.1 Determining individual heating loads and cooling capacities of all process streams for all temperature intervals using this formula: Qnm = F1Cp1* (Ts-Te) in energy units (kW) Ts is the interval start temperature and Te is the interval end temperature n is stream number and m is the interval number Example 1: Interval # 1 in the hot section: The interval start temperature is 560 K The interval end temperature is 520 K Q11(Q for stream #1 in interval #1) = F1Cp1*(560-520) Since there is no H1 stream in this interval, hence, F1Cp1=0.0 Q stream # 1(exchangeable load) in this interval = 0.0*(560-520) = zero Example 2: Interval # 2 in the hot section: The interval start temperature is 520 K The interval end temperature is 390 K The flow specific heat F1Cp1= 10 kW/K
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
Then, Q stream #1(exchangeable load) in interval #1 = 10*(520-390) = 1300 kW Example 3: Interval # 1 in the cold section: The interval start temperature is 550 K The interval end temperature is 520 K The flow specific heat of this cold stream is F1Cp1 = 119 kW/K Then, Q stream #1(cooling capacity) in interval #1= 19*(560-520) = 760 kW Upon the completion of this step 2.2 Obtain the collective loads (capacities) of the hot (cold) process streams. These collective loads (capacities) are calculated by summing up the individual loads of the hot process streams that pass through that interval and the collective cooling capacity of the cold streams within the same interval.
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
These calculations for the above problem are shown in the following tables:
Interval 1 2 3 4 5 6
Total Load, kW 0.0+0.0= 0.0 1300+0.0= 1300 100+0.0= 100 500+250= 750 0.0+ 100= 100 0.0+50= 50
10*(520-390)= 1300 0.0*(520-390)= 0.0 10*(390-380)= 100 10*(380-350)= 500 0.0*(330-310)= 0.0 0.0*(310-300)= 0.0 0.0*(390-380)= 0.0 5*(380-330)= 250 5*(330-310)= 100 5*(310-300)= 50
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
Interval 1 2 3 4 5 6
Total Load, kW 760+0.0= 760 2470+0.0= 2470 190+20= 210 950+100= 1050 380+ 0.0= 380 0.0+0.0= 0.0
19*(510-380)= 2470 0.0*(510-380)= 0.0 19*(380-370)= 190 19*(370-320)=950 19*(320-300)= 380 0.0*(300-290)= 0.0 2*(380-370)= 20 2*(370-320)= 100 0.0*(320-300)= 0.0 0.0*(300-290)= 0.0
3. Constructing thermal cascade diagrams This diagram is constructed using the total hot loads and cooling capacities obtained in the previous step for each temperature intervals. The temperature intervals are drawn as rectangular with two inlets and two outlets. The inlet from the left is the total hot load available in this interval (for instance, 1300 kW in case of interval # 2). The inlet from above is the utility input load, in case of the first interval, or the input from interval above in case of second, third,,N intervals. The output from the right is the total cooling capacity of this interval (for instance, 2470 kW in case of interval #2). The output from the bottom is the difference between the total inputs and the cooling capacity of the interval.
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
Right Output
Heat Balance Top Input+ Left Input- Right Output = Bottom Output
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
Right Output=760 kW
= - 760 kW
Heat Balance Top Input+ Left Input- Right Output = Bottom Output 0.0 + 0.0 - 760 = - 760 kW
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
Right Output
Heat Balance Top Input+ Left Input- Right Output = Bottom Output
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
Numerical Example for Subsequent Intervals Heat Balance For instance; Interval # 2
Hot Load From Above Interval Top Input = -760
Heat Balance Top Input+ Left Input- Right Output = Bottom Output - 760 + 1300 -2470 = -1930
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
Upon the completion of heat balance around each interval the following diagram will be produced:
Thermal Cascade Diagram (Un-Balanced) Note: During this step the input from Hot Utility to the first interval is equal to zero 0.0 0.0 1300 100 750 100 50 1 - 760 2 - 1930 3 - 2040 4 -2340 5 - 2620 6 - 2570 0.0 380 1050 760 2470 210
The maximum difference between the available hot loads and cooling capacities from the heat balances of these intervals is 2620 kW. This deficiency in heat will be supplied via outside hot utility.
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
This value will be the input (from the top of the first interval) and the same heat balance calculation conducted above will be repeated to produce the balanced thermal cascade diagram below.
Thermal Cascade Diagram (Balanced) Note: During this step the input from Hot Utility to the first interval is equal to zero Minimum Q-heating = 2620 kW 0.0 1300 100 750 100 50 760 1860 2 690 3 580 4 280 Thermal Pinch 5 0.0 6 0.0 380 1050 2470 210
Minimum Q-cooling = 50 kW
With the completion of this step, now the minimum heating utility and minimum cooling utility required are 2620 kW and 50 kW respectively. These targets can give some idea about the potential of utility saving in the facility. To get better idea in terms of utility types needed, diagram known as grand composite curve shall be drawn to be used in defining kind of utilities needed and compare it with the current facility needs from such utility. This step will help in capturing some potential savings upon the heat integration of certain process area.
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
4. Constructing the grand composite curve (G.C.C) This curve will be drawn between T* calculated before and the corresponding top heat inputs to each interval. These data are depicted below:
295
50 kW Enthalpy ( kW)
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
Drawing these data as T* versus Enthalpy results in the following diagram that can be used to define different levels of utilities that can be used to satisfy the process heating utility requirement as shown below.
T* (K) 600
300
200
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
Multiple utility targeting/selection using Grand Composite Curve (GCC) Upon maximizing heat recovery in the heat exchanger network, those heating duties and cooling duties not serviced by heat recovery must be provided by external utilities. The most common utility is steam. It is usually available at several levels. High temperature heating duties require furnace flue gas or a hot oil circuit. Cold utilities might be refrigeration, cooling water, air cooling, furnace air preheating, boiler feed water preheating, or even steam generation at higher temperatures. Although the composite curves can be used to set energy targets, they are not a suitable tool for the selection of utilities. The grand composite curve drawn above is a more appropriate tool for understanding the interface between the process and the utility system. It is also as will be shown in later chapters a very useful tool in studying of the interaction between heat-integrated reactors, separators and the rest of the process. The GCC is obtained via drawing the problem table cascade as we shown earlier. The graph shown above is a typical GCC. It shows the heat flow through the process against temperature. It should be noted that the temperature plotted here is the shifted temperature T* and not the actual temperature. Hot streams are represented by Tmin/2 colder and the cold streams Tmin/2 hotter tan they are in the streams problem definition. This method means that an allowance of Tmin is already built into the graph between the hot and the cold for both process and utility streams. The point of zero heat flow in the GCC is the pinch point. The open jaws at the top and the bottom represent QHmin and QCmin respectively. The grand composite curve (GCC) provides convenient tool for setting the targets for the multiple utility levels of heating utilities as illustrated above.
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
The graphs below further illustrate such capability for both heating and cooling utilities.
The above figure (a) shows a situation where HP steam is used for heating and refrigeration is used for cooling the process. In order to reduce utilities cost, intermediate utilities MP steam and cooling water (CW) are introduced. The second graph (b) shows the targets for all the utilities. The target for the MP steam is set via simply drawing a horizontal line at the MP steam temperature level starting from the vertical axis until it touches the GCC. The remaining heat duty required is then satisfied by the HP steam. This maximizes the MP steam consumption prior to the remaining heating duty be fulfilled by the HP steam and therefore, minimizes the total utilities cost. Similar logic is followed below the pinch to maximize the use of the cooling water prior the use of the refrigeration.
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
The points where the MP steam and CW levels touch the GCC are called utility pinches since these are caused by utility levels. The graph (C) below shows a different possibility of utility levels where furnace heating is used instead of HP steam. Considering that furnace heating is more expensive than MP steam, the use of the MP steam is first maximized. In the temperature range above the MP steam level, the heating duty has to be supplied by the furnace flue gas. The flue gas flowrate is set as shown in graph via drawing a sloping line starting from the MP steam to theoretical flame temperature Ttft. If the process pinch temperature is above the flue gas corrosion temperature, the heat available from the flue gas between the MP steam and pinch temperature can be used for process heating. This will reduce the MP steam consumption. In summary, the GCC is one of the basic tools used in pinch technology for the selection of appropriate utility levels and for targeting for a given set of multiple utility levels. The targeting involves setting appropriate loads for the various utility levels by maximizing cheaper utility loads and minimizing the loads on expensive utilities.
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
(C) T*
T-tft
MP
CW
Refrigeration
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
Normally, Plants Operations have choices of many hot and cold utilities and the graph below shows some of available options. Generally, it is recommended to use hot utilities at the lowest possible temperature while generating it at the highest possible temperature. And for the cold utilities it is recommended to use it at the highest possible temperature and generate at the lowest possible temperature. These recommendations are best addressed systematically using the grand composite curve.
Steam Turbines
W Gas Turbines W
BFW preheat
Process
Heat Pump
Furnace
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
Understanding the Grand Composite Curve: The graph below shows that utility pinches are formed according to the number of utilities used. Each time a utility is used a utility pinch is created. It also shows that the GCC right noses sometimes known as pockets are areas of heat integration/energy recovery. In other words it does not need any external utilities. These right noses/pockets are caused by; Region of net heat availability above the pinch Region of net heat requirement below the pinch
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
Applying the Grand Composite Curve: GCC curve can be used by engineers to select the best match between utility profile and process needs profile. For instance, the steam system shown below needs to be integrated with the process demands profile to minimize low pressure steam flaring and high or medium pressures steam let downs. Besides it helps selecting steam header pressure levels and loads.
HP Boiler
HP
Proc. #1
Proc. #2 MP Boiler
HP Process Condensate
chemicals
Vent
MP
Proc. #4 Proc. #1 Vent Deaerator
MP Process Condensate
LP
Effluent Proc. #1
Process Condensate
Proc. #3
LP Process Condensate
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
Superimposed Utility Profile with Process Profile Nominal Case Supply-Demand Matching Problem
T
HP
MP
Process GCC
LP
BFW CW
H
The superimposed steam system on the process grand composite curve shows that while process heating needs can be achieved electricity can also be generated to satisfy process demands and/or export the surplus to the grid.
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
The graph below shows how we can use the GCC not only to select utility type, load but also to define the steam headers minimum pressure/temperature to minimize driving force and save energy.
Qh
HP MP
LP
BFW
CW
Qc H
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
Grand Composite Curve can also be utilized to select the load and return temperature of hot oil circuits. The graph below shows that while in many cases the process pinch can be our limiting point in defining the load (slop of the hot oil line) and the return temperature of the heating oil. In some other cases the topology of the GCC is the limiting point not the process pinch. This is also shown in the second graph below. This practical guide to select the load and the target temperature of the hot oil circuits is also applicable to furnaces as will be shown later in this chapter.
Process Pinch temperature is the Limiting temperature for the Hot oil return temperature
T*
T supply Hot Oil
CW
Refrigeration
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
Process Pinch temperature is not the Limiting temperature for the Hot oil return temperature But the topology of the GCC curve
T*
Hot Oil CP-min T return
T supply
Process Pinch
CW
Refrigeration
Page 49 of 54
Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
Grand composite curve (GCC) can also be used to select the process refrigeration levels and the synthesis of the multiple-cycles refrigeration systems as we did in the steam system. The schematic graph below shows a simplified refrigeration system.
Condenser
25C
CW -5C
Process 0C
Process -35C
-40C
Process -65C
-70C
Work Compressor
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
The GCC as we mentioned before can be used to place the refrigeration levels as we did with steam levels. The graph below shows how we can do that.
We can place the refrigeration levels like steam levels. Maximizing the highest temperature load to minimize the lower temperature loads
Tcw
- 5 C
- 40 C - 70 C
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
When a hot utility needs to be at a high temperature and/or provide high heat fluxes, radiant heat transfer is used from combustion of fuel in furnace. Furnace designs vary according to the function of the furnace, heating duty and type of fuel, and method of introducing combustion air.
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
W2/W1 = (T reject 2 Tc)/ (T reject 1 Tc) Treject is the temperature at which heat is rejected to the cooling medium (water) Tc is the temperature at which heat is taken into the refrigeration) cycle _ Material balance for the cooling tower Assuming the system is at equilibrium Make-up = Evaporation+ Blowdown+ Windage loss Cooling towers cycles of concentration (C) C= concentration of solids in the circulating water/ concentration of solids in make-up water _ Energy saving in adjusting of combustion in a natural gas fired boiler/furnace Analysis on the exhaust from the boilers sometimes or most of the times in some places reveals excess oxygen levels which result in unnecessary energy consumption. This excess air defines a low efficiency on the combustion process. Portable or even on-line flue gas analyzer can be used as a part of a rigorous boilers/furnaces inspection program. The optimum amount of O2 in the flue gas of a gas fired boiler is 2%, which corresponds to 10% excess air. Controlling the combustion process could lead to at least 2% fuel saving upon bringing the excess O2 from for instance 6% to 2%. Cost saving $/year= Energy usage per year* % possible fuel savings* fuel cost per unit of energy Energy saving in adjusting of combustion in a an oil fired boiler/furnace. Analysis on the exhaust from the boilers sometimes or most of the times in some places reveals excess oxygen levels which result in unnecessary energy consumption. This excess air defines a low efficiency on the combustion process. Portable or even on-line flue gas analyzer can be used as a part of a rigorous boilers/furnaces inspection program. The optimum amount of O2 in the flue gas of an oil fired boiler is 4%. Controlling the combustion process could lead to at least 1% fuel saving upon bringing the excess O2 from for instance 6% to 1%.
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
Cost saving $/year= Energy usage per year* % possible fuel savings* fuel cost per unit of energy Energy saving in preheating boiler/furnace combustion air with stacks waste heat: If the intake air (air drawn from outside into the natural gas boiler) is at ambient outdoor temperature unnecessary fuel will be consumed to heat up this combustion air. In order to reduce fuel consumption, it is recommended to install recuperative air pre-heater on the air intake of the boiler to preheat combustion air using heat which is exhausted along with the combustion from the boiler. Stack exhaust losses are part of all fuel-fired processes. They increase with the exhaust temperature and the amount of excess air the exhaust contains. A high quality air pre-heater could recover more than 40% of this waste heat. Therefore, the potential savings from the installation of air pre-heater on the boiler is: Cost saving = fuel cost ($)/unit of energy* Energy Consumed/year*(boiler efficiency)*percent of energy recovered by air pre-heater Note: The following attached pages are two curves and a table that can be used to estimate the percentage of fuel savings.
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