Beruflich Dokumente
Kultur Dokumente
CHEMICAL PROCESS
INDUSTRIES
Dr.V.SIVASUBRAMANIAN
Associate Professor
Former Head
Chemical Engineering
NIT Calicut
1
DEPARTMENT OF CHEMICAL
ENGINEERING
Agenda
1. Introduction
2. Energy Conservation in Reactors
3. Energy Conservation in Packed Beds
4. Energy Conservation in Heat Exchangers
5. Energy Conservation in Evaporators
6. Energy Conservation in Crushers and Grinders
7. Heating and Cooling Requirement in Distillation
Columns
8. Energy Conservation in Dryers
9. Energy Conservation in Pumps
10. Methodology of Optimizing Energy Use
11. Areas of energy Optimization in CPI
12. Energy Efficiency Improvement and Cost Saving
Opportunities in Petrochemical Industry 3
1. Introduction
CHEMICAL
PROCESS
UNIT UNIT
PROCESS OPERATION
WASTE
2 Alkylation 17 Hydrodealkylation
3 Hydrogenation 18 Isomerization
4 Dehydration 19 Oxyacetylation
5 Hydroformylation 20 Oligormerization
6 Halogenation 21 Nitration
7 Hydrolysis/Hydration 22 Hydrohalogenation
8 Dehydrogenation 23 Reduction
9 Esterification 24 Sulfonation
10 Dehydrohalogenation 25 Hydrocyanation
11 Ammonolysis 26 Neutralization
12 Reforming 27 Hydrodimerization
13 Oxyhalogenation 28 Miscellaneous
29 Nonreactor processes
14 Condensation
15 Cleavage
U.S.-EPA (1993) 6
Unit Operations
Liquid-vapor separation (distillation, evaporation,
stripping)
Liquid-liquid separation (extraction, decanting)
8
Broad Classification of Reactor
Types
(a) The batch reactor. (b) The steady-state flow reactor. (c), (d), and
(e) Various forms of the semibatch reactor
CHEMICAL ENGINEERING DEPT NIT CALICUT 9
Material Balance for the
Element of Volume of Reactor
10
Material Balance for the
Element of Volume of Reactor
11
Energy Balance for the Element
of Volume of Reactor
12
Energy Balance for the Element
of Volume of Reactor
13
AGITATION PROCESS VESSEL
14
Mixing Impellers
15
Design of Agitated Vessel
16
17
Power Consumption in Agitated
Vessel
Np power no.
P power in kW
gc Newtons law proportionality factor
n rotational speed r/s
Da diameter of impeller in m
18
density in kg/m3
Power Correlation
20
Prevention of Swirling
21
Multiple turbines in tall tanks
22
Draft tubes, baffled tank
23
Energy Efficiency in Reactors
Nusselt Number
hw individual htc of gas film near tube wall
Dp diameter of particle
kg thermal conductivity of gas
Prandtl Number,
25
4. Energy Conservation in Heat
Exchangers
28
EXTENDED SURFACE
EQUIPMENT
30
Climbing-film, long-tube
vertical evaporator
31
Evaporator Capacity and
Economy
33
6. Energy Conservation in
Crushers and Grinders
Rittingers Law
Kicks Law
Bonds Law
34
7. Heating and Cooling Requirement
in Distillation Column
If saturated steam is used as the heating medium, the
steam required at the reboiler
steam consumption
vapor rate from reboiler
s latent heat of steam
molal latent heat of mixture
35
If water is used as the cooling medium in
the condenser and the condensate is not
subcooled, the cooling-water requirement is
water consumption
T2 - Tl = temperature rise of cooling
water
36
8. Energy Conservation in
Dryers
Tray Dryer
37
Temperature Patterns in Dryers
38
Calculation of Heat Duty
Heat transferred per unit mass of solid
39
9.ENERGY
CONSERVATION IN
PUMPS
40
www.enviro-stewards.com 49
10. Methodology of Optimizing
Energy Use
1. Measure and benchmark consumption. Compare
with globally accepted norms.
63
j. Trim impellers wherever pumps are over designed.
k. Valve throttling indicates pump over design; replace
pump with correct size pump or install lower size
impeller
l. Coat hydraulic passages of pumps with resins
having better surface finish to reduce internal friction
and increase efficiency.
m. Minimize pressure drop in piping by rerouting of
pipeline, removing valves, which never need to be
operated, and resizing of pipeline.
64
3. COOLING TOWERS
a. Control CT fans based on cold well temperature; use
two speed or VFD if fans are few and on-off stage
control if cells are many.
b. Select CT with low pressure drop, high efficiency
PVC cellular fills in place of splash bars.
c. Periodically clean, water distribution nozzles. Ensure
that no channeling of water flow is taking place.
Uniform flow distribution will improve performance of
cooling tower.
d. Optimize cooling water chemical treatment.
e. Replace aluminum fans by aerodynamic FRP fans.
65
4. REFRIGERATION
SYSTEMS
a. Challenge the need of refrigeration system,
particularly, for old batch processes. Optimise the
temperature requirement.
67
5. LIGHTING
a. Select high efficiency lighting luminaries having
highest lumens / watt output. eg. Compact
fluorescent lamp (CFL), low pressure sodium vapour
lamp.
69
6. FANS & BLOWERS
a. Select fans with aerofoil fan blades; replace old
inefficient fans by modern high efficincy fans /
blowers.
70
d.Minimize speed to minimum possible.
f.Eliminate leakages.
71
7. MOTORS
a. Properly size the motor for the optimum efficiency.
73
12. Energy Efficiency
Improvement and Cost
Saving Opportunities in
Petrochemical Industry
74
The U.S. Petrochemical
Industry
The North American Industry Classification (NAICS) distinguishes
seven 4-digit sub-sectors of the chemical industry:
Boilers, Combined Heat and Power (CHP) plants and other parts
of the steam infrastructure including pipes and valves.
Furnaces and process heaters.
76
Energy use in the chemical industry by
fuels and feedstock category, 2002
77
Energy use by sub-sector,
2002
78
End use of electricity in the total
chemical industry and the sub-
sectors studied, 2002
79
Estimated final energy
consumption for selected key
chemicals
80
Main elements of a strategic
energy management program
81
Simplified schematic of a steam
production and distribution system
82
Summary of energy efficiency
measures in boilers (Steam Supply)
83
Steam Supply - Combined
Heat and Power
84
Summary of energy efficiency
measures in steam distribution
systems
85
Furnaces and Process Heaters
Heat Generation
Control the air-fuel ratio
Excess air should be limited to 2-3%
oxygen
86
Heat transfer and heat
containment in heaters
Use of soot blowers, burning off carbon and other
deposits from radiant tubes and cleaning the heat
exchange surfaces. Typical savings are 5-10%.
Ceramic coated furnace tubes can improve heat
transfer
Reducing wall heat losses (typical savings 2-5%),
furnace pressure control (5-10%), maintenance of door
and tube seals (up to 5%), reducing cooling of internal
parts (up to 5%) and reducing radiation heat losses (up
to 5%).
87
Flue gas heat recovery
Others controls, maintenance and
electric heaters
88
Electric Motors
Motor Management Plan
89
Strategic motor selection
Maintenance
Properly sized motors
Adjustable speed drives
Power factor correction
Minimizing voltage unbalances
90
Pumps
Operations and maintenance
Monitoring
Reduce need
More efficient pumps
Correct sizing of pump(s) (matching pump to
intended duty)
Use multiple pumps
Trimming impeller (or shaving sheaves)
Controls
91
Adjustable speed drives (ASDs)
Avoid throttling valves
Correct sizing of pipes
Replace belt drives
Precision castings, surface coatings or polishing
Sealings
Curtailing leakage through clearance reduction
Dry vacuum pumps
92
Fans and Blowers
Fan oversizing
Adjustable speed drives (ASDs) and
improved controls
High efficiency belts (cog belts)
93
Compressors and Compressed
Air Systems
Compressed air maintenance
Monitoring
Reduce leaks (in pipes and equipment)
Reducing the inlet air temperature
Maximize allowable pressure dew point at air intake
Optimize the compressor to match load
Controls
Properly sized regulators
Sizing pipe diameter correctly
Heat recovery for water or space heating preheating
Adjustable speed drives (ASDs)
High efficiency motors
94
Distillation
Enhanced distillation controls
Optimization of reflux ratios
Check product purity
Seasonal operating pressure adjustments
Column insulation
Reducing reboiler duty
Feed conditioning
Upgrading column internals
Stripper optimization
95
Buildings: HVAC and Lighting
Energy Efficiency Measures for HVAC Systems
Energy efficient system design
Recommissioning
Energy monitoring and control systems
Non-production hours set-back temperatures
Duct leakage repair
Variable-air-volume systems
Adjustable-speed drives (ASDs)
Heat recovery systems
Fan modification
Efficient exhaust fans
Use of ventilation fans
Cooling water recovery
Solar air heating
Building reflection
Building insulation
96
Low emittance (Low-E) windows
Energy Efficiency Measures for
Lighting
Turning off lights in unoccupied areas
Lighting controls
Exit signs
Electronic ballasts
Replacement of T-12 tubes with T-8 tubes
Replacement of mercury lights
High-intensity discharge (HID) voltage reduction
High-intensity fluorescent light
Daylighting
97
CONCLUSIONS
A key first step in any energy improvement initiative is to establish
a focused and strategic energy management program, which will
help to identify and implement energy efficiency measures and
practices across and organization and ensure continuous
improvement.
While the expected savings associated with some of the
individual measures may be relatively small, the cumulative effect
of these measures across an entire plant may potentially be quite
large.
The degree of implementation of these measures will vary by plant
and end use; continuous evaluation of these measures will help to
identify further cost savings in ongoing energy management
programs.
98
ACKNOWLEDGEMENT
Octave Levenspiel, Chemical Reaction
Engineering, Wiley Eastern Limited.
McCabe, W.L. and Smith, J.C., Unit Operation of
Chemical Engineering, McGraw Hill, New York.
Internet sources
99
THANK YOU