Chalmers University of Technology What is Process Integration? NTNU by Truls Gundersen Department of Energy and Process Engineering Norwegian University of Science and Technology (NTNU) Trondheim, Norway 20.03.13 T. Gundersen Slide no. 1 Content of the Presentation n n Definitions and the birth of Process Integration Process Integration (PI) as a Term ♦ Heat, Power, Chemical and Equipment Integration n Some early stage Developments, however … ♦ Bodo Linnhoff: “A Historical Overview of early Developments” n NTNU n 3 Major and Generic Results from Pinch Analysis with widespread Use in Process Integration The Tool Box in PI ♦ Graphical Diagrams, Representations and Concept n Various Extensions of Pinch Analysis in PI ♦ Applications, Objectives, Scope, etc. n n Use of Optimization in Process Integration PI and Global Warming / Emissions Reduction ♦ From Energy Focus to Environmental Concern 20.03.13 T. Gundersen Slide no. 2 The IEA Definition of Process Integration NTNU "Systematic and General Methods for Designing Integrated Production Systems, ranging from Individual Processes to Total Sites, with special emphasis on the Efficient Use of Energy and reducing Environmental Effects" P R O C E S S From an Expert Meeting in Berlin, October 1993 20.03.13 INTEGRATION IEA OECD T. Gundersen Slide no. 3 More Descriptions of Process Integration n An Alternative to the IEA Definition: ♦ Process Integration is a Methodology for Analysis, Design and Optimization of Material and Energy related Production Systems n What is unique in Process Integration (PI)? ♦ Pinch Analysis (PA) was developed in the 1970s/1980s based on the Discovery of a Heat Recovery Pinch, and PA was the Birth of PI as a Systems oriented Process Design Methodology ♦ PA/PI represented a Departure from Traditional Design Practice ♦ Improving Process Technologies (following the Learning Curve) through Operating & Engineering Insight using Design based on Case Studies was replaced by Systematic Design using Targets ♦ The new Design Methods enabled Step Changes in Performance NTNU n The real Value of Performance Targets ahead of Design: ♦ Removing the Uncertainty among Engineers whether a Process Design could be further improved and by how much 20.03.13 T. Gundersen Slide no. 4 The use of Process Integration as a Term 1800" 1666 2071 1600" 1420 1400" 1200" 1000" 714 800" 651 600" " 20 10 )P re se nt 20 05 )2 00 9" 0" 20 00 )2 00 4" 8 121 19 90 )9 9" 0 19 70 )7 9" 200" 19 80 )8 9" 400" 19 60 )6 9" NTNU Date: 7 March 2013 – Source: Science Direct, Journal papers only Subjects: Chemical Engineering, Energy, Engineering 20.03.13 T. Gundersen Slide no. 5 The Title: What is Process Integration? This Question can be decomposed into What do we mean by a Process? NTNU and What do we mean by Integration? 20.03.13 T. Gundersen Slide no. 6 A Process can be regarded as a “Converter” Mechanical Energy Com Thermal Energy HP, MP, LP Flue Gas AP, CW Refrigerants NTNU Exp Energy Thermal Energy HP, MP, LP Cooling Material Product(s) Raw Material(s) Byproduct(s) 20.03.13 T. Gundersen Slide no. 7 What is the meaning of Integration? n n NTNU Integration means combining Needs/Tasks of “opposite” kinds so that Savings (or Synergies) can be obtained Examples of such Integration in the Process Industries: ♦ Heat Integration • Cooling & Condensation integrated with Heating & Evaporation • Identify near-optimal Level of Heat Recovery • Design the corresponding Heat Exchanger Network ♦ Power Integration • Expansion integrated with Compression • Same Shaft or combined in “Compander” ♦ Chemical Integration • Byproducts from one Plant used as Raw Materials in other Plants • The Idea of materials integration is used in Industrial “Clusters” ♦ Equipment Integration • Multiple Phenomena (Reaction, Separation, Heat Transfer) are integrated in the same piece of Equipment è Process Intensification 20.03.13 T. Gundersen Slide no. 8 T (°C) ST QH,min 300 270ºC - - - - - - - 250ºC H1 QRecovery 250 720 kW 230ºC - - - - - - - 210ºC ΔTmin 200 500 kW 180 kW 150 C2 - 520 200 kW 220ºC - - - - - - - 200ºC 2000 kW 720 kW - 1200 100 880 kW 180ºC - - - - - - - 160ºC 800 kW 360 kW 50 Pinch 0 T' (°C) 300 C1 440 kW 160ºC - - - - - - - 140ºC H (kW) 2000 400 kW + 400 QC,min NTNU + 720 4000 1980 kW H2 6000 70ºC - - - - - - - - 50ºC Heat Integration QH,min 250 1800 kW + 180 220 kW + 220 60ºC - - - - - - - - 40ºC ΔTmin = 20°C CW Pinch 180° 200 270° H1 235.6° 3 mCp (kW/°C) 180° 2 Ca 160° 18.0 360 kW 150 220° H2 1 180° 4 100 80° Cb 60° 22.0 440 kW 210° 50 160° 2 1000 kW QC,min Q (kW) 210° H 190° 1000 kW 0 20.03.13 500 1500 3 620 kW T. Gundersen 177.6° 1 4 2200 kW 160° C2 50° C1 20.0 50.0 880 kW 160° Slide no. 9 Simultaneous Heat and Power Integration? n n Feng and Zhu (1997) introduced the Energy Level (Ω) Energy Level is defined as Exergy/Energy: ♦ For Work and Electricity: Ω = 1 ♦ For Heat: Ω = ηC = 1 − T0 / T ♦ For Steady-State Flow Systems: Ω = ΔE / ΔH n NTNU n n n The Energy Level Concept is used to identify Losses in Energy Quality (which is why Exergy is used) Energy Level is evaluated at the Entrance and Exit of the Process Units based on inlet and outlet Process Streams Energy Level Composite Curves (ELCCs) are Energy Level vs. Enthalpy Curves plotted in a Cumulative manner Energy Level of Units will increase or decrease ♦ Synergies possible through Integration? ♦ Problem: High Energy Level caused by Temperature or Pressure? 20.03.13 T. Gundersen Slide no. 10 ELCCs for a Methanol Process 0.6 Primary Reformer Primary Reformer, Sec Reformer Shift Reactor 0.5 Sec Reformer Product Cooler Raw Product Cooler, Sec Reformer Product Cooler, Prereformer 1 Energy Level 0.4 NTNU Sec Reformer Product Cooler, Prereformer 1 Primary Reformer, Sec Reformer Prereformer 2, Primary Reformer Prereformer 2 Raw Product Cooler, Sec Reformer Product Cooler 0.3 Steam Generator, Prereformer 2 Steam Generator, MeOH Reactor Water Jacket, Prereformer 2 Steam Generator, MeOH Reactor Water Jacket Raw Product Cooler 0.2 Steam Generator, MeOH Reactor Steam Generator, MeOH Reactor Feed Preheater Steam Generator, Syn Gas Compressor Steam Generator, MeOH Recycle Compressor, Syn Gas 0.1 Omega Increasing Units Steam Generator, Burner, MeOH Recycle Compressor, Syn Gas Compressor Steam Generator, Burner, MeOH Recycle Compressor Omega Decreasing Units Steam Generator 0 0 50 100 150 200 250 300 350 400 450 Cummulative Enthalpy (MW) Anantharaman R., Abbas O.S., Gundersen T., “Energy Level Composite Curves – A New Graphical Methodology for the Integration of Energy Intensive Processes”, Applied Thermal Engineering, vol. 26, pp. 1378-1384, 2006. 20.03.13 T. Gundersen Slide no. 11 500 Chemical Integration in an Industrial Cluster NTNU Kaggerud K.H., Bolland O., Gundersen T., “Chemical and Process Integration: Synergies in Co-Production of Power and Chemicals from Natural Gas with CO2 Capture”, Applied Thermal Engineering, vol. 26, pp. 1345-1352, 2006. 20.03.13 T. Gundersen Slide no. 12 Equipment Integration – Methyl Acetate NTNU Eastman Chemical Company Siirola J.J., “Industrial Applications of Chemical Process Synthesis”, Advances in Chemical Engineering, vol. 23, pp. 1-62, 1996. 20.03.13 T. Gundersen Slide no. 13 Various Terms in Perspective Energy Conservation Heat Integration NTNU Process Integration Process Synthesis 20.03.13 T. Gundersen Slide no. 14 Some early stage Developments Energy Equipment Raw Materials NTNU From powerful results and insight based on the Concept of a Heat Recovery Pinch through a Development along several “axes” to reaching the Level or Status of a Design Discipline !! 20.03.13 T. Gundersen Batch Retrofit Grassroot Environment Bodo Linnhoff used the Rubic Cube to illustrate Progress Slide no. 15 3 Major Results from PA with widespread Use in PI T QH,min QC,min n C Heat Pinch Water Pinch Watermin H m The Concept of Composite Curves (Cumulative Plots) ♦ Applicable whenever an “Amount” has a “Quality” ♦ Heat & Temperature, Mass & Concentration (Chemical Potential), NTNU Refinery Gases & H2 Purity (and Pressure), Money & Time, etc. n n Targets for Best Performance ahead of Design Decomposition of Systems into Surplus and Deficit Regions ♦ PDM for Grassroot Design develops Separate Networks ♦ Process Modifications guided by the Plus/Minus Principle ♦ Appropriate Placement (or Integration) of Distillation Columns, Evaporators, Heat Engines (Steam Turbines) and Heat Pumps 20.03.13 T. Gundersen Slide no. 16 “Correct” Integration and Appropriate Placement Process Cascade Distillation Column Heat Pump Steam Turbine QHP,out QST,in QH,min QReboiler Above Pinch Q=0 NTNU WST WHP Below Pinch QCondenser QHP,in QST,out QC,min Simple Rule: “Connect Sources with Sinks” 20.03.13 T. Gundersen But: TSource > TSink Slide no. 17 Diagrams, Representations and Concepts in PI n NTNU Graphical Diagrams ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ n Composite Curves Grand Composite Curve Energy Target Plot Area/Energy Plot Driving Force Plot Column Grand Composite Curve Exergy Composite Curves Exergy Grand Composite Curve Column Grand Composite Curve Total Site Source & Sink Curves More? Representations & Concepts ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ Process & Utility Pinch Feasibility Table Problem Table Heat Cascade Grid Diagram Penalty Heat Flow Diagram Bipartite Graph Heat Load Loops Heat Load Paths Rubic Cube and the “Onion” More? Important Tools for Analysis, Design and Optimization as well as for Learning and Communication 20.03.13 T. Gundersen Slide no. 18 Expansions in Process Integration based on Pinch Analysis and using Analogies NTNU 20.03.13 n Applications Areas n Objectives n Scope n Type of Plants n Type of Projects n Thermodynamics T. Gundersen Slide no. 19 n NTNU Expansions Application Areas w From Heat Pinch for Heat Recovery and CHP in Thermal Energy Systems w to Mass Pinch for Mass Transfer / Mass Exchange Systems w to Water Pinch for Wastewater Minimization and Distributed Effluent Treatment Systems w to Hydrogen Pinch for Hydrogen Management in Oil Refineries w to Oxygen Pinch for Wastewater Bio-Treatment Plants w to Carbon Pinch to satisfy Energy Requirements while meeting CO2 Emission Limits in the Energy Sector 20.03.13 T. Gundersen of PA & PI Slide no. 20 Expansions n of PA & PI Objectives w from Energy Cost w to Equipment Cost w to Total Annualized Cost w and also Operability, including Flexibility Controllability Switchability NTNU à Start-up & Shut-down à New Operating Conditions w and finally Environment, including Emissions Reduction Waste Minimization 20.03.13 T. Gundersen Slide no. 21 Expansions n of PA & PI Scope w from Heat Exchanger Networks w to Separation Systems, especially Distillation and Evaporation (heat driven) w to Reactor Systems w to Heat & Power, including Steam & Gas Turbines and Heat Pumps w to Utility Systems, including Steam Systems, Furnaces, Refrigeration Cycles w to Entire Processes w to Total Sites w to Regions NTNU 20.03.13 T. Gundersen Slide no. 22 Expansions n of PA & PI Plants w from Continuous w to Batch and Semi-Batch n Projects w from New Design w to Retrofit w to Debottlenecking NTNU n Thermodynamics w from Simple 1st Law Considerations w to Various 2nd Law Applications Exergy in Distillation and Refrigeration 20.03.13 T. Gundersen Slide no. 23 Process Integration Methodologies Expert Systems qualitative Knowledge Based Systems NTNU automatic Optimization Methods Heuristic Methods Hierarchical Analysis interactive Thermodynamic Methods quantitative Stochastic Methods Mathematical Programming 20.03.13 Rules of Thumb T. Gundersen Pinch Analysis Exergy Analysis Slide no. 24 Limitations in Pinch Analysis & the PDM n Rigor sometimes replaced by Heuristic Rules ♦ The (N – 1) Rule for minimum Number of Units ♦ The “Bath” formula for minimum total Heat Transfer Area n The Composite Curves have their Limitations ♦ Cannot handle Forbidden Matches between Streams ♦ Simple Rules for Appropriate Placement do not work when Distillation Columns are included in the Composite Curves NTNU n The Pinch Design Method is Sequential in Nature ♦ Targeting è Design è Optimization (Evolution) ♦ One Match at a time, one Loop at a time, one Path at a time, etc. ♦ è Unable to properly handle Multiple Trade-offs n Pinch Decomposition guides Correct Integration, but ♦ In Network Design, less Costly and less Complex Designs can be found by actually ignoring strict Pinch Decomposition n Time consuming but normally results in “good” Designs 20.03.13 T. Gundersen Slide no. 25 CMU Why not use Optimization? UMIST T (°C) HP 250 200 150 LP Energy Minimum Area => Counter-Current or “Vertical” Heat Transfer 100 50 CW NTNU MILP Units 0 H (kW) 2000 MINLP NLP 4000 6000 Targeting Design Evolution Area Considerations using a “vertical” MILP Model? Area/TAC Software: MAGNETS Transshipment Models (LP & MILP) Clever Stream Superstructure (NLP) 20.03.13 Gundersen T., Grossmann I.E., “Improved Optimization Strategies for Automated Heat Exchanger Networks through Physical Insights”, Comput. chem. Engng., vol. 14, no. 9, pp. 925-944, 1990. T. Gundersen Slide no. 26 UMIST Comments after Sabbatical NTNU Promoting Mathematical Programming was quite challenging in those Days ! 20.03.13 T. Gundersen Slide no. 27 The Sequential Framework – SeqHENS n Heat Transfer Area: Loops 1 & 2 n # of Heat Exchangers: Loop 3 n Energy Consumption: Loop 4 NTNU Compromise between Pinch Design and MINLP Methods Surprisingly few Iterations thanks to excessive use of Insight Anantharaman R., Gundersen T., “The Sequential Framework for Heat Exchanger Network Synthesis – Network Generation and Optimization”, PRES’2007, Ischia Island, Chemical Engineering Transactions, vol. 12, pp. 19-24, 2007 20.03.13 T. Gundersen Slide no. 28 Process Integration and Global Warming n The IEA: 3 main Measures to reduce CO2 Emissions ♦ Energy Efficiency (short term, even profitable?) ♦ Carbon Capture & Storage (medium term, expensive!) ♦ Renewable Energy Forms (long term, expensive?) n Public Discussion in the US (2012) ♦ Energy Efficiency is the 5th Energy Form ♦ Following Oil, Gas, Coal and Nuclear NTNU n An obvious Observation ♦ “The cleanest Energy is the one that is not used” n A Shift of Focus in Process Integration ♦ From Energy Focus in the 1970s and 1980s (Availability and Cost) to Environmental Concern in the 1990s and later n Global Warming – A new Opportunity for PI? ♦ Energy Efficiency is a Core Activity in Process Integration 20.03.13 T. Gundersen Slide no. 29 Pinch Analysis developed by an “Accident”? Bodo Linnhoff, PhD Thesis, University of Leeds, April 1979: “Thermodynamic Analysis in the Design of Process Networks” Abstract: “This thesis discusses the use of thermodynamic Second Law analysis in the context of chemical process design” 2nd Law of Thermodynamics for Open/Flowing Systems: Q j dScv = ∑ + ∑ m i ⋅ si − ∑ m ⋅ se + σ cv dt j Tj i e NTNU Entropy (S) is the twin brother/sister of Exergy (Ex) ⎛ T0 ⎞ dExcv dVcv ⎞ ⎛ = ∑ ⎜ 1− ⎟ ⋅ Q j − ⎜ Wcv − p0 ⋅ + ∑ m i ⋅ e f ,i − ∑ m ⋅ e f ,e − Ex ⎟ d ⎝ dt Tj ⎠ dt ⎠ i j ⎝ e 20.03.13 T. Gundersen Slide no. 30
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