Department of Energy and Process Engineering

Truls Gundersen 10.01.10

TEP 4215 - Energy Utilization and Process Integration in Industrial Plants, or for short: “Energy and Process”

•  The Objective is to convey u  Systems Thinking and Systematic Methods for:

§  Analysis and Design (and partly Operation) of §  Processes and Utility Systems, with focus on §  Efficient Use of Energy while considering §  Economy, Operation and (to some extent) Environment

•  Requirements to be able to join the Course u  None (meaning previous courses), but it is an advantage to

have some basic knowledge about the following: §  heat exchangers, distillation columns, evaporators §  turbines, heat pumps and “simple” thermodynamics

u  Fall 98: 100 students from 8 departments in 4 faculties !! u  From Spring 2009: Compulsory for the “PuP” Program

Truls Gundersen 10.01.10

•  The Course Content is primarily u  System based Strategy for Design of integrated

Process Plants with corresponding Utility Systems u  Systematic Methods for Analysis and Design of

§  Reactor Systems (very limited and not in depth) §  Thermally driven Separation Systems, such as (primarily)

Distillation and (to a much less extent) Evaporation §  Heat Exchanger Networks and Correct Heat Integration §  Utility Systems (heating, cooling and power)

u  The Thermodynamically based Pinch Analysis u  Brief Introduction to the use of Optimization u  Environmental Issues related to Energy Usage u  New Design and Retrofit of Existing Plants

TEP 4215 - Energy and Process

Department of Energy and Process Engineering

Truls Gundersen 01.01.10

•  The Curriculum for the Course is: u  R. Smith: “Chemical Process Design and Integration”, 2nd ed., John

Wiley & Sons, January 2005. Alternative Text Book: u  I.C. Kemp: “Pinch Analysis and Process Integration”, Elsevier,

Butterworth Heinemann, December 2006. u  T. Gundersen: “Basic Concepts for Heat Recovery in Retrofit

Design of Continuous Processes”, Ch. 6 in “A Process Integration Primer”, IEA, 2000 (18 pages).

u  Lectures and Assignments. u  Assignments are Examination oriented (most are previous Ex Q’s) u  Examination will test Understanding through Calculation Examples.

This requires Training established by working with Assignments.

•  Home Page: http://www.ivt.ntnu.no/ept/fag/tep4215/

TEP 4215 - Energy and Process

Department of Energy and Process Engineering

Truls Gundersen 12.01.13

Ass. Topic Supervised Deadline

1 Sequence of Distillation Columns 22.01 29.01 2 Minimum Energy Requirements and Pinch 29.01 05.02 3 Design of Heat Exchanger Networks (1) 05.02 12.02 4 Optimization of Heat Exchanger Networks 12.02 26.02 5 Retrofit Design of Heat Exchanger Networks 26.02 05.03 6 Indirect Integration of Plants using Steam 05.03 12.03 7 Integration of Distillation Columns 12.03 09.04 8 Optimal Use of Heat Pump 09.04 16.04 9 Area in Heat Exchanger Networks 16.04 23.04 10 Heat Integration and Forbidden Matches 23.04 30.04 11 Design of Heat Exchanger Networks (2) 30.04 none

Guidance: One Ph.D. Student (?), 6 Student Assistants and the Lecturer

TEP 4215 - Plan for Assignments with Guidance

Department of Energy and Process Engineering

Introduction and Background

E-stat 1 T. Gundersen

Process, Energy and System

RussiaUSACanadaIranNorwayAlgerieUKOthers

20.7%

18.6% 6.2% 3.8% 2.8%

2.5%

42.4% ”others”

Norway as an Energy Nation Natural Gas Production (GSm3)

Norway: 1997: 43.0 (1.9%) − 2007: 89.7 (3.1%)

World Production (2007): 2940 GSm3

3.1%

Saudi ArabiaRussiaUSAIranChinaMexicoNorwayOthers

Introduction and Background

T. Gundersen

Process, Energy and System

Norway as an Energy Nation Oil Production (mill. tonnes)

Norway: 1997: 156.2 (4.6%) − 2007: 118.8 (3.0%)

World Production (2007): 3905.9 mill. tonnes

12.6% 12.6%

8% 5.4%

4.8%

49.1%

3.0%

E-stat 2

Introduction and Background

T. Gundersen

Process, Energy and System

Energy Production (PJ) in Norway in 2007 (Total: 9 512.7 PJ − Export: 8 474.6 PJ (89.1%)

Crude OilNatural GasHydro PowerLNGGasolineCoalBio Energy

38.8% + 48.4% = 87.2%

6.0%

E-stat 3

P(eta) = 1015

Introduction and Background

T. Gundersen

Process, Energy and System

Energy Consumption in Norway by Sector in 2007 (Total: 813.5 PJ)

Industry & MiningTransportationOther Sectors

Other Sectors: Private household (20.0%), Community Consumption (13.7%) and Fishing/Agriculture (3.6%)

37.3% 35.1%

27.6%

The Course “Energy & Process” makes Sense !!

E-stat 4

T(erra) = 1012

Introduction and Background

T. Gundersen

Process, Energy and System

AluminumChemicalPulp & PaperPetrochemicalFood IndustryIron & SteelMineralsWood WareMiningOthers

Energy Consumption (TWh) in Norwegian Industry in 2007 (Total: 80.66 TWh)

29.6%

17.6% 13.6% 12.0%

E-stat 5

Introduction and Background

T. Gundersen

Process, Energy and System

Energy Consumption, Fossil Fuels and the Impacts on the

Environmental

E-stat 6

•  Emissions include: u  Greenhouse Gases u  Acid Gases u  Particles

•  Options to mitigate: u  Carbon Capture and

Storage (CCS) u  Fuel Switch u  Renewables u  Energy Efficiency

•  The Cleanest Energy?

"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"

Definitions and Relations

Intro 1 T. Gundersen

Process, Energy and System

P R O C E S S I N T E G R A T I O N

IEA OECD

The IEA Definition of Process Integration

From an Expert Meeting in Berlin, October 1993

Intro 2 T. Gundersen

Process Synthesis - Definition “Process Synthesis is a Systematic approach

to the selection and interconnection of unit operations and to the specification of their operating conditions,

in order to develop a conceptual flowsheet that

produces desired products from available raw materials, in a safe and environmentally acceptable way,

with maximum profit, while the plant exhibits flexibility, operability and controllability”

Definitions and Relations

Process, Energy and System

Intro 3 T. Gundersen

Systems Engineering (SE) (Cybernetics)

Process Systems Engineering (PSE) (SE applied to Process Systems)

IPD - Integrated Process Design

(disciplines) (software)

LCA - Life Cycle Analysis

(time)

Process Integration

and Synthesis (space)

Process Integration & Systems Engineering

Definitions and Relations

Process, Energy and System

T. Gundersen

Terms in Perspective

Process Integration

Energy Conservation

Heat Integration

Process Synthesis

Intro 4

Definitions and Relations

Process, Energy and System

T. Gundersen

Process as a “Converter”

Energy

Material

Com Exp

Raw Material(s) Product(s)

Byproduct(s)

Steam HP MP LP Cooling

Steam HP MP LP

Cooling

Mechanical Energy

Intro 5

Introduction to Process Design

Process, Energy and System

T. Gundersen

A “Generic” Process

Feed

Gas Recycle

Liquid Recycle

Feed Treatment Reactor Separation

System

Purge

Product

Byproduct

Intro 6

Process, Energy and System

Introduction to Process Design

T. Gundersen

Conseptual Design and the “Onion”

R S H U

R = Reactor System S = Separation System H = Heat Integration U = Utility System

Decomposition

R

S

H

U

Interactions

Intro 7

Process, Energy and System

Introduction to Process Design

T. Gundersen

Process Example with elements of R/S/H/U

Intro 8

REACTOR TO

LUEN

E C

OL.

BEN

ZEN

E C

OL.

STA

BIL

IZER

Diphenyl

Benzene

Fuel Gas

Toluene Feed

Toluene Recycle

H2 Feed

Flash Drum

Purge Compressor

Gas Recycle

Process, Energy and System

Introduction to Process Design

T. Gundersen

4-way Trade-off in Process Design

Energy Steam, Cooling water

Refrigeration, etc. Capital Investment in

Equipment, Interest

Raw Materials Conversion, Losses Selectivity, Yield

Operation Flexibility, Safety and Controllability

Topology Process parameters

Ex.: ΔTmin

Intro 9

Process, Energy and System

Introduction to Process Design

T. Gundersen

Project Life Cycle

Idea

Commercial Justification

Technology Definition

Commercial Endorsement

Process Package

Detailed Design

Plant Completion

Process Redesign

Plant Operation and Maintenance

Plant Dis- assembling

Engineering Research Operation

Process Process Functional Detailed Plant Conception Simulation Design Design Construction

w Laboratory w Rigorous w PFD + P&ID w Equipment w Project Control w Pilot Plant Simulation w Functional Design Time w Synthesis w Parameter Performance w Piping Materials w Structural Optimization Specs w Layout Labor

Optimization w Stream w Major Equipm. w Isometrics Schedule w Flowsheeting Compositions w Costing w Structural Density w Costing Conditions w Instrumentation w Electrical w Cost Control

w Duty Sizing Performance w Civil Specifications w Mechanical

Phases and corresponding Technical Activities

Intro 10

Process, Energy and System

Introduction to Process Design

T. Gundersen

Motivating Example Traditional

Design

Feed Product

Reactor

ST

ST

CW

Recycle

Sepa- rator QST = 1722 kW

QCW = 654 kW Area = 629 m2 Units = 6 stk.

Process, Energy and System

Motivation

Intro 11

T. Gundersen

Motivating Example Systematic

Design

QST = 1068 kW QCW = 0 kW Area = 533 m2 Units = 4 stk. Feed Product

Reactor

ST Recycle

Sepa- rator

Intro 12

Process, Energy and System

Motivation

T. Gundersen

Motivating Example Comparison

Tradi- Syste- tional matic design design

QST (kW) 1722 1068 QCW (kW) 654 0 Area (m2) 629 533 Units 6 4

A

QST

Tradi- tional

Syste- matic

1722

629

1068

533

Intro 13

Process, Energy and System

Motivation

Dual Pressure Nitric Acid Plant

T. Gundersen Intro 14

Process, Energy and System

Motivation

T. Gundersen

Methods for Process Integration • Pinch Analysis

§  Graphical Thermodynamic Diagrams §  “Best performance” Targets ahead of design §  Systematic Design Methods

• Exergy Analysis §  Components and the Systems Level §  “Sound” Design, but at what Price ?

• Mathematical Programming §  Constrained Optimization §  Discrete and Continuous Variables

PI Methods

Intro 15

Process, Energy and System

T. Gundersen

Areas of Application – Process Tasks • Optimal Level of Heat Recovery

§  Trade-off Investment and Operating Cost • Design of Heat Exchanger Networks • Design, Sequence and Heat Integration of

thermally driven Separation Systems §  Distillation, Evaporation and Drying

• Design of Utility Systems §  Boilers, Fired Heaters, Refrigeration Cycles §  Integration of Heat Pumps and Turbines

• Design of Operable Plants §  Flexibility, Controllability, Startup, Shutdown

Intro 16

Application Areas

Process, Energy and System

T. Gundersen

Areas of Application – Industrial Branches

• Chemical and Petrochemical Industry §  Ethylene, Methanol, Ammonia §  Nitric Acid, Fertilizer, etc., etc.

• Oil Refineries • Oil & Gas (including Offshore) • Thermal Power Plants • Pulp and Paper Industry • Metal Industry • Food and Drink Industry

§  Breweries, Dairies • Pharmaceutical Industry

Intro 17

Process, Energy and System

Application Areas

Why Process Integration ?

T. Gundersen

Nordisk Energi Forsknings Program

Diagnosis (analysis)

“Global” considerations

Smart Solutions Economy

Innovation

Why PI ?

We cannot afford not to

Intro 18

Motivation

Process, Energy and System

T. Gundersen

Summary of the Introduction • PI aims at the Conceptual Phase

§  Critical Decisions are made §  The Creative Part of Process Design

• PI offers a Design Philosophy with Focus on the System (total Plant)

• Process Structure (flowsheet/topology) more important than Process Parameters

• PI provides Systematic and General Methods for Integrated Design Solutions

• PI is heavily used in many Industrial Companies and Industrial Branches

Intro 19

Process, Energy and System

Summary of Intro

T. Gundersen

Challenges in Process Design and Integration

•  “Open-ended” è Can “always” be improved

•  Discrete Decisions è Combinatorial Explosion

•  Non-Linear Relations è Numerical Problems

•  Uncertainty in Cost Calculations §  Energy: Price of Oil (10 to 150 to 60 to 110 $/bbl)

§  Equipment: Bid, Future, Installation, etc.

Intro 20

Process, Energy and System

Summary of Intro