The RAIN CII Experience with Process Heat Recovery

Tulane Engineering Forum

April 3, 2009

Presented by Robert Tonti

When considering energy issues todayWhen considering energy issues today……

“The scientists are virtually screaming from the

rooftops now. The debate is over! .... it’s an

inconvenient truth … it’s a moral imperative.”

Al Gore – on global warming

“We need to break our dependency on foreign

sources of oil, which leaves us at the mercy of

foreign powers.” Bobby Jindal – on oil imports

“If I were emperor of the world, I would put the

pedal to the floor on energy efficiency and

conservation for the next decade.”

Stephen Chu – on energy efficiency

Engineering process design featuresEngineering process design features……

Materials

Labor

Energy

Products

Exhaust

“Heat Loss”

Investment Capital

•Fossil Fuel

•Electricity

Energy efficiencyEnergy efficiency

Process

Heat Energy in Heat Loss

Energy

Efficiency Energy In100%

Heat Loss

Heat recovery increases energy efficiencyHeat recovery increases energy efficiency……

Process

Heat Recovery

Less

Heat Energy in

Less

Waste Heat

Export to other use

Heat Integration

Heat Recovery

Lower CO2

Emission

Natural Resource Conservation

Economic

Heat recovery benefitsHeat recovery benefits……

• Power Generation - Combined cycle turbine generator

with heat recovery boiler and other “CHP“ applications

• Chemical Manufacture - Pyrolysis thermo-siphon boilers

• Petroleum Refining - Various steam generating processes: Cat Crackers, Methane reformers

• Industrial Kiln Operations -Exhaust heat recovery boilers – Including Petroleum Coke Kilns

• And many others

Examples in industry are vastExamples in industry are vast

Petroleum Coke CalciningPetroleum Coke Calcining

Oil Refining

Coke Calcining

Aluminum

Steel

Titanium Dioxide

Other Applications

Petroleum Coke

Oil

Gasoline and Other

Light Products

Heat Recovery Energy

Petroleum CokePetroleum Coke

“Raw” petroleum coke contains residual hydrocarbon.

“Calcining” removes hydrocarbons and raises fixed carbon content to > 99%.

“Raw Coke” is converted to “Calcined Coke” in a rotary kiln typically heating to 2400 degrees F (~1320 degrees C)

Coke Calciner

( NO HEAT RECOVERY)

Petroleum

Coke

Hot Gas

1800 F (983 C)

2400 F

100%Total Output

26%Exhaust

74%Product

Heat Content Outputs

100%Total Input

1%Natural Gas

99%Raw Material Feed

Heat ContentInputs (other than air)

Typical Petroleum Coke Calciner Heat BalanceTypical Petroleum Coke Calciner Heat Balance

Typical Exhaust in excess of 200 million BTU/hr

Loss of high quality heatLoss of high quality heat

Heat recovered from one petroleum coke kiln on an

equivalent basis could.…

Heat 20,000 average US homes

Power 10,000 average US homes

Avoid 275,000 barrels of crude oil import/year

Offset….100,000 Tons CO2 emission/year

Off-Setting CO2 Emission Reduction

Recovered energy can offset CORecovered energy can offset CO22 emissionsemissions

Coke

Calciner

CO2

Gas Fired Industrial Boiler

or

Utility Power Boilers

Steam Heat or Electric Power

CO2

Heat

Recovery

by reducing CO2 emissions from utility or other industrial plants

Coke Calciner (with heat recovery)Coke Calciner (with heat recovery)

KilnKiln PyroscrubberPyroscrubber

BoilerBoiler

ScrubberScrubber

Electric Power Generator

Practical Problems of Heat Recovery

Design

�Economics

�Scale

�Auxiliary supporting equipment

�Proximity to energy demand

Practical ProblemsPractical Problems

Commercial

�Uncertain future energy values

�Short term energy mismatch –supply not equal demand

�Long term energy inter-dependency

�Not your primary business

Practical Problems Practical Problems …… Continued..Continued..

Governmental/Regulatory

�Taxation

�Energy regulation

�Environmental

Practical Problems Practical Problems …… ContinuedContinued

Heat Recovery Projects (annual energy recovery)

Vishapatnam, India 310 x 106 KW-hr + CERs

Norco, LA 1.6 x 1012 BTU

Gramercy, LA 1.9 x 1012 BTU

Chalmette, LA 112 x 106 KW-hr

Lake Charles, LA 2.5 x 1012 BTU

Moundsville, WVA 1.0 x 1012 BTU

Robinson, IL 158 x 106 KW-hr

Existing

Potential

Rain CII Heat Recovery ProjectsRain CII Heat Recovery Projects

�Petroleum coke kilns are a high temperature

example of heat recovery

�Technology is also available for lower temperature

heat capture

Lower temperature technology

Slide Courtesy of the National Renewable Energy Laboratory and American Solar

Energy Society – (CO2 expressed as elemental carbon component only)

How to Reduce US Carbon Emissions by 2030How to Reduce US Carbon Emissions by 2030

�Target CO2 reduction demands both energy

efficiency and renewable energy efforts nationally.

�Energy efficiency opportunities, if proportionate to

existing US energy consumption, would comprise

40% buildings, 30% transportation and 30% industry.

Figures from writings for the National Renewable Energy Laboratory and American Solar Energy Society “Tackling Climate Change in the US”, Charles F. Kutscher, Editor January 2007

State and Federal Incentiveshttp://www.dsireusa.org

Best Practices and Industrial Assessments

http://www.eere.energy.gov/industry/bestpractices/iacs.html

Incentives and AssistanceIncentives and Assistance

Heat recovery should play a role to reduce future CO2 emissions, increase industrial energy efficiency and conserve natural resources.

ConclusionConclusion

Thank you!