Upload
vazzoleralex6884
View
233
Download
1
Embed Size (px)
Citation preview
8/20/2019 Truls Gundersen March 18.pdf
1/30
NTNU
20.03.13 T. Gundersen Slide no. 1
What is Process Integration?
by
Truls Gundersen
Department of Energy and Process Engineering
Norwegian University of Science and Technology (NTNU)
Trondheim, Norway
Chalmers
University of
Technology
8/20/2019 Truls Gundersen March 18.pdf
2/30
NTNU
20.03.13 T. Gundersen Slide no. 2
Content of the Presentation
! Definitions and the birth of Process Integration
!
Process Integration (PI) as a Term ! Heat, Power, Chemical and Equipment Integration
!
Some early stage Developments, however …! Bodo Linnhoff: “A Historical Overview of early Developments”
! 3 Major and Generic Results from Pinch Analysis with
widespread Use in Process Integration
!
The Tool Box in PI ! Graphical Diagrams, Representations and Concept
!
Various Extensions of Pinch Analysis in PI
!
Applications, Objectives, Scope, etc.! Use of Optimization in Process Integration
!
PI and Global Warming / Emissions Reduction! From Energy Focus to Environmental Concern
8/20/2019 Truls Gundersen March 18.pdf
3/30
NTNU
20.03.13 T. Gundersen Slide no. 3
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
"Systematic and General Methods for Designing
Integrated Production Systems, ranging from
Individual Processes to Total Sites, with specialemphasis on the Efficient Use of Energy and
reducing Environmental Effects"
8/20/2019 Truls Gundersen March 18.pdf
4/30
NTNU
20.03.13 T. Gundersen Slide no. 4
More Descriptions of Process Integration
!
An Alternative to the IEA Definition:
!
Process Integration is a Methodology for Analysis, Design andOptimization of Material and Energy related Production Systems
! 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
! 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
8/20/2019 Truls Gundersen March 18.pdf
5/30
NTNU
20.03.13 T. Gundersen Slide no. 5
!
#!!
$!!
%!!
&!!
'!!!
'#!!
'$!!
'%!!
'&!!
' ( % ! )
% (
' ( * ! ) * (
' ( & ! ) & (
' ( ( ! ) ( (
# ! ! ! )
# ! ! $
# ! ! + )
# ! ! (
# ! ' !
) , - . / . 0 1
The use of Process Integration as a Term
Date: 7 March 2013 – Source: Science Direct, Journal papers only
Subjects: Chemical Engineering, Energy, Engineering
0 8121
714 651
1420
1666
2071
8/20/2019 Truls Gundersen March 18.pdf
6/30
NTNU
20.03.13 T. Gundersen Slide no. 6
The Title: What is Process Integration?
This Question can be decomposed into
What do we mean by a Process?
and
What do we mean by Integration?
8/20/2019 Truls Gundersen March 18.pdf
7/30
NTNU
20.03.13 T. Gundersen Slide no. 7
Energy
Material
Com Exp
Raw Material(s) Product(s)
Byproduct(s)
Thermal Energy
HP, MP, LPFlue Gas
AP, CW
Refrigerants
Thermal Energy
HP, MP, LP
Cooling
Mechanical
Energy
A Process can be regarded as a “Converter”
8/20/2019 Truls Gundersen March 18.pdf
8/30
NTNU
20.03.13 T. Gundersen Slide no. 8
What is the meaning of Integration?
!
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" Process Intensification
8/20/2019 Truls Gundersen March 18.pdf
9/30
NTNU
20.03.13 T. Gundersen Slide no. 9
Heat
Integration
2000 4000 60000
300
250
200
150
100
50
T (°C)
H (kW)
Q H,min
QC,min
Pinch
Q Recovery
!T min
Pinch
180°
C2210° 160°
C1210°
50°
H2
220° 60°
H1
270°160°
160°
Ca
4
4
H
1
13
3
2
2
190° 177.6°
1000 kW
1000 kW 620 kW 880 kW
Cb
360 kW
440 kW
2200 kW
160°
180°
180°
80°
235.6°
mCp (kW/°C)
18.0
22.0
20.0
50.0
270ºC - - - - - - - 250ºC
230ºC - - - - - - - 210ºC
220ºC - - - - - - - 200ºC
180ºC - - - - - - - 160ºC
160ºC - - - - - - - 140ºC
70ºC - - - - - - - - 50ºC
H1
H2
CW
C1
C2
ST
720 kW
180 kW
720 kW
880 kW
440 kW
1980 kW
500 kW
200 kW
800 kW
1800 kW
+ 720
- 520
- 1200
2000 kW
400 kW
+ 180
+ 220
+ 400
60ºC - - - - - - - - 40ºC
360 kW
220 kW
!T min
= 20°C300
250
200
150
100
50
T' (°C)
Q (kW)
500 15000
QH,min
QC,min
8/20/2019 Truls Gundersen March 18.pdf
10/30
NTNU
20.03.13 T. Gundersen Slide no. 10
Simultaneous Heat and Power Integration?
!
Feng and Zhu (1997) introduced the Energy Level (!)
!
Energy Level is defined as Exergy/Energy: ! For Work and Electricity: ! = 1
! For Heat: ! = "C = 1 " T 0 / T
! For Steady-State Flow Systems: ! = # E / # H
! The Energy Level Concept is used to identify Losses inEnergy Quality (which is why Exergy is used)
!
Energy Level is evaluated at the Entrance and Exit of theProcess 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?
8/20/2019 Truls Gundersen March 18.pdf
11/30
NTNU
20.03.13 T. Gundersen Slide no. 11
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.
0
0.1
0.2
0.3
0.4
0.5
0.6
0 50 100 150 200 250 300 350 400 450 500
Cummulative Enthalpy (MW)
E n e r g
y
L e v e l
Omega Increasing Units
Omega Decreasing Units
Raw Product Cooler
Raw Product Cooler,
Sec Reformer Product Cooler
Raw Product Cooler,
Sec Reformer Product Cooler,
Prereformer 1
Sec Reformer Product Cooler,
Prereformer 1
Sec Reformer Product Cooler
Steam Generator
Steam Generator, Burner, MeOH Recycle Compressor
Steam Generator, Burner, MeOH Recycle Compressor, Syn Gas Compressor
Steam Generator, MeOH Recycle Compressor, Syn Gas
Steam Generator, Syn Gas Compressor
Steam Generator, MeOH Reactor Feed Preheater
Steam Generator, MeOH Reactor
Steam Generator, MeOH Reactor Water Jacket
Steam Generator, MeOH Reactor Water Jacket, Prereformer 2
Steam Generator, Prereformer 2
Prereformer 2
Prereformer 2, Primar Reformer
Primary Reformer, Sec Reformer
Primary Reformer, Sec Reformer Shift Reactor
Primary Reformer
ELCCs for a Methanol Process
8/20/2019 Truls Gundersen March 18.pdf
12/30
NTNU
20.03.13 T. Gundersen Slide no. 12
Kaggerud K.H., Bolland O., Gundersen T., “Chemical and Process Integration:
Synergies in Co-Production of Power and Chemicals from Natural Gas with CO 2
Capture”, Applied Thermal Engineering , vol. 26, pp. 1345-1352, 2006.
Chemical Integration in an Industrial Cluster
8/20/2019 Truls Gundersen March 18.pdf
13/30
NTNU
20.03.13 T. Gundersen Slide no. 13
Equipment Integration – Methyl Acetate
Siirola J.J., “Industrial Applications of Chemical Process Synthesis”,
Advances in Chemical Engineering , vol. 23, pp. 1-62, 1996.
Eastman
Chemical
Company
8/20/2019 Truls Gundersen March 18.pdf
14/30
NTNU
Process Synthesis
Process Integration
Heat Integration
20.03.13 T. Gundersen Slide no. 14
Various Terms in Perspective
Energy
Conservation
8/20/2019 Truls Gundersen March 18.pdf
15/30
NTNU
20.03.13 T. Gundersen Slide no. 15
Some early stage
Developments
Energy
Equipment
Raw Materials
Environment G
r a s s r o o t
R e t r
of i t
B a t c h Bodo Linnhoff
used the Rubic Cube
to illustrate
Progress
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 !!
8/20/2019 Truls Gundersen March 18.pdf
16/30
NTNU
20.03.13 T. Gundersen Slide no. 16
3 Major Results from PA with widespread Use in PI
!
The Concept of Composite Curves (Cumulative Plots) ! Applicable whenever an “Amount” has a “Quality”! Heat & Temperature, Mass & Concentration (Chemical Potential),
Refinery Gases & H2 Purity (and Pressure), Money & Time, etc.
!
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
T
H
C
m
Heat
Pinch
Water
Pinch
QC,min
Q H,min
Water min
8/20/2019 Truls Gundersen March 18.pdf
17/30
NTNU
20.03.13 T. Gundersen Slide no. 17
Above
Pinch
Below
Pinch
Q H,min
QC,min
Q = 0
Process
Cascade
Q Reboiler
QCondenser
Distillation
Column
Heat
Pump
Q HP,out
Q HP,in
W HP
Steam
Turbine
QST,in
QST,out
W ST
“Correct” Integration and Appropriate Placement
Simple Rule: “Connect Sources with Sinks” But: T Source > T Sink
8/20/2019 Truls Gundersen March 18.pdf
18/30
NTNU
20.03.13 T. Gundersen Slide no. 18
Diagrams, Representations and Concepts in PI
!
Graphical Diagrams
!
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
8/20/2019 Truls Gundersen March 18.pdf
19/30
NTNU
20.03.13 T. Gundersen Slide no. 19
Expansions in Process Integration
based on Pinch Analysis
and using Analogies
! Applications Areas
!
Objectives
! Scope
! Type of Plants
!
Type of Projects
! Thermodynamics
8/20/2019 Truls Gundersen March 18.pdf
20/30
NTNU
20.03.13 T. Gundersen Slide no. 20
! Application Areas
# From Heat Pinch for Heat Recoveryand CHP in Thermal Energy Systems
# to Mass Pinch for Mass Transfer /Mass Exchange Systems
#
to Water Pinch for WastewaterMinimization and Distributed
Effluent Treatment Systems
#
to Hydrogen Pinch for HydrogenManagement in Oil Refineries
#
to Oxygen Pinch for Wastewater
Bio-Treatment Plants# to Carbon Pinch to satisfy Energy
Requirements while meeting CO2 Emission Limits in the Energy Sector
Expansionsof PA & PI
8/20/2019 Truls Gundersen March 18.pdf
21/30
NTNU
20.03.13 T. Gundersen Slide no. 21
Expansionsof PA & PI
! Objectives
#
from Energy Cost
# to Equipment Cost
#
to Total Annualized Cost
# and also Operability, including$
Flexibility
$ Controllability
$ Switchability% Start-up & Shut-down
% New Operating Conditions
#
and finally Environment, including
$ Emissions Reduction
$ Waste Minimization
8/20/2019 Truls Gundersen March 18.pdf
22/30
NTNU
20.03.13 T. Gundersen Slide no. 22
Expansionsof PA & PI
! Scope
#
from Heat Exchanger Networks# to Separation Systems, especially
$ Distillation and Evaporation (heat driven)
# to Reactor Systems
#
to Heat & Power, including$
Steam & Gas Turbines and Heat Pumps
# to Utility Systems, including
$ Steam Systems, Furnaces, Refrigeration Cycles
# to Entire Processes
# to Total Sites
# to Regions
8/20/2019 Truls Gundersen March 18.pdf
23/30
NTNU
20.03.13 T. Gundersen Slide no. 23
Expansionsof PA & PI
! Plants
#
from Continuous# to Batch and Semi-Batch
! Projects
# from New Design
#
to Retrofit
# to Debottlenecking
! Thermodynamics
# from Simple 1st Law Considerations
#
to Various 2nd Law Applications$ Exergy in Distillation and Refrigeration
8/20/2019 Truls Gundersen March 18.pdf
24/30
NTNU
20.03.13 T. Gundersen Slide no. 24
Process Integration Methodologies
Hierarchical
Analysis
Heuristic
Methods
Knowledge
Based Systems
Optimization
Methods
Thermodynamic
Methods
Pinch Analysis
Exergy Analysis
Stochastic Methods
Mathematical Programming
Rules of ThumbExpert Systems qualitative
quantitative
interactiveautomatic
8/20/2019 Truls Gundersen March 18.pdf
25/30
NTNU
20.03.13 T. Gundersen Slide no. 25
Limitations in Pinch Analysis & the PDM
! Rigor sometimes replaced by Heuristic Rules!
The (N – 1) Rule for minimum Number of Units!
The “Bath” formula for minimum total Heat Transfer Area
!
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 !
The Pinch Design Method is Sequential in Nature ! Targeting " Design " Optimization (Evolution)
! One Match at a time, one Loop at a time, one Path at a time, etc. ! " Unable to properly handle Multiple Trade-offs
!
Pinch Decomposition guides Correct Integration, but ! In Network Design, less Costly and less Complex Designs can
be found by actually ignoring strict Pinch Decomposition
! Time consuming but normally results in “good” Designs
8/20/2019 Truls Gundersen March 18.pdf
26/30
NTNU
2000 4000 60000
250
200
150
100
50
T (°C)
H(kW)
CW
HP
20.03.13 T. Gundersen Slide no. 26
Why not use Optimization?
MILP
LP
NLP
Energy
Units
Area/TAC
Software: MAGNETS
Transshipment Models (LP & MILP)
Clever Stream Superstructure (NLP)
MINLP
Minimum Area
=> Counter-Current or
“Vertical” Heat Transfer
Area Considerations using
a “vertical” MILP Model?
Targeting
Design
Evolution
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.
CMU UMIST
8/20/2019 Truls Gundersen March 18.pdf
27/30
NTNU
20.03.13 T. Gundersen Slide no. 27
UMIST Comments after Sabbatical
Promoting Mathematical Programming
was quite challenging in those Days !
8/20/2019 Truls Gundersen March 18.pdf
28/30
NTNU
20.03.13 T. Gundersen Slide no. 28
The Sequential Framework – SeqHENS
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
Compromise between Pinch Design and MINLP Methods
Surprisingly few Iterations thanks to excessive use of Insight
!
Heat Transfer Area: Loops 1 & 2
!
# of Heat Exchangers: Loop 3
!
Energy Consumption: Loop 4
8/20/2019 Truls Gundersen March 18.pdf
29/30
NTNU
20.03.13 T. Gundersen Slide no. 29
Process Integration and Global Warming
!
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?)
!
Public Discussion in the US (2012)! Energy Efficiency is the 5th Energy Form
!
Following Oil, Gas, Coal and Nuclear
!
An obvious Observation ! “The cleanest Energy is the one that is not used”
!
A Shift of Focus in Process Integration
!
From Energy Focus in the 1970s and 1980s (Availabilityand Cost) to Environmental Concern in the 1990s and later
!
Global Warming – A new Opportunity for PI? ! Energy Efficiency is a Core Activity in Process Integration
8/20/2019 Truls Gundersen March 18.pdf
30/30
NTNU
20.03.13 T. Gundersen Slide no. 30
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:
dS cv
dt =
!Q j
T j + !mi ! si " !m ! se + !# cv
e
$i
$ j
$
Entropy (S ) is the twin brother/sister of Exergy ( Ex)
dExcv
dt = 1!
T 0
T j
"
# $
%
& ' ( !Q j ! !W cv ! p0 (
dV cv
dt
" # $
% & ' + !mi (e f ,i ! !m (e f ,e ! ! Exd
e
)i
) j
)