Energy Saving and Carbon Reduction: Approaches for Energy and Chemical Industries

About This Book
About the Author
Preface
Acknowledgements
Contents
List of Figures
List of Tables
Part I Thermodynamic Basis of Energy Utilization Analysis
1 Thermodynamics Fundamentals
1.1 Basic Terms
1.1.1 System and Environment
1.1.2 State and State Parameters [4]
1.1.3 Dead State and Reference State
1.1.4 Energy
1.1.5 Reversible and Irreversible Processes
1.1.6 Energy Use Process, Energy Use Process Thermodynamics
1.2 Energy Form and Reference State
1.2.1 The Form of Energy
1.2.2 Determination of the Reference State
1.3 The First Law of Thermodynamics
1.3.1 General Expression of the First Law of Thermodynamics
1.3.2 Energy Balance Equation of Stable Flow System [2]
1.3.3 The Form of the Total Energy Balance Equation Under Different Conditions
1.3.4 Application of the First Law in the Petrochemical Process
1.4 The Second Law of Thermodynamics
1.4.1 The Expression of the Second Law of Thermodynamics
1.4.2 The Maximum Limit of Thermal Variable Work, Carnot Factor
1.4.3 The Expression and Significance of the Energy Use Process of the Second Law
1.4.4 Concept and Calculation of Exergy
1.4.5 The Exergy Balance Equation of the Energy Use Process [1]
1.5 Energy Saving and GHG Gas Mitigation
References
2 Calculation of Thermophysical Energy and Exergy
2.1 Calculation of Energy and Exergy of Process Thermal Effect
2.1.1 Calculation of Process Stream Sensible Heat Energy and Exergy
2.1.2 Energy and Exergy Calculation of Phase Change Latent Heat
2.1.3 Reaction Heat Effect and Reaction Exergy
2.1.4 Mixed Heat and Exergy
2.2 Calculation of Energy and Exergy of Petroleum and Its Fractions
2.2.1 Expansion of Nelson Enthalpy Diagram Fitting Correlation
2.2.2 Calculation on Liquid Petroleum Fraction Exergy with Liquid Reference Phase
2.2.3 Calculation of Gas Petroleum Fraction Physics Exergy at Gas Reference Phase
2.2.4 Calculation of Gas Phase Petroleum Fraction Exergy at Liquid Reference Phase
2.3 Calculation of Energy and Exergy of Light Hydrocarbon and Its Mixture
2.3.1 Ideal Gas Hydrocarbon Enthalpy, Entropy and Exergy Calculation
2.4 Calculation of Steam, Water and Air Energy and Exergy
2.4.1 Steam
2.4.2 Energy Item Such as Water and Air
2.5 Calculation of Heat Dissipation Energy and Exergy
References
3 Calculation of Mechanical Energy and Chemical Exergy
3.1 Calculation of Real Gas Energy and Exergy
3.1.1 Calculation Method of Real Gas Energy and Exergy
3.1.2 Calculation of Residual Properties
3.2 Calculation of Energy in the Fluid Flowing Process
3.2.1 Volume Work, Shaft Work and Flow Work
3.2.2 Calculation of Shaft Work and Effective Work [5, 6]
3.3 Chemical Exergy and Calculation of Fuel Exergy
3.3.1 Basic Concepts of Chemical Exergy [9]
3.3.2 Calculation Method of Chemical Exergy
3.3.3 Chemical Exergy of Complex Substances and Fuels
References
4 Thermodynamic Analysis of Process Energy Utilization
4.1 Thermodynamic Analysis of Heat Transfer Process
4.1.1 Heat Transfer with Ignoring the Heat Dissipation
4.1.2 Heat Transfer Process with Heat Loss
4.2 Thermodynamic Analysis of Fluid Flow Process [2]
4.3 Thermodynamic Analysis of Mass Transfer Process
4.3.1 The Minimum Exergy Consumption of the Separation Process
4.3.2 Thermodynamic Analysis of Actual Separation Process
4.4 Thermodynamic Analysis of Chemical Reaction Process
4.4.1 Calculation of Chemical Reaction Exergy
4.4.2 Reaction Exergy Loss and Reaction Exergy Calculation on Complex Reaction
4.5 Thermodynamic Analysis of the Combustion Process [5, 6]
4.5.1 Adiabatic Combustion Process
4.5.2 Heat Transfer Process
4.5.3 Approaches to Reduce Combustion Exergy Loss
References
Part II Three-Link Energy Analysis Approach and Energy/Exergy Balance
5 Energy Utilization Three-Link Analysis Method
5.1 Energy Consumption Characteristics of Petrochemical Industry
5.2 Improvement of the Three-Link Model of Energy Consumption Analysis [3]
5.3 The Consideration of Using Energy Utilization Three-Link Model
5.3.1 Energy Consumption Analysis and Calculation Benchmark
5.3.2 Effective Power of Pumps for Non-Process Fluids
5.3.3 Equipment Heat Dissipation in the Energy Use Link
5.3.4 Feed Raw Materials Chemical Energy
5.3.5 The Reaction Exotherm Should Be Included in the Total Process Energy Consumption
5.3.6 Principles for Handling Some Special Equipment
5.4 The Detail Items of the Improved Three-Link Model
5.4.1 Energy Balance Parameters
5.4.2 Exergy Balance Parameters
5.5 Balance Relationship and Evaluation Index of the Three-Link Model
5.5.1 Energy Balance Relationship and Evaluation Index
5.5.2 Exergy Balance Relationship and Its Evaluation Index
5.5.3 Energy Balance and Exergy Balance Result (Diagram)
References
6 Equipment Energy Balance and Exergy Balance
6.1 The Content and Requirements of the Plant Energy Analysis Test
6.1.1 Determination of Test Conditions and Test Scope
6.1.2 Testing Trial Requirements [1]
6.2 Pump and Compressor Equipment
6.2.1 Centrifugal Pump
6.2.2 Compressor
6.3 Industrial Furnace Equipment
6.3.1 Process Fired Heater Energy and Exergy Balance Calculation
6.3.2 Reactor and Tail Gas Incinerator
6.4 Catalytic Cracking Regenerator
6.5 Process Energy Utilization Equipment
6.5.1 Column Equipment
6.5.2 Reaction Equipment
6.6 Energy Recovery and Utilization Equipment
6.6.1 Cooling and Heat Exchange Equipment
6.6.2 Power Recovery Equipment
References
7 Energy Balance and Exergy Balance of Petrochemical Plants
7.1 Balance Verification of System Energy Consumption Data in the Plant
7.1.1 Process Plant Material Balance
7.1.2 Thermodynamic Energy Consumption
7.1.3 Thermodynamic Exergy Consumption DT
7.1.4 Calculation of Energy and Exergy of Recycling and Output Streams
7.1.5 Streams Rejection Waste Energy and Exergy
7.2 Plant Heat Loss Verification and Summary
7.2.1 Analysis of the Characteristics of Heat Dissipation
7.2.2 Calculation Summary of Heat Loss of Equipment and Pipeline
7.2.3 Pipeline Heat Dissipation Verification and Summary of Plant Heat Dissipation
7.3 Balance of Supply and Consumption of Steam, Electricity and Water
7.3.1 Steam
7.3.2 Water
7.3.3 Power Consumption
7.4 Plant Energy Balance and Exergy Balance Calculation and Summary
7.4.1 Energy Conversion Link
7.4.2 Energy Process Use Link
7.4.3 Energy Recovery and Utilization Link
7.4.4 Entire Plant Summary of the Balance
References
8 Utility/Auxiliary System and Energy Balance of the Whole Plant
8.1 Energy Balance of Utility System
8.1.1 Energy Balance of Heating System
8.1.2 Test and Balance of Power Supply System
8.1.3 Energy Balance of Water Supply and Air Supply System
8.2 Energy Balance of Auxiliary System
8.2.1 Storage and Transportation System
8.2.2 Wastewater Treatment System
8.2.3 Energy Consumption Verification of Auxiliary Systems for Indirect Production
8.3 Summary of Plant-Wide Energy Balance
8.3.1 Energy Balance Summary Method and Calculation Basis
8.3.2 Summary of Energy Balance of Test Conditions
References
Part III Energy Analyses and Carbon Reduction Approaches
9 Energy Consumption Analysis and Energy-Saving Improvement Methods
9.1 The Influence of Plant Size and Ambient Temperature on Energy Consumption
9.1.1 Impact of Plant Size
9.1.2 Influence of Ambient Temperature [1, 2]
9.2 Analysis of the Impact of Loading on Plant Energy Consumption [3]
9.2.1 Load Ratio Impact on Plant Energy Consumption and Its Estimation
9.2.2 Estimate from Energy Balance Data
9.2.3 The Influence of Load Ratio on Heat Dissipation Fixed Energy Consumption
9.2.4 The Influence of Load Rate on Electricity Fixed Energy Consumption
9.2.5 The Influence of Load Ratio on Steam Fixed Energy Consumption
9.2.6 Other Fixed Energy Consumption
9.3 Assessment of Energy Use Level and Energy Saving Potential
9.3.1 Apply “Benchmark Energy Consumption” to Evaluate the Energy Consumption [6]
9.3.2 Evaluation on Energy Utilization Level and Potential of Equipment and System
9.4 Approaches for Energy-Saving Improvement of Production Plant [21]
9.4.1 Improve Process Conditions to Reduce the Total Energy Consumption of the Process
9.4.2 Reduce Process Exergy Loss in Process Energy-Using Link
9.4.3 Improve Energy Recovery Efficiency and Reduce Rejection Energy and Exergy Loss
9.4.4 Improve the Energy Conversion Link Efficiency to Reduce the Energy Consumption
9.5 Large-Scale System Optimization Method and Improvement Approach
9.5.1 Improve Production Process
9.5.2 Heat Integration Among the Plants and System
9.5.3 Low Temperature Heat Recovery and Utilization
9.5.4 Make Steam System Cascade Utilization
References
10 CO2 Capture and Utilization
10.1 Fuel Efficiency Improvement, Using Lower-Carbon Fuel and Renewable Energy
10.1.1 Smart Using Fossil Fuel with Improved Energy Efficiency
10.1.2 Using Lower Carbon Fuel Instead of Higher Carbon Fuel
10.1.3 Using Renewable Energy and Nuclear Energy Instead of Fossil Fuel
10.2 Properties of CO2 and Its Distribution
10.2.1 CO2 Distribution Categories
10.2.2 CO2 Physical Properties
10.3 CO2 Capture Approaches
10.3.1 Absorption Solvents
10.3.2 Acid Gas Removal/CO2 Capture Using Chemical Solvents
10.3.3 Acid Gas Removal/CO2 Capture Using Physical Solvent
10.4 Sour Natural Gas CO2 Capture
10.4.1 Nature Gas CO2 Capture via Acid Gas Enrichment—Case Study 1
10.4.2 Cascade Sour Nature Gas CO2 Capture—Case Study 2
10.4.3 Acid Gas Enrichment and CO2 Capture—Case Study 3
10.5 Syngas CO2 Capture
10.5.1 Syngas CO2 Capture with Single Absorber Using DEPG Solvent—Case Study 4
10.5.2 Syngas CO2 Capture with Dual Absorber Using DEPG Solvent—Case Study 5
10.6 Flue Gas CO2 Capture
10.6.1 Flue Gas CO2 Capture Using DEA Solvent—Case Study 6
10.6.2 Flue Gas CO2 Capture Using Oxygen Instead of Combustion Air—Case Study 7
10.7 CO2 Compression and Dehydration
10.7.1 Background Information
10.7.2 Gas Stripping in Dehydration Regenerator
10.7.3 CO2 Dehydration and Compression—Case Study 8
10.7.4 Flue Gas CO2 Capture, Compression and Dehydration—Case Study 9
10.8 CO2 Cryogenic Separation
10.8.1 Actual Rich CO2 Gas Stream Gas Liquid Dewpoint and Freezeout Curve
10.8.2 Cryogenic Temperature Selection
10.8.3 Cryogenic Technology Development
10.8.4 Flue Gas Cryogenic CO2 Capture—Case Study 10
10.8.5 Comparison Between Conventional CO2 Capture and a Cryogenic CO2 Capture
10.9 CO2 Chemical Utilization and Storage
10.9.1 Urea Production Using CO2
10.9.2 Ammonia Bicarbonate Production Using CO2
10.9.3 Sodium Bicarbonate Production Using CO2
10.9.4 Using CO2 as Feed to Produce Methanol
10.9.5 CO2 Storage
References
11 Technical and Economic Evaluation of Energy-Saving Measures
11.1 Time Value of Capital
11.1.1 Interest
11.1.2 Currency Equivalent, Present Value and Future Value
11.1.3 Equivalent Value Calculation of Funds
11.2 Static Evaluation Method
11.2.1 Investment Profit Rate
11.2.2 Payback Period
11.2.3 Cash Flow and Cash Flow Curve
11.3 Dynamic Evaluation Method
11.3.1 Dynamic Payback Period
11.3.2 Simplified Calculation Equation for Dynamic Payback Period
11.3.3 Net Present Value Method
11.3.4 Internal Rate of Return
11.4 Estimation of Economic Benefits of Energy-Saving Measures
11.4.1 Determination of Fuel Price [7]
11.4.2 Determination of the Price of Steam and Power of Back Pressure Power Generation [8]
11.4.3 Determination of the Price of Electricity and Water
11.4.4 Other Benefits of Energy-Saving Measures
11.5 Cost Estimate and Technical Economic Evaluation
11.5.1 Classification of Energy-Saving Measures
References
Part IV Energy Utilization Optimization and Key Energy Saving Technologies
12 Optimization on Pipeline and Equipment
12.1 Process Rate and Exergy Loss
12.1.1 Heat Transfer Process
12.1.2 Fluid Flow Process [1]
12.1.3 Mass Transfer and Chemical Reaction Process [2]
12.1.4 Dynamic Efficiency of Driving Force (Exergy Loss)
12.2 Economical Insulation Thickness of Hot Fluid Pipeline
12.2.1 Objective Function
12.2.2 Classification of Optimization Methods [7]
12.2.3 Economical Insulation Thickness of Hot Fluid Pipeline
12.3 Economical Pipe Diameter and Insulation Thickness for Fluid Transportation [10]
12.3.1 Economical Pipe Diameter for Ambient Fluid Transportation
12.3.2 Economical Diameter and Insulation Thickness of Insulated Pipeline
12.4 Optimization of Heat Exchange Equipment [5, 12]
12.4.1 Optimization of a Single Heat Exchanger
12.4.2 Determination of the Best Outlet Temperature of the Cooling Water of the Cooler
12.5 Economical Thermal Efficiency of Heating Furnace
12.5.1 Background
12.5.2 Method for Determining Economic Thermal Efficiency
References
13 Pinch Energy-Saving Technology and Its Application
13.1 The Concept of Pinch Point and Its Determination
13.1.1 Pinch Concept
13.1.2 How to Determine the Pinch Point
13.1.3 Grand Composite Curve
13.2 Pre-estimate the Heat Exchange Network Area and the Optimal ΔTmin
13.2.1 Area Estimation Method
13.2.2 Determination of Total Annual Cost and ΔTmin
13.3 Energy Target Determination
13.4 Heat Exchange Network Pinch Design
13.4.1 Pinch Design Concept
13.4.2 Graphical Method of Heat Exchange Network
13.4.3 Pinch Point Design Method of Heat Exchange Network
13.4.4 Manually Input to Aspen Energy Analyzer
13.4.5 Transfer Data from HYSYS File to Aspen Energy Analyzer
13.5 Placement of the Heat Engine (Pump) in the Total Energy System [5, 14]
13.5.1 Heat Engine
13.5.2 Heat Pump
13.6 The Effect of Cross Heat Transfer on Heat Exchange Network Area and Energy
13.6.1 Heat Transfer Model and Driving Force Diagram
13.6.2 The Effect of Cross Heat Transfer on Area Targets
13.6.3 The Effect of Cross Heat Transfer on Energy (Heat Exchanger) and Exergy Loss
13.6.4 Estimation of Cross Heat Transfer Factor α of Existing Heat Exchange Network
13.7 Energy Saving Principle of Pinch Technology
13.7.1 The Main Characteristics of Pinch Technology and Exergy Analysis
13.7.2 Technical Characteristics of the Pinch
13.7.3 Heat Transfer Exergy Loss
References
14 Key Energy-Saving Technologies
14.1 Pump Speed Control Technology
14.1.1 Variation Law of Pump Flow Rate with Speed
14.1.2 Speed Control Method and Classification [1]
14.2 Gas Turbine and Its Selection
14.2.1 Energy Saving Principle
14.2.2 Gas Turbine Selection
14.3 Combined Gas Turbine Cycle and Its Application
14.3.1 Combined Gas Turbine Cycle
14.3.2 Application of LNG Plant
14.4 Flue Gas Turbine Energy Saving of Fluid Catalytic Cracking Unit
14.4.1 Energy-Saving Principle and Expansion Work Estimate
14.4.2 Energy-Saving Benefit Estimation
14.4.3 Technical and Economic Evaluation
14.4.4 Ways to Improve the Power Recovery Rate of Flue Gas Turbine
14.5 FCCU Regenerating Gas CO Combustion Outside of Regenerator
14.5.1 Background
14.5.2 Laboratory Research Results
14.5.3 Flue Gas CO Duct Pre-Combustion
14.5.4 Technical Process Flow of CO Combustion Outside Regenerator [8]
14.5.5 Test Trial Results
14.6 CO Combustion and Flue Gas Energy Recovery System Optimization
14.6.1 Two-Stage Regeneration Flue Gas Mixed Pre-Combustion
14.6.2 Flue Gas Energy Recovery Processes and Characteristics
14.6.3 Comparison of Energy-Saving Effects of Various Energy Recovery Processes
14.7 Low-Temperature Heat Recovery and Utilization
14.7.1 Direct Use as a Heat Source for Heating
14.7.2 Heat Pump
14.7.3 Refrigeration
14.7.4 Power Generation
14.7.5 Low-Grade Heat Integration System
References
Appendix Frequently Used Data