Advanced Energy Saving and its Applications in Industry

81 Pages·2013·1.913 MB·English

by  Kazuo Matsuda, Yasuki Kansha, Chihiro Fushimi, Atsushi Tsutsumi, Akira Kishimoto (auth.)

SpringerBriefs in Applied Sciences
and Technology
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Kazuo Matsuda Yasuki Kansha
•
Chihiro Fushimi Atsushi Tsutsumi
•
Akira Kishimoto
Advanced Energy Saving
and its Applications
in Industry
123
KazuoMatsuda AtsushiTsutsumi
Chiyoda Corporation CollaborativeResearch Center for
4-6-2,Minatomirai, Nishi-ku Energy Engineering
Yokohama 220-8765 Instituteof IndustrialScience
Japan The Universityof Tokyo
4-6-1Komaba, Meguro-ku
Yasuki Kansha Tokyo153-8505
CollaborativeResearch Center for Japan
Energy Engineering
Instituteof IndustrialScience AkiraKishimoto
The Universityof Tokyo CollaborativeResearch Center for
4-6-1Komaba, Meguro-ku Energy Engineering
Tokyo153-8505 Instituteof IndustrialScience
Japan The Universityof Tokyo
4-6-1Komaba, Meguro-ku
ChihiroFushimi Tokyo153-8505
Department of Chemical Engineering Japan
TokyoUniversity ofAgriculture
and Technology
2-24-16Naka-cho, Koganei
Tokyo184-8588
Japan
ISSN 2191-530X ISSN 2191-5318 (electronic)
ISBN 978-1-4471-4206-5 ISBN 978-1-4471-4207-2 (eBook)
DOI 10.1007/978-1-4471-4207-2
SpringerLondonHeidelbergNewYorkDordrecht
LibraryofCongressControlNumber:2012938865
(cid:2)TheAuthor(s)2013
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Preface
Refineries that occupy large sites in heavy chemical complexes and the petro-
chemical industry in general, have for long years been utilizing and consuming a
hugeamountoffossilfuelasanenergysource foroperation.‘‘Energysaving’’,in
the way of reduction in the use offossil fuel, has been under active consideration
formanyyearsasthisleadstothestrengtheningofcompetitivenessbysavingcost
inoperation.Moreovertheindustryingeneralfullyrecognizesthatpublicopinion
islessaccepting ofthe combustionoffossilfuelthatresults inthe generation and
release oflarge amounts of the greenhouse gas CO in tothe atmosphere. Energy
2
saving eventually leads to a significant reduction in the emission of greenhouse
gases and is oneof the mostimportant measuresthat can be taken tomitigate the
problem of global warming.
The sites in heavy chemical complexes have two systems in general; the pro-
cess system and the utility system. The history of energy saving in the process
systemshowsthatitspurposewastoimproveandstrengthenheatrecovery.Pinch
technology, a methodology of heat analysis based on thermodynamic principles,
was developed in 1980s and applied for the study of heat recovery. Pinch tech-
nology is used to minimize the energy consumption of chemical processes by
calculating thermodynamically feasible energy targets (or minimum energy con-
sumption)andachievingthembyoptimizingheatrecoverysystems,energysupply
methods and process operating conditions. Over the past 30 years, pinch tech-
nologyhasbeenappliedonthousandsofprocesseswithalargeamountofenergy
savings having been achieved.
However the general consensus in engineers was that almost all possible
methods of heat recovery had already been investigated and that a new break-
throughwasneededtobeanyfurthersignificantimprovementinenergyefficiency.
Thatbreakthroughwasanewapproachinthedevelopmentoftheprocesssystem,
which would replace the conventional system.
Theprocesssystem,inheavychemicalcomplexes,hasareactionsectionanda
distillation section. In these sections, the amount of low-grade heat discarded as
waste heat is about the same amount required to be supplied for the operation of
the process. Conventionally heat recovery is maximized by using pinch
v
vi Preface
Fig.1 Fromtheorytoappli-
cationsaboutself-heat
recuperation
Theory Self-heat
recuperation
Methodology of
Methodology
self-heat recuperation
Self-heat
Applications
recuperation technology
technology,whichmeansthattheamountofheatinputisminimizedandthewaste
heat is reduced. It should be noted that with this methodology the process oper-
ating condition is not changed but maintained as it is.
To achieve further energy saving in the process system, ‘‘self-heat recupera-
tion’’ (SHR) was developed. (see Fig. 1) SHR is able to be applied for both the
reaction section and the distillation section. SHR has a novel approach in that the
processoperatingconditionischangedbyusingacompressor,buttheprocesscore
condition, such as a reactor inlet condition, is still maintained. Self-heat recu-
peration technology (SHRT) was applied to the reaction section of the naphtha
HDS process and the benzene distillation section in the refinery and it was found
thattheadvancedprocess withSHRT wasabletoreducetheenergyconsumption
significantlyforboththereactionsectionandthedistillationsection.SHRTisable
tobeappliednotonlytotheprocesssystemsintheheavychemicalcomplexesbut
also to the other processes which require heating and cooling, such as drying and
gas separation processes. It was found that SHRT was effective to reduce energy
consumption considerably in such processes.
The utility system has also been targeted to become more efficient in energy
saving. Major items of equipment, such as boilers and turbines, are considered to
have reached the limit for further improvement in efficiency and therefore the
utility system must be optimized. However, when looking at heavy chemical
complexes, it appeared that a refinery would discharge low-grade heat as waste
heat whereas, at same time, an adjacent petrochemical plant could make use of
such heat. There could, therefore, be a large energy saving potential by utilizing
the surplus heat across the sites. The total site approach, based on pinch
Preface vii
technology,wasappliedtotheheavychemicalcomplexesanditbecameapparent
that there was a huge amount of energy saving potential through energy sharing
among various sites in the complexes, despite the very high efficiency of the
individual sites in the complex.
Tokyo, Japan Kazuo Matsuda
Atsushi Tsutsumi
Contents
Part I Process System
1 Energy Saving Technology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Yasuki Kansha
1.1 Pinch Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Self-Heat Recuperation Technology. . . . . . . . . . . . . . . . . . . . . 5
1.2.1 Process Design Methodology . . . . . . . . . . . . . . . . . . . . 6
1.2.2 Design Methodology for Separation Process. . . . . . . . . . 10
1.2.3 Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Part II Application of Self-Heat Recuperation Technology
2 Reaction Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Kazuo Matsuda
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Process Flow Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3 Applying Self-Heat Recuperation Technology. . . . . . . . . . . . . . 18
2.4 Prospect of Applying Self-Heat Recuperation Technology . . . . . 19
2.5 Mass and Heat Balance Calculation. . . . . . . . . . . . . . . . . . . . . 20
2.5.1 Conventional Case . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5.2 Proposed Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.6 Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.7 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
ix
x Contents
3 Distillation Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Kazuo Matsuda and Yasuki Kansha
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.2 Process Flow Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.3 Study Basis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.4 Applying Self-Heat Recuperation Technology. . . . . . . . . . . . . . 29
3.5 Prospect of Applying Self-Heat Recuperation Technology . . . . . 29
3.6 Mass and Heat Balance Calculation. . . . . . . . . . . . . . . . . . . . . 31
3.6.1 Conventional Case . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.6.2 Proposed Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.7 Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.8 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4 Drying Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Chihiro Fushimi
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.2 Basic Concept of Drying Based on Self-Heat
Recuperation Technology. . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.3 Drying Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.4 Mass and Heat Balance Calculation of the Proposed
Drying Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.5 Primary Energy Consumption and CO Emission . . . . . . . . . . . 45
2
4.6 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5 Gas Separation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Akira Kishimoto
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.2 Cryogenic Air Separation (Distillation) . . . . . . . . . . . . . . . . . . 50
5.2.1 Conventional Cryogenic Air Separation Process. . . . . . . 50
5.2.2 Proposed Cryogenic Air Separation Process. . . . . . . . . . 51
5.2.3 Mass and Heat Balance Calculation . . . . . . . . . . . . . . . 52
5.3 CO Absorption Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2
5.3.1 Conventional CO Absorption Process. . . . . . . . . . . . . . 55
2
5.3.2 Proposed CO Absorption Process. . . . . . . . . . . . . . . . . 56
2
5.3.3 Mass and Heat Balance Calculation . . . . . . . . . . . . . . . 57
5.4 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Contents xi
Part III Utility System
6 Utility System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Kazuo Matsuda
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.2 Area-Wide Pinch Technology. . . . . . . . . . . . . . . . . . . . . . . . . 64
6.2.1 Total Site Profile Analysis. . . . . . . . . . . . . . . . . . . . . . 64
6.2.2 R-curve Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.2.3 Work Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.3 Application of Area-Wide Pinch Technology . . . . . . . . . . . . . . 67
6.3.1 Mizushima and Chiba Industrial Areas . . . . . . . . . . . . . 68
6.3.2 Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.4 Area-Wide Integration Projects for Energy Saving. . . . . . . . . . . 70
6.4.1 Energy Sharing System . . . . . . . . . . . . . . . . . . . . . . . . 70
6.4.2 Heat Sharing System. . . . . . . . . . . . . . . . . . . . . . . . . . 72
6.4.3 Low Heat Power Generation System. . . . . . . . . . . . . . . 72
6.5 Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75