DUAL REPRESENTATION OF MINIMUM ENERGY REQUIREMENTS APPLICATIONS TO P&P PROCESSES
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1 Congrès s Annuel ATIP Annecy avril 2005 DUAL REPRESENTATION OF MINIMUM ENERGY REQUIREMENTS APPLICATIONS TO P&P PROCESSES David Brown Zoé Périn-Levasseur François Maréchal Jean Paris EP Montréal EP Montréal EFP Lausanne EP Montréal EFP Lausanne EFP Lausanne ATIP
2 Highlights Minimum energy requirement (MER) Integrated process-energy system Pinch analysis & MER Dual representation Application to P&P operations Heating of a process stream Dilution and heating Paper machine drying section Illustration : Integrated TMP-Newsprint Mill Concluding remarks ATIP
3 Integrated Process-Energy System ATIP
4 Minimum Energy Requirement : Process Side 200 Heat Production, Q Hot 150 Heat Consumption, Q Cold T(oC) 100 Hot Composite Curve Cold Composite Curve MER = Q Hmin Pinch (ΔT min=10 o C) 50 0 Q Cmin =60 Internal Heat Recovery, Q exch Q Hmin = Q (kw) Q Cmin= Q Hot +Q Hmin + Q Cold ATIP
5 Process MER and Grand Composite Curve Shifted Temperatures 200 Hot streams : T f = T i - T min/2 Cold streams : T f = T i + T min/2 T(oC) Q (kw) Table of temperatures Actual ( o C) IN/OUT Shifted ( o C) IN/OUT Cp (kw/ o C) 170/60 165/ /30 145/ /135 25/ /140 85/145 4 ATIP
6 Process MER and Grand Composite Curve Diagram Construction Q (kw) Q Hmin = 20 (kw) 60 T Shifted ( o C) Q Hmin Pincement, ΔTmin = 10 o C Q Cmin = 60 (kw) 20 0 Q Cmin Q (kw) ATIP
7 Dual Representation: Energy Requirement and its Technical Implementations Cold Stream Definition for One Demand Heat Exchanger P 60 o C S 179 o C 110 o C T( o C) Reservoir Heater (CST model) S 179 o C P 60 o C o C T( o C) 110 Q exch Q P: process stream, D: dilution, S: steam Q exch Q MER = Q exch, determined from demand on utility ATIP
8 P&P Application 1 : Dilution and heating Heat Exchanger P D 60 o C 110 o C S 179 o C 5 o C 110 o C T( o C) S 179 o C 5 Q Reservoir Heater (CST model) P 60 o C D 5 o C S 179 o C T( o C) o C Q Steam Injection P D S 60 o C 5 o C 179 o C 110 o C 5 ATIP Q P: process stream, D: dilution, S: steam T( o C) 179
9 Heating by steam injection : The pinch point pitfall Steam should not be used below the pinch point This does not result in any net energy savings The effect is: the more in, the more out ATIP
10 P&P Application 2 : PM Drying section HP steam MP steam LP steam Stream Stream Table P (kpa) T ( C) m (t/h) HP Wet sheet Uncondensed vapor Dried sheet HP cond MP MP cond LP LP cond HP cond. MP cond. LP cond. ATIP
11 PM Drying Section : Process and Utility Representations Process GCC (Thermodynamic demand) Utility GCC (Technological demand) Water evaporation Paper & water heating 9 1 HPS superheating 2 Production of HPS 3 HPS post condensation 4 Exchange between HP water preheating and HP condensate 5 Production of MPS 6 Exchange between HP & MP water preheating and HP condensate 7 Production of LPS 8 MHS and LPS post condensation 9 Condensate reheating ATIP
12 Illustration : Integrated TMP-Newsprint Mill ATIP
13 Thermodynamic MER chip washing & preheating + TMP, DIP & PM whitewater heating Miscellaneous: Soot blowing Saw mill Heating (misc.) Primary Effluent treatment refiners Deaerator Sheet drying Secondary refiners T min = 10 K Pinch point (threshold) at 283 K Process MER = 79 MW Diagram implies maximum heat recovery; HX network to be defined ATIP
14 Technological MER LP steam to drying section HP steam to drying section MP steam to drying section soot blowing Primary refiners T min = 10 K Pinch point at 373 K Process MER = 79 MW Deaerator Chip preheat Chip washing Secondary refiners TMP, DIP & PM whitewater heating Effluent treatment Sawmill Heating (misc.) System integration represented by the two GCCs are different, corresponding heat recovery network will be different ATIP
15 Integrated Process-Energy System Production MER by energy conversion Thermodynamic or technological MER ATIP
16 MER Production by Energy Conversion A Steam flowrates optimized H E G F D F B F G C Multiple pinch points Combined heat and power Minimum fuel consumption A Combustion (fossil/biomass) B Combustion gases recovery C Water preheating D HP steam production E HP steam superheating F Steam utilisation in process G Process GCC H Expansion turbines ATIP
17 Proposed modifications Recuperation of heat from secondary refiner exhaust steam (21% reduction of utility steam) Heat exchangers for whitewater and wood chip heating & use of a condensing extraction turbine, recycle condensate to boilers (10 % reduction of utility steam) Higher outlet pressure of boilers to improve cogeneration of electricity ATIP
18 An overview of process energy enhancement Data extraction Reconciliation Pretreatment Pinch analysis Targeting Violations detection Dual representation Condensates recovery System closure Engineering Optimisation Quantum gains : New technologies ATIP
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