CN4205R Pinch Analysis and Process Integration
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1 CN4205R Pinch Analysis and Process Integration Sachin V JANGAM Department of Chemical and Biomolecular Engineering National University of Singapore Singapore chejsv@nus.edu.sg Office location: E AY
2 Introduction Energy: Use, Recovery, Reuse and Efficiency Heat Exchanger Networks Pinch Analysis Industrial Experience Process Integration Process Data Analysis Syllabus and Schedule Learning Outcomes Books/References Sachin V JANGAM 2
3 Energy: Worldwide usage Coal Oil Electricity (Source: Sachin V JANGAM 3
4 Energy Use: Statistics for Singapore Source: Sachin V JANGAM 4
5 Industry Responsible for CO 2 Emission World's CO 2 emissions by sector in 2013 Source: pdf Sachin V JANGAM 5
6 Energy: Recovery, Reuse and Efficiency Energy Savings Potential for Industrial Sectors (Source: 4-Step Approach o Data Acquisition & Process Simulation o o o Mass & Energy Balance Analysis Application of Process Integration Techniques Techno-economic Evaluation of Selected Projects Sachin V JANGAM 6
7 Energy: Recovery, Reuse and Efficiency Success Stories of Process Integration o o o o o Chemical Food and Drink Pulp and Paper Oil Refining Textile Energy Efficiency in ExxonMobil (Source: o o (Source: Global Energy Management System (GEMS) : Energy Efficiency Improved by 9% in Refining and by 12% in Chemicals Sachin V JANGAM 7
8 Energy: Recovery, Reuse and Efficiency GSK in Singapore Sachin V JANGAM 8
9 Energy: Recovery, Reuse and Efficiency Industry Energy Efficiency (Technology Roadmap) 2030 Technical potential energy savings contribution, by subsector Petroleum refining: 2030 technical potential energy savings o o o Refinery and chemical plant integration Supercritical CO 2 cycle Heat recovery systems and other lowgrade waster heat recovery systems Pinch analysis Source: Sachin V JANGAM 9
10 The process design hyerarchy Reactor Separation/ Recycle System Heat Recovery System Heating & Cooling Utilities Water & Effluent Treatment Onion Diagram Sachin V JANGAM 10
11 Heat Exchanger Networks Chemical Process/Plant Heat Exchanger Network Steam (Hot Utility) = = 1722 kw Cooling Water (Cold Utility) = 654 kw Number of Units = 6 Sachin V JANGAM 11
12 Heat Exchanger Networks Pinch Analysis HEN Design with Targets Steam = 1068 kw Cooling Water = 0 kw Number of Units = 4 Reduction: Steam = = 654 kw CW = 654 kw Units = 2 Sachin V JANGAM 12
13 Heat Exchanger Networks Industrial Experience ICI, UK Crude Preheat Train (Section 9.2, Kemp) Bulk Chemical Plants to Specialty Units Energy Savings of ~ 30% Union Carbide, USA Better Results than ICI BASF, Germany Over 150 Projects Energy Savings of > 25% from Retrofitting Sachin V JANGAM 13
14 Heat Exchanger Networks Why Does Pinch Analysis Work? Conventional Approach Problem and Solution/Design Role of Thermodynamics Approach in Pinch Analysis Problem, Targets and Solution/Design Sachin V JANGAM 14
15 Heat Exchanger Networks Cost Considerations Capital Cost (CC) for Units Exchangers, Heaters, Coolers Operating Cost (OC) Utilities/Energy Pumping Cost CC and OC are often conflicting Pinch analysis may reduce both CC and OC Sachin V JANGAM 15
16 Process Integration Deals mainly with optimal use of Heat Utilities Also, considers environmental protection, control and safety aspects The approach consists of developing alternatives to arrive at cost-effective and sustainable solutions Sachin V JANGAM 16
17 Process Integration Heat and Power Systems Interaction of heating and cooling utilities with power requirements Combined heat and power (CHP) systems Heat pump and refrigeration systems Steam systems and cogeneration Total site analysis - Optimizing the heating, cooling and power requirements of entire plant Sachin V JANGAM 17
18 Process Integration Process Modifications for Energy Efficiency Distillation column Distillation sequencing heat integration characteristics Heat pumping in distillation Evaporators and Dryers Sachin V JANGAM 18
19 Process Integration Wastewater minimization Water use in process industries Targeting and design for maximum water reuse for single contaminants Process changes to reduce water consumption Sachin V JANGAM 19
20 Process Data Analysis Process Measurements Measured process data Inevitably contain some inaccurate information Observed value of measured variable is composed of true value and some error value (random or gross error) Leads to significant deterioration of plant performance Important to estimate true condition of process state using measurements, for process control and optimization Sachin V JANGAM 20
21 Process Data Analysis Data Reconciliation (DR) Estimation of process variables based on process measurements and models (usually mass and energy conservation equations) Sachin V JANGAM 21
22 Process Data Analysis Gross Error Detection Companion technique to data reconciliation, to identify and eliminate gross errors DR is based on the assumption that only random errors are present. When gross error is present, gross error detection techniques are used to improve accuracy of reconciled data Makes use of a statistical test known as measurement test Industrial applications Sachin V JANGAM 22
23 Syllabus Overview (1 hour) Pinch Analysis (12 hours) Basic Concepts of Pinch Analysis (Data Extraction, Energy Targeting, Supertargeting), and Heat Exchanger Network Design (Basic Principles, Stream Splitting, Network Relaxation, Retrofit Design) Process Integration (16 hours) Heat Integration Issues for Utilities, Heat and Power Systems (Combined Heat and Power, Heat Pumps, Refrigeration Systems, Total Site Analysis), Process Modifications for Energy Efficiency (applied to Distillation Columns), Wastewater Minimization, Project Presentations Process Data Analysis (10 hours) Data Reconciliation, Gross Error Detection and Identification, Multiple Gross Errors, Industrial Applications Sachin V JANGAM 23
24 Schedule Lectures and Tutorials indicated in the following table will be held in E (Wed). Each of the many sessions includes tutorial for about one hour. The details of changes (if any) will be discussed in the class and communicated through IVLE Sachin V JANGAM 24
25 Tentative Schedule No. Date Topic 1 TBA Overview, Pinch Analysis (Basic Concepts) 2 TBA Pinch Analysis (Basic Concepts) 3 TBA Pinch Analysis (Heat Exchanger Network Design) 4 TBA Pinch Analysis (Heat Exchanger Network Design) 5 TBA Lecture on Process Integration (Heat Integration Issues for Utilities) 6 TBA Test 1 on Pinch Analysis; Process Integration (Heat and Power Systems) 7 TBA Process Integration (Process Modifications for Energy Efficiency) 8 TBA Process Integration (Process Modifications for Energy Efficiency; Wastewater Minimization) 9 TBA Process Integration (Wastewater Minimization), Process Data Analysis (Data Reconciliation) 10 TBA Lecture on Process Data Analysis (Data Reconciliation, Gross Error Detection and Identification) 11 TBA Test 2 on Process Integration; Process Data Analysis (Gross Error Detection and Identification) 12 TBA Process Data Analysis (Multiple Gross Errors, Industrial Applications); Project Presentations 13 TBA Test 3 on Process Data Analysis; Project Presentations Sachin V JANGAM 25
26 Learning Outcomes On successful completion of this module, students will be able to: 1. Extract stream data, and find targets for heat exchanger network synthesis 2. Design and evolve heat exchanger networks 3. Reduce utility loads in chemical process industries by using energy recovery techniques 4. Analyse opportunities for altering process operating conditions for cost savings by maximizing heat integration 5. Reconcile, detect and identify gross errors in industrial/ measured data 6. Work on a group project to improve energy efficiency of a chemical process using the concepts taught in this module, and communicate the work Sachin V JANGAM 26
27 Assessment CA 100% (No Final Examination) Test 1 on Pinch Analysis: 22% Test 2 on Process Integration: 28% Test 3 on Process Data Analysis: 15% Project (Reports and Presentation): 35% May require minimum use of HYSYS, only in the later part of the project (towards the end of semester) Sachin V JANGAM 27
28 Books/References 1. Pinch Analysis and Process Integration: A User Guide on Process Integration for Efficient Use of Energy, I.C. Kemp, 2 nd Edition, Butterworth-Heinemann (2007) 2. Chemical Process Design and Integration, R. Smith, John Wiley (2005) 3. Narasimhan S. and Jordache C., Data Reconciliation and Gross Error Detection: An Intelligent Use of Process Data, Gulf Publishing (1999). Sachin V JANGAM 28
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