Energy and Process Optimization for the Process Industries

by Zhu, Frank (Xin X.)

• ISBN13: 9781118101162
• ISBN10: 1118101162
• Edition: 1st
• Format: Hardcover
• Copyright: 2013-12-16
• Publisher: Wiley-AIChE

Summary

Exploring methods and techniques to optimize processing energy efficiency in process plants, Energy and Process Optimization for the Process Industries provides a holistic approach that considers optimizing process conditions, changing process flowschemes, modifying equipment internals, and upgrading process technology that has already been used in a process plant with success. Field tested by numerous operating plants, the book describes technical solutions to reduce energy consumption leading to significant returns on capital and includes an 8-point Guidelines for Success. The book provides managers, chemical and mechanical engineers, and plant operators with methods and tools for continuous energy and process improvements.

Author Biography

FRANK (Xin X.) ZHU is a Senior Fellow at UOP LLC, where he has led innovation efforts to optimize industrial process design and operation to achieve higher energy efficiency and lower capital cost. Before joining UOP, Dr. Zhu served as a research professor at the Centre for Process Integration at the University of Manchester in the UK. He is also a former editor-in-chief of CACS Communications, the magazine of the Chinese-American Chemical Society.

Table of Contents

Dedications

Preface

Part 1: Basic concepts and theory

Chapter 1: Overview of this book

1.1 Introduction

1.2 Who is the book written for

1.3 Five ways to improve energy efficiency

1.4 Four key elements for continuous improvements

1.5 Promoting improvement ideas in the organization

Chapter 2: Theory of Energy Intensity

2.1 Introduction

2.2 Definition of energy intensity for a process

2.3 The concept of fuel equivalent for steam and power

2.4 Energy intensity for a total site

2.5 Concluding remarks

2.6 Nomenclature

2.7 References

Chapter 3: Energy benchmarking

3.1 Introduction

3.2 Data extraction from historian

3.3 Convert all energy usage to fuel equivalent

3.4 Energy balance

3.5 Fuel equivalent for steam and power

3.6 Energy performance index method for energy benchmarking

3.7 Concluding remarks

3.8 Nomenclature

3.9 References

Chapter 4: Key indicators and targets

4.1 Introduction

4.2 Key indicators represent operation opportunities

4.3 Define key indicators

4.4 Set up targets for key indicators

4.5 Economic evaluation for key indicators

4.6 Application 1: Implementing key indicators into an “Energy Dashboard”

4.7 Application 2: Implementing key indicators to controllers

4.8 It is worth the effort

4.9 Nomenclature

4.10 References

Part 2: Energy system assessment methods

Chapter 5: Fired heater assessment

5.1 Introduction

5.2 Fired heater design for high reliability

5.3 Fired heater operation for high reliability

5.4 Efficient fired heater operation

5.5 Fired heater revamp

5.6 Nomenclature

5.7 References

Chapter 6: Heat exchanger performance assessment

6.1 Introduction

6.2 Basic concepts and calculations

6.3 Understand Performance criterion – U values

6.4 Understand pressure drop

6.5 Heat exchanger rating assessment

6.6 Improving heat exchanger performance

6.7 Appendix: TEMA Types of Heat Exchangers

6.8 Nomenclature

6.9 References

Chapter 7: Heat exchanger fouling assessment

7.1 Introduction

7.2 Fouling mechanisms

7.3 Fouling mitigation

7.4 Fouling mitigation for crude preheat in oil refining

7.5 Fouling resistance calculations

7.6 A cost-based model for clean cycle optimization

7.7 Revised cost-based model for clean cycle optimization

7.8 A practical method for clean cycle optimization

7.9 Putting all together – A practical example of fouling mitigation

7.10 Nomenclature

7.11 References

Chapter 8: Energy loss assessment

8.1 Introduction

8.2 Energy loss audit

8.3 Energy loss audit results

8.4 Energy loss evaluation

8.5 Brainstorming

8.6 Energy audit report

8.7 Nomenclature

8.8 References

Chapter 9: Process heat recovery opportunity assessment

9.1 Introduction

9.2 Data extraction

9.3 Composite curves

9.4 Basic concepts

9.5 Energy targeting

9.6 Pinch golden rules

9.7 Cost targeting: determine optimal ΔT_min

9.8 Case study

9.9 Be aware of sub-optimal

9.10 Integrated cost targeting and process design

9.11 Challenges for applying the systematic design approach

9.12 Nomenclature

9.13 References

Chapter 10: Heat recovery modification assessment

10.1 Introduction

10.2 Network pinch – the bottleneck of existing heat recovery system

10.3 Identification of modifications

10.4 Automated network pinch retrofit approach

10.5 Case studies for applying the network pinch approach

10.6 References

Chapter 11: Process integration opportunity assessment

11.1 Introduction

11.2 Definition of process integration

11.3 Plus and minus (+/-) principle

11.4 Grand composite curves

11.5 Appropriate placement principle for process changes

11.6 Examples of process changes

11.7 References

Part 3: Process system assessment and optimization

Chapter 12: Distillation operating window

12.1 Introduction

12.2 What is distillation

12.3 Distillation efficiency

12.4 Definition of feasible operating window

12.5 Understanding operating window

12.6 Typical capacity limits

12.7 Effects of design parameters

12.8 Design check list

12.9 Example calculations for developing operating window

12.10 Concluding remarks

12.11 Nomenclature

12.12 References

Chapter 13: Distillation system assessment

13.1 Introduction

13.2 Define a base case

13.3 Calcu7lations for missing and incomplete data

13.4 Building process simulation

13.5 Heat and material balance assessment

13.6 Tower efficiency assessment

13.7 Operating profile assessment

13.8 Tower rating assessment

13.9 Heat integration assessment for column design

13.10 Guidelines for reuse of an existing tower

13.11 Nomenclature

13.12 References

Chapter 14: Distillation system optimization

14.1 Introduction

14.2 Tower optimization basics

14.3 Energy optimization for distillation system

14.4 Overall process optimization

14.5 Concluding remarks

14.6 References

Part 4: Utility system assessment and optimization

Chapter 15: Modeling of steam and power system

15.1 Introduction

15.2 Boiler

15.3 Deaerator

15.4 Steam turbine

15.5 Gas turbine

15.6 Letdown valve

15.7 Steam desuperheater

15.8 Steam flush drum

15.9 Steam trap

15.10 Steam distribution losses

15.11 Nomenclature

15.12 References

Chapter 16: Establishing steam balances

16.1 Introduction

16.2 Guidelines for generating steam balance

16.3 A working example for generating steam balance

16.4 A practical example for generating steam balance

16.5 Verify steam balance

16.6 Concluding remarks

16.7 Nomenclature

16.8 References

Chapter 17: Determining steam pricing

17.1 Introduction

17.2 The cost of steam generation from boiler

17.3 Enthalpy-based steam pricing

17.4 Work-based steam pricing

17.5 Fuel equivalent-based steam pricing

17.6 Cost-based steam pricing

17.7 Comparison of different steam pricing methods

17.8 Marginal steam pricing

17.9 Effects of condensate recovery on steam cost

17.10 Concluding remarks

17.11 Nomenclature

17.12 References

Chapter 18: Benchmarking steam and power system

18.1 Introduction

18.2 Benchmark steam cost – minimize generation cost

18.3 Benchmark steam and condensate losses

18.4 Benchmark process steam usage and energy cost allocation

18.5 Benchmark steam system operation

18.6 Benchmark steam system efficiency

18.7 Nomenclature

18.8 References

Chapter 19: Steam and power management and optimization

19.1 Introduction

19.2 Optimizing steam header pressure

19.3 Optimizing steam equipment loadings

19.4 Optimizing onsite power generation versus import

19.5 Minimizing steam letdowns and venting

19.6 Optimizing steam system configuration

19.7 Developing steam system optimization model

19.8 Nomenclature

19.9 References

Part 5: Retrofit project evaluation and implementation

Chapter 20: Determine true benefits from OSBL

20.1 Introduction

20.2 Energy improvement options under evaluation

20.3 A method for evaluating energy improvement options in OSBL

20.4 Feasibility assessment and make decision for implementation

Chapter 21: Determine true benefits from operation variations

21.1 Introduction

21.2 Collect online data for the whole operation cycle

21.3 Normal distribution and Monte Carlo simulation

21.4 Basic statistic summary for normal distribution

21.5 Nomenclature

21.6 References

Chapter 22: Feasibility Assessment

22.1 Introduction

22.2 Scope and stages of feasibility assessment

22.3 Feasibility assessment methodology

22.4 Get the project basis and data right in the very beginning

22.5 Get the project economics right

22.6 Don’t forget OSBL costs

22.7 Squeeze capacity out of design margin

22.8 Identify and relax plant constraints

22.9 Interactions of process conditions, yields ad equipment

22.10 Don’t get misled by false balances

22.11 Prepare for fuel gas long

22.12 Two revamp cases for shifting bottlenecks

22.13 Concluding remarks

22.14 Nomenclature

22.15 References

Chapter 23: Create optimization culture with measurable results

23.1 Introduction

23.2 Site wide energy optimization strategy

23.3 Case study of the site wide energy optimization strategy

23.4 Establishing energy management system

23.5 Energy operation management

23.6 Energy project management

23.7 An overall work process from idea discovery to implementation

23.8 References