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More About This Title Energy and Process Optimization for the Process Industries
English
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.
English
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.
He is the recipient of the 2014 AIChE Energy and Sustainability Award.
English
PREFACE xv
PART 1 BASIC CONCEPTS AND THEORY 1
1 Overview of this Book 3
1.1 Introduction, 3
1.2 Who is this Book Written for?, 4
1.3 Five Ways to Improve Energy Efficiency, 5
1.4 Four Key Elements for Continuous Improvement, 7
1.5 Promoting Improvement Ideas in the Organization, 8
2 Theory of Energy Intensity 9
2.1 Introduction, 9
2.2 Definition of Process Energy Intensity, 10
2.3 The Concept of Fuel Equivalent (FE), 11
2.4 Energy Intensity for a Total Site, 13
2.5 Concluding Remarks, 15
3 Benchmarking Energy Intensity 16
3.1 Introduction, 16
3.2 Data Extraction from Historian, 17
3.3 Convert All Energy Usage to Fuel Equivalent, 17
3.4 Energy Balance, 21
3.5 Fuel Equivalent for Steam and Power, 23
3.6 Energy Performance Index (EPI) Method, 29
3.7 Concluding Remarks, 32
4 Key Indicators and Targets 35
4.1 Introduction, 35
4.2 Key Indicators Represent Operation Opportunities, 36
4.3 Define Key Indicators, 39
4.4 Set up Targets for Key Indicators, 45
4.5 Economic Evaluation for Key Indicators, 49
4.6 Application 1: Implementing Key Indicators into an "Energy Dashboard," 53
4.7 Application 2: Implementing Key Indicators to Controllers, 56
4.8 It is Worth the Effort, 57
PART 2 ENERGY SYSTEM ASSESSMENT METHODS 59
5 Fired Heater Assessment 61
5.1 Introduction, 61
5.2 Fired Heater Design for High Reliability, 62
5.3 Fired Heater Operation for High Reliability, 68
5.4 Efficient Fired Heater Operation, 73
5.5 Fired Heater Revamp, 80
6 Heat Exchanger Performance Assessment 82
6.1 Introduction, 82
6.2 Basic Concepts and Calculations, 83
6.3 Understand Performance Criterion—U Values, 89
6.4 Understanding Pressure Drop, 94
6.5 Heat Exchanger Rating Assessment, 96
6.6 Improving Heat Exchanger Performance, 106
7 Heat Exchanger Fouling Assessment 112
7.1 Introduction, 112
7.2 Fouling Mechanisms, 113
7.3 Fouling Mitigation, 114
7.4 Fouling Mitigation for Crude Preheat Train, 117
7.5 Fouling Resistance Calculations, 119
7.6 A Cost-Based Model for Clean Cycle Optimization, 121
7.7 Revised Model for Clean Cycle Optimization, 125
7.8 A Practical Method for Clean Cycle Optimization, 128
7.9 Putting All Together—A Practical Example of Fouling Mitigation, 130
8 Energy Loss Assessment 138
8.1 Introduction, 138
8.2 Energy Loss Audit, 139
8.3 Energy Loss Audit Results, 147
8.4 Energy Loss Evaluation, 149
8.5 Brainstorming, 150
8.6 Energy Audit Report, 152
9 Process Heat Recovery Targeting Assessment 154
9.1 Introduction, 154
9.2 Data Extraction, 155
9.3 Composite Curves, 156
9.4 Basic Concepts, 159
9.5 Energy Targeting, 160
9.6 Pinch Golden Rules, 160
9.7 Cost Targeting: Determine Optimal DTmin, 162
9.8 Case Study, 165
9.9 Avoid Suboptimal Solutions, 169
9.10 Integrated Cost Targeting and Process Design, 171
9.11 Challenges for Applying the Systematic Design Approach, 172
10 Process Heat Recovery Modification Assessment 175
10.1 Introduction, 175
10.2 Network Pinch—The Bottleneck of Existing Heat Recovery System, 176
10.3 Identification of Modifications, 179
10.4 Automated Network Pinch Retrofit Approach, 181
10.5 Case Studies for Applying the Network Pinch Retrofit Approach, 183
11 Process Integration Opportunity Assessment 195
11.1 Introduction, 195
11.2 Definition of Process Integration, 196
11.3 Plus and Minus (+/-) Principle, 198
11.4 Grand Composite Curves, 199
11.5 Appropriate Placement Principle for Process Changes, 200
11.6 Examples of Process Changes, 205
PART 3 PROCESS SYSTEM ASSESSMENT AND OPTIMIZATION 225
12 Distillation Operating Window 227
12.1 Introduction, 227
12.2 What is Distillation?, 228
12.3 Distillation Efficiency, 229
12.4 Definition of Feasible Operating Window, 232
12.5 Understanding Operating Window, 232
12.6 Typical Capacity Limits, 253
12.7 Effects of Design Parameters, 255
12.8 Design Checklist, 257
12.9 Example Calculations for Developing Operating Window, 257
12.10 Concluding Remarks, 276
13 Distillation System Assessment 281
13.1 Introduction, 281
13.2 Define a Base Case, 281
13.3 Calculations for Missing and Incomplete Data, 284
13.4 Building Process Simulation, 287
13.5 Heat and Material Balance Assessment, 288
13.6 Tower Efficiency Assessment, 292
13.7 Operating Profile Assessment, 295
13.8 Tower Rating Assessment, 298
13.9 Column Heat Integration Assessment, 300
13.10 Guidelines for Reuse of an Existing Tower, 302
14 Distillation System Optimization 305
14.1 Introduction, 305
14.2 Tower Optimization Basics, 306
14.3 Energy Optimization for Distillation System, 312
14.4 Overall Process Optimization, 318
14.5 Concluding Remarks, 326
PART 4 UTILITY SYSTEM ASSESSMENT AND OPTIMIZATION 327
15 Modeling of Steam and Power System 329
15.1 Introduction, 329
15.2 Boiler, 330
15.3 Deaerator, 333
15.4 Steam Turbine, 334
15.5 Gas Turbine, 338
15.6 Letdown Valve, 339
15.7 Steam Desuperheater, 341
15.8 Steam Flash Drum, 342
15.9 Steam Trap, 342
15.10 Steam Distribution Losses, 344
16 Establishing Steam Balances 345
16.1 Introduction, 345
16.2 Guidelines for Generating Steam Balance, 346
16.3 AWorking Example for Generating Steam Balance, 347
16.4 A Practical Example for Generating Steam Balance, 357
16.5 Verify Steam Balance, 362
16.6 Concluding Remarks, 364
17 Determining True Steam Prices 366
17.1 Introduction, 366
17.2 The Cost of Steam Generation from Boiler, 367
17.3 Enthalpy-Based Steam Pricing, 371
17.4 Work-Based Steam Pricing, 372
17.5 Fuel Equivalent-Based Steam Pricing, 373
17.6 Cost-Based Steam Pricing, 376
17.7 Comparison of Different Steam Pricing Methods, 377
17.8 Marginal Steam Pricing, 379
17.9 Effects of Condensate Recovery on Steam Cost, 384
17.10 Concluding Remarks, 384
18 Benchmarking Steam System Performance 386
18.1 Introduction, 386
18.2 Benchmark Steam Cost: Minimize Generation Cost, 387
18.3 Benchmark Steam and Condensate Losses, 389
18.4 Benchmark Process Steam Usage and Energy Cost Allocation, 394
18.5 Benchmarking Steam System Operation, 396
18.6 Benchmarking Steam System Efficiency, 397
19 Steam and Power Optimization 403
19.1 Introduction, 403
19.2 Optimizing Steam Header Pressure, 404
19.3 Optimizing Steam Equipment Loadings, 405
19.4 Optimizing On-Site Power Generation Versus Power Import, 407
19.5 Minimizing Steam Letdowns and Venting, 412
19.6 Optimizing Steam System Configuration, 413
19.7 Developing Steam System Optimization Model, 417
PART 5 RETROFIT PROJECT EVALUATION AND IMPLEMENTATION 423
20 Determine the True Benefit from the OSBL Context 425
20.1 Introduction, 425
20.2 Energy Improvement Options Under Evaluation, 426
20.3 A Method for Evaluating Energy Improvement Options, 429
20.4 Feasibility Assessment and Make Decisions for Implementation, 442
21 Determine the True Benefit from Process Variations 447
21.1 Introduction, 447
21.2 Collect Online Data for the Whole Operation Cycle, 448
21.3 Normal Distribution and Monte Carlo Simulation, 449
21.4 Basic Statistics Summary for Normal Distribution, 456
22 Revamp Feasibility Assessment 459
22.1 Introduction, 459
22.2 Scope and Stages of Feasibility Assessment, 460
22.3 Feasibility Assessment Methodology, 462
22.4 Get the Project Basis and Data Right in the Very Beginning, 465
22.5 Get Project Economics Right, 466
22.6 Do Not Forget OSBL Costs, 470
22.7 Squeeze Capacity Out of Design Margin, 471
22.8 Identify and Relax Plant Constraints, 472
22.9 Interactions Between Process Conditions, Yields, and Equipment, 473
22.10 Do Not Get Misled by False Balances, 474
22.11 Prepare for Fuel Gas Long, 475
22.12 Two Retrofit Cases for Shifting Bottlenecks, 477
22.13 Concluding Remarks, 480
23 Create an Optimization Culture with Measurable Results 481
23.1 Introduction, 481
23.2 Site-Wide Energy Optimization Strategy, 482
23.3 Case Study of the Site-Wide Energy Optimization Strategy, 487
23.4 Establishing Energy Management System, 492
23.5 Energy Operation Management, 496
23.6 Energy Project Management, 499
23.7 An Overall Work Process from Idea Discovery to Implementation, 500
References, 502
INDEX 503
