11 Chapter3 Section3 Chemical Industry Page137 192

Section 3 Chemical Industry Process Flow 3-1 Ammonia 3-2 Caustic Soda 3-3 Naphtha Cracking 3-4 BTX
137
Chemical (Ammonia) : Production Process and Energy Saving Technology
Grassification (reforming) process
CO conversion process
Gas refining process
Synthesis process
Item No.
Technology Item/Title
Item No.
Item No. Technology Item/Title
Item No.
CA-PE-2 Heat exchanger type primary reformer for waste heat recovery in ammonia production process CA-ME-4 Installation of pre-reformer in ammonia reforming process CA-ME-5 Primary reformer waste heat recovery unit for ammonia plant
CA-PE-5 Isothermal CO converter for ammonia production CA-OM-1 Humidification process prior to primary reforming in ammonia production process
CA-PE-6 CO oxidizer in ammonia production process CA-ME-3 High pressure water power recovery turbine in ammonia production process CA-OM-3 Ammonia production process: Carbonate removal process
CS-PE-3 Ion exchange membrane NaCl electrolysis bath for caustic soda production CA-ME-4 Installation of pre-reformer in ammonia reforming process CA-ME-1 Waste heat recovery unit for synthesis gas compressor exit gas in ammonia production process CA-ME-2 Membrane separation hydrogen recovery unit in ammonia production process CS-ME-2 Improvement of active cathode for ion exchange membrane electrolysis for caustic soda production
Item No.
CS-OM-2 Reduction of electrolytic power for NaCl electrolysis bath in caustic soda production process
138 -139
Chemical (Caustic soda) : Production Process and Energy Saving Technology
Caustic soda production process
Item No. CS-PE-3 CS-PE-2 CS-ME-1 CS-ME-2 CS-OM-1
Technology Item/Title Ion exchange membrane NaCl electrolysis bath for caustic soda production Energy saving ion exchange membrane electrolysis bath for caustic soda production Brine preheater using recovered heat of NaCl electrolysis in caustic soda production process Improvement of active cathode for ion exchange membrane electrolysis for caustic soda production Caustic soda production process: Switching from diaphragm electrolytic process to ion exchange membrane electrolytic process Reduction of electrolytic power for NaCl electrolysis bath in caustic soda production process
Item No. CS-PE-1
Technology Item/Title Quadruple-effect concentration for diaphragm-type electrolytic caustic soda production
CS-OM-2
140 -141
Chemical (Naptha Cracking) : Production Process and Energy Saving Technology
Naptha cracking production process
Item No.
CN-ME-1 Switching quenching tower trays to packing in naphtha cracking process CN-ME-2 Installation of turbo-expander in top gas line of demethanizing column in naphtha cracking process CN-ME-3 Cold heat recovery from demethanizing column bottom liquid in naphtha cracking process CN-ME-4 Combustion air preheating for boilers using cooling tower bottom hot water in naphtha cracking process CN-ME-5 Hot water heating by distillation column top vapor CN-OM-1 Control of excess air ratio at cracking furnace in naphtha cracking process CN-OM-2 Change of feed step for depropanizing column in naphtha cracking process CN-OM-3 Pressure control of ethylene rectification column by suction pressure of propylene refrigerator in naphtha cracking process CN-OM-4 Naphtha cracking process: Energy saving in ethylene cracker
142 - 143
Chemical(BTX) : Production Process and Energy Saving Technology
Item No.
CB-ME-1 Recovery of top vapor heat of ortho-xylene separation column in aromatics production process CB-ME-2 Waste heat recovery from heating furnace flue gas in BTX production CB-ME-3 Steam turbine power generation using waste heat of distillation column top vapor in BTX production process CB-OM-1 Change of washing system in amine desulfurization process for BTX production CB-OM-2 Reboiler heating by waste heat of top vapor of distillation column in BTX production process CB-OM-4 Control of reflux ratio of distillation column using on-line analyzer
144 -145
Data Sheets 3-1 Ammonia 3-2 Caustic Soda 3-3 Naphtha Cracking 3-4 BTX 3-5 General
146
CA-PE-1
[Industry Classification] Chemical : Ammonia [Technology Classification] Production Equipment Outline
Energy Conservation Directory

[Energy Source] Fuel (general) Steam
Multi-effect evaporator
[Practical Use] After 1960
An evaporator used for vaporizing aqueous solution containing nonvolatile substances in a chemical plant. 1. The saturation temperature of generated vapor is lower than the boiling point of the solution, corresponding to the boiling point rise. 2. In the next evaporator in which the pressure is further reduced, the boiling point of the solution is lower than the saturation temperature of the vapor generated in the preceding stage. 3. The vapor generated in the preceding stage is used as the heat source of the next evaporator with reduced pressure. Vaporizers in which pressure is reduced from the preceding stage are installed in a train to use the vapor generated in preceding stage. This type of facility is called a multi-effect evaporator. 1. For a multi-effect evaporator with n-stage, the consumption of heating steam is theoretically 1/n times. 2. If the number of stages is increased at aspecific temperature difference, the temperature difference per stage becomes small, thus the heat transfer area increases. 3. Accordingly, the number of stages less than 6 is generally adopted, taking into account of the investment and operating cost. 4. Figure shows a multi-effect (2-stage) distillation flow scheme.
Principle & Mechanism
[Description]
Structure explanation, Shape, and/or System diagram
Improved section
Fig. 1 Liquid supplying method example of multi-effect evaporator
The steam consumption becomes 0.7 to 0.8 times the steam consumption of a single stage evaporator divided by the number of stages. That is, the general formula given below determines the steam consumption. Energy saving effects Q = Qs/kn where, Q : steam consumption for a n-stage evaporator Qs : steam consumption for a single stage evaporator n : number of stages k : effectivity factor (normally 0.7 to 0.8)
[Economics] Equipment cost Remarks [Example sites]
Investment amount: 130 million yen Improvement effect: 40 million yen/year Investment payback: 3.2 years Production of nonvolatile products such as NaCl and NaOH. Production of concentrated fruit juice. Concentration and solidification of nonvolatile matters in waste liquid. Desalination of sea water. [References] [Inquiry] Energy Conversion Forum, "Energy Utilization Japan Chemical Industry Association / Engineering," P190, Ohm Sha, 1980. ECCJ (JIEC)
147
CA-PE-2
[Industry Classification] Chemical : Ammonia [Technology Classification] Production Equipment Outline Principle & Mechanism

Heat exchanger type primary reformer for waste heat recovery in ammonia production process
[Energy Source] Fuel (natural gas) [Practical Use] 1990s -
By using the reactor in the reforming process of an ammonia plant, the high-temperature process waste heat at the exit of the secondary reformer is utilized as the reaction heat for the endothermic reaction in the primary reforming process to achieve energy saving. 1) Process waste heat of about 1,000C at the exit of the secondary reformer is utilized as the reaction heat (endothermic reaction) in the primary reformer. 2) The principle is to use the primary reformer as a heat-exchanger-type reactor. The heat transfer tubes are filled with Ni-based catalyst. The exit gas of the secondary reformer flows through the shell side, and works as heating fluid. [Structure of heat-exchanger-type reactor] (Refer to Fig. 1) 1) The primary reformer is used as a heat-exchanger-type reactor. The heat transfer tubes are filled with Ni-based catalyst, and the exit gas of the secondary reformer flows through the shell side as heating fluid. 2) The catalyst tubes are of a double-tube type, where inner tubes are inserted into outer tubes. The mixture of preheated feed natural gas and steam flows through an annular space filled with catalyst between the outer tube and the inner tube. 3) The mixture flows downward through the catalyst bed while being reacted, then turns upward inside of the inner tube to enter the secondary reformer. 4) Each outer tube is surrounded by a sheath tube, and the hot gas from the secondary reformer flows through the annular space between these tubes.
[Description]
Structure explanation, Shape, and/or [Improved process flow] (Refer to Fig. 2) System diagram
Fig. 1. Heat-exchanger-type primary reformer
Improved section
Fig. 2 Improved reforming process flow of ammonia plant Table 1 Energy saving effect by heat-exchanger-type primary reformer (production capacity: 2,000 t/D)
Energy saving effects
Improvement effect Reduction in specific energy consumption Reduction in energy consumption Reduction in crude oil equivalent 0.15 x 106 kcal/NG3-t 10,102 x 103 m3/y 10,708 kL/y
Remark Accounting for about 10% of the fuel supplied to the primary reformer Operation days 330 d/y
[Economics] Equipment cost Remarks
Investment amount: 200 million yen Improvement effect: 200 million yen/year Investment payback: 1 year
[Example sites] Adopted at many sites.
[References] [Inquiry] Makers in-house technical documents Japan Chemical Industry Association / Chemical Process p. 50, 51, Tokyo Kagaku ECCJ (JIEC) Dojin
148
CA-PE-3

Ammonia plant High conversion synthesis reactor
[Energy Source] Fuel (natural gas) [Practical Use] 1970s ~
The facility is an energy saving type reactor which is placed between the reactors of synthesis process of ammonia plant and which effectively recovers the heat of exit gas while controlling the reaction heat to maintain the reaction temperature at an adequate level through the heat exchange with the reactor inlet gas. 1) There are two methods for removing reaction heat in the ammonia synthesis reactor: the indirect cooling method that employs a heat exchanger having the structure that is applied in this case; and the quenching method which uses unreacted synthesis gas directly for cooling. 2) Conventionally-applied quenching method has a simple structure facility. The method has, however, disadvantages that the ammonia concentration which was increased by the synthesis reaction is diluted by the cooling gas and that the temperature at exit of the reactor is lowered. 3) Owing to the drawbacks, recent ammonia synthesis plants have adopted a new synthesis reactor of indirect cooling method. [Features of the high conversion synthesis reactor (indirect cooling reactor)] 1) The method uses the inlet gas of the reactor to cool the hot exit gas at each catalyst bed through a heat exchanger. Thus, the disadvantages of cool gas quenching method are solved. 2) The indirect cooling reactor gives the exit gas temperatures of the reactor from about 300C to 450 - 500C, which temperature allows effective use of the reaction heat to generate high pressure steam and superheated steam. The method achieves energy saving of about 0.14 x 106 kcal/t-NH3 of unit requirement compared with that of conventional quenching method. 3) Fig. 1 shows an example of indirect cooling high conversion synthesis reactor.
[Description]
Improved section
Fig. 1 Schematic drawing of cross section of indirect cooling high conversion synthesis reactor Table 1 Improvement in unit requirement of high conversion synthesis reactor (production rate of 300,000 t/y)

Heat recovered to steam Reduction of energy (crude oil basis)
Reduction in unit requirement after the improvement 0.14 x 106 kcal/t-NH3
Effect of improvement
5,708 kL/y
Investment amount: 150 million yen Improvement effect: 100 million yen/year Investment payback: 1.5 years
[References] Makers in-house technical documents
[Inquiry] Japan Chemical Industry Association / ECCJ (JIEC)
Adopted at some sites.
149
CA-PE-4

Ammonia plant Low pressure difference synthesis reactor
The improvement is related to an energy saving reactor of ammonia synthesis process, in which the direction of gas flow within the reactor catalyst bed is controlled to reduce the pressure loss. A feature of the ammonia synthesis process is unavoidably forming a synthesis loop. The pressure difference in the synthesis loop reaches to a range of from 7 to 14 kg/cm2. With the use of a low pressure difference type synthesis reactor, energy saving resulted from reduced pressure difference and packing of small sized synthetic catalyst particles owing to the reduction of pressure difference are available. Since the catalyst of small particle size has high activity, the conversion increases and the driving energy for circulator and refrigerator decreases.
Table 1 Comparison of gas flow directions and of power consumption
Power consumed for circulation Axial direction flow Cross sectional direction flow Radial direction flow Axial-radial direction flow 44 kWh/t-NH3 39 kWh/t-NH3 37 kWh/t-NH3 32 kWh/t-NH3 5 kWh/t-NH3 7 kWh/t-NH3 12 kWh/t-NH3 Reduced power
[Features of low pressure difference reactor] 1) Conventional synthesis reactor employs axial gas flow direction through the catalyst bed, which induces pressure differences of from 7 to 14 kg/cm2. The new [Description] design of reactor which uses the gas flow directions of radial, cross sectional, and axial-radial significantly reduces the presStructure sure difference. Reduction of pressure difference reduces the power consumption of explanation, the circulator. (Refer to Table 1.) Shape, and/or 2) The developed low pressure difference reactor allows to reduce the catalyst particle System size from 6 - 12 mm to 1.5 - 3 (6) mm, diagram thus the catalyst activity is improved the conversion at exit of reactor is improved, and the exit ammonia concentration is increased. 3) Increased conversion reduces the circulation gas rate, thus decreases the power consumption of the circulator. 4) Increased ammonia concentration at exit of the synthesis reactor increases the condensation temperature, increases the condensed generated ammonia by water cooling, thus decreases the condensed refrigerant ammonia and decreases the power consumption of the refrigerator.
Improved section
Fig. 1 Schematic cross sectional drawing of radial direction flow reactor Table 2 Reduction in unit requirement in a pressure difference reactor

Heat recovered to steam Reduction of energy (crude oil basis)
Reduction in unit requirement after the improvement 0.17 x 106 kcal/t-NH3
Effect of improvement
6,931 kL/y
Investment amount: million yen Improvement effect: million yen/year Investment payback: years
[References]
[Inquiry]
Makers in-house technical documents Japan Chemical Industry Association / ECCJ (JIEC)
150
CA-PE-5

Ammonia plant Isothermal CO converter
[Energy Source] Electricity [Practical Use] 1990s ~
The converter is a reactor with built-in heat exchanger to implement the CO conversion in the ammonia plant at a single stage and to recover the reaction heat. 1) The secondary reformer exit gas contains about 13 vol.% of CO. The CO is converted to H2 by the reaction of CO + H2O = CO2 + H2 The reaction is advantageous in terms of chemical equilibrium at lower temperatures. 1) Conventionally, an adiabatic reactor filled with Fe-Cr catalyst (usually) is operated to conduct two stage reactions: namely, the high temperature conversion operated at temperatures of from 370 to 430C, and the low temperature conversion operated at temperatures of from 200 to 230C. 2) The facility adopts an isothermal reactor to carry out the reaction in a single stage at about 250C. The reaction heat generated by the CO conversion in the reactor is recovered by generating medium pressure steam in a built-in heat exchanger. 3) Fig. 1 shows the reactor used in the CO conversion process in the ammonia plant.
[Description]
Improved section
Fig. 1 Reactor used in the CO conversion process Table 1 Effect of improvement of energy unit requirement during ammonia production
(at operation rate of 100,000 t/y)
Unit requirement after the improvement Heat recovered as steam Reduction of energy (crude oil basis) 0.1 x 106 kcal/t-NH3
Effect of the improvement
128,000 kL/y
Investment amount: 500 million yen Improvement effect: 2,560 million yen/year Investment payback: 0.2 years The facility is also applicable to hydrogen plants. [References] Energy Saving Journal (Vol. 31, No. 8, 1979), [Inquiry] Japan Chemical Industry Association / ECCJ (JIEC)
151
CA-PE-6
[Industry Classification] Chemical : Ammonia [Technology Classification] Production Equipment Outline

[Energy Source] Fuel (natural gas)
CO oxidizer in ammonia production process
[Practical Use] 1971~
The improvement relates to the CO conversion step in ammonia plant, particularly to the unit which conducts two stage reactions at high and low temperature levels, (CO + H2O = CO2 + H2), followed by oxidizing the residual CO with air on a Pd catalyst to obtain CO2. [Pd metal catalyst] The catalyst selectively oxidizes CO remained at 0.3 to 0.5 vol.% after the CO conversion, into CO2 gas. Since the treatment reduces CO amount, the amount of CH4 generated in downstream methanation stage decreases, which improves the purity of the syn-gas. 1) The CO remained after the conversion is converted to CH4 in the downstream methanation stage. The CO is, however, accumulated in the synthesis reaction to hinder the reaction. 2) The unit oxidizes CO into CO2 using a catalytic reaction, which CO2 is removed in succeeding carbonate removing stage. Increased purity of syn-gas decreases the amount of purge gas in the synthesis stage. As a result, the H2 loss also decreases. 3) Fig. 1 shows the ammonia production flow diagram with the addition of the CO oxidizer.
[Description]
Improved section
Fig. 1 Flow diagram of CO conversion in ammonia production process
Table 1 Improvement in energy unit requirement in CO converter (at production rate of 300,000 t/y)

Recovered energy Reduction of energy
Reduced unit requirement after improvement 0.07 x 106 kcal/t-NH3
Effect of improvement 2,851 kL/y
Investment amount: 80 million yen Improvement effect: 57 million yen/year Investment payback: 1.4 years The facility is also applicable to hydrogen plants. [References] Makers in-house technical documents [Inquiry] Japan Chemical Industry Association / ECCJ (JIEC)
152
CA-ME-1
[Industry Classification] Chemical : Ammonia [Technology Classification] Machinery & Equipment

Waste heat recovery unit for synthesis gas compressor exit gas in ammonia production process
[Energy Source] Fuel [Practical Use] 1984
Outline
Before Improvemet
In an ammonia plant, in-process heat recovery from compressed gas out of the synthesis-gas compressor was not applied because the heat exchanger hinders temperature control in the succeeding process. For effective use of the heat exchanger, the boiler feed water is injected into the process gas, thus the temperature control becomes possible. Feed steam to the reboiler of the CO2 regenerator is decreased as well owing to the increase in the heating value. Feed gas generated in the reformer was purified, compressed by the ammonia synthesis-gas compressor from 24 kg/cm2 to 150 kg/cm2 , and fed. A heat exchanger to preheat the methanator feed gas was installed as the intercooler of this compressor. The heat exchanger was, however, not used because it gives bad influence to the control of the inlet temperature of the low-temperature converter of the succeeding process. It also shortens the catalyst life. Thus the heat of compression was discarded into coolImproved section ing water. (Refer to Fig. 1)
Fig. 1 Flow chart of synthesis gas purification and compression process
1) When the heat is exchanged with the compressor exit gas, the inlet temperature of the low-temperature converter increases from 214C to 238C. The boiler feed water at 130C is injected into the process gas to change the sensible heat to the latent heat. In this manner, the heating value increases without raising the [Description temperature, which is maintained at the set level of 214C. (Refer to Fig. 2) & 2) This improvement increases the supply rate of latent heat to the process reboiler of the CO 2 regenerator. Accordingly, the load of feed steam to the steam reboiler can be decreased. Improvement] Structure explanation, Shape, and/or System diagram
Improved section
Fig. 2 System to inject boiler feed water to low-temperature converter
Table 1 Energy saving effect

Amount of steam reduction Recovered heat of boiler feed water at heat exchanger Reduction in steam supply to steam reboiler Reduction in crude oil equivalent 1,664 MMkcal/h 3.572 t/h 1,454 kL/y Effect Total 1,372 kL/y (in heavy oil equivalent)
Investment amount: 60 million yen Improvement effect: 30 million yen/year Investment payback: 2 years
[References]
Mitsui Toatsu Chemicals Collection of Energy Conservation Cases Osaka plant 1985, p. 1223
153
CA-ME-2
[Industry Classification] Chemical : Ammonia [Technology Classification] Machinery & Equipment Outline

Membrane separation hydrogen recovery unit in ammonia production process
[Energy Source] Fuel (natural gas) [Practical Use] 1979 ~
The membrane separation unit is an energy saving unit which does not employ any moving parts and does not need any complex operation while consuming minimum energy, because the separation is carried out using the pressure of the gas itself as the driving force. [Features of the membrane separation process] 1) The process attains high hydrogen recovery rate in a high-pressure process, and is suitable for a process for producing hydrogen of the concentration of 90-99%. 2) After installed, the throughput can be readily changed responding to the operating conditions. 3) The process has no moving part, and saves energy. Its maintenance is easy. 4) The product hydrogen has a low pressure owing to the permeation treatment. 5) Condensation of the heavy fraction in feed gas results in the decrease in the hydrogen permeation rate. To prevent it, an adequate pre-treatment is required. 6) The investment cost is low. [Structure of hydrogen separation membrane] 1) The gas separation membrane used for hydrogen gas recovery is made of a non-porous polymer which has excellent properties in the heat resistance, pressure durability, chemicals resistance, separation coefficient and permeation rate. 2) The membrane element is either a hollow type having approximate diameters of 0.1-0.5 mm or a flat membrane wound in a spiral form. These elements are packed in a pressure vessel to form a module. (Refer to Fig. 1.)
[Description] Structure explanation, Shape, and/or System diagram
Improved section
Fig. 1 Schematic cross section of separation membrane module
- Energy saving effect Energy saving effects

Table 1 Improvement effect in specific consumption by membrane separation hydrogen recovery (production rate of 300,000 t/y)
Reduction in specific consumption after improvement Heat recovered as steam Reduction in crude oil equivalent 0.14 x 106 kcal/t-NH3 5,708 kL/y Improvement effect
- Additional effect: From the same volume of natural gas, the production is increased by 4-6% compared with conventional process. [Economics] Equipment cost Remarks [Example sites] [References] [Inquiry] Adopted at some sites. Oil Refinery Process (Japan Petroleum Society) Japan Chemical Industry Association / ECCJ (JIEC) Kodansha Investment amount: 220 million yen Improvement effect: 114 million yen/year Investment payback: 2 years
154
CA-ME-3

High pressure water power recovery turbine in ammonia production process
This improvement is to utilize a high-pressure water turbine in order to recover power from the high-pressure liquid which absorbed carbon-dioxide in the carbon-dioxide removal process of an ammonia plant. [Power recovery system using high-pressure water turbine and power recovery calculation formula]
[Before the improvement] [Description] 1) In the carbon-dioxide removal process, a large quantity of absorbent liquid is supplied to the top of the absorbing column under a pressure of about 30 kg/cm2 to remove about 15 vol.% of CO2 contained in the crude gas coming from the reforming process and the CO conversion process. 2) The liquid which absorbed CO2 is sent to the regenerating column after the pressure is reduced from 30 to 1 kg/cm2 by a pressure-reducing valve. Structure explanation, [After the improvement] Shape, and/or 1) The facility employs a power recovery turbine instead of the pressure-reducing valve, and utilizes the pressure to drive the feed pump for the absorbent liquid. System 2) The facility comprises an electric motor with shafts on both sides, which are directly connected to a power recovery turbine and to a absorbing liquid feed pump via clutches. diagram
Improved section
Fig. 1 Flow diagram of waste heat recovery of primary reformer of ammonia plant Table 1 Energy saving effect by power recovery turbine
After improvement Reduction in specific energy consumption Reduction in crude oil equivalent Reduction by 0.04 x 10 kcal/(NH3-t) 1,794 kL/y
6
Production and operation conditions Production rate 1,000 t/d Operation days 330 d/y
[References] Hydrocarbon Processing (Aug.1992)
Adopted at many sites.
155
CA-ME-4
[Industry Classification] Chemical : Ammonia [Technology Classification] Machinery & Equipment Outline Before Improvemet

Installation of pre-reformer in ammonia reforming process
This technology is a process improvement aiming at energy saving by installing a pre-reformer in the reforming stage of the ammonia production process. - The conventional process adopted natural gas reforming by the primary reformer.
1) Using high-temperature (600C or more) waste heat of the primary reformer flue gas, the mixture of feed natural gas and reaction steam is heated up to 620C. [Description 2) The heated mixture is sent to the primary reformer, where the feed natural gas is cracked by steam on a Ni catalyst to yield H2, CO, and CO2. & 3) Part of the primary reforming reaction is carried out in the pre-reformer (adiabatic reformer) which is also Improvement] filled with a Ni catalyst. Since the reaction heat (endothermic reaction) is supplemented by the sensible heat of the mixture, the exit gas temperature is lowered by 60-80C. 4) The reactor exit gas is reheated by the flue gas, which is then fed to the primary reformer. Structure 5) Installation of the pre-reformer allows to reduce the capacity of the primary reformer by 10%. explanation, Shape, and/or System diagram
Fig. 1 Flow chart of reforming process with pre-reformer Table 1 Energy saving effect by pre-reformer
Improvement effect Remark
Improved section
Reduction in specific energy consumption Reduction in energy consumption * Reduction in crude oil equivalent
0.15 x 106 kcal/NH3-t 5,051 x 103 m3/y 5,354 kL/y
Accounting for about 10% of the fuel supplied to the primary reformer
(Note *: Production capacity of 2,000 t/d, operating days of 330 d/y) [Economics] Equipment cost Remarks [Example sites] [References] Hydrocarbon Processing (Aug. 1992) [Inquiry] Japan Chemical Industry Association / ECCJ (JIEC) Investment amount: 280 million yen Improvement effect: 110 million yen/year Investment payback: 1.7 years
156
CA-ME-5

Primary reformer waste heat recovery unit for ammonia plant
This unit preheats the combustion air by hot flue gas generated by combustion, and supplies the heat to the endothermic reaction (reforming reaction) in the heating-furnace-type primary reformer of an ammonia plant. 1) In the primary reformer, fuel is combusted outside of catalyst tubes to supply heat to the reforming reaction (endothermic reaction) in the catalyst tubes. The waste heat of the flue gas (about 1,000C) generated by combustion is used to heat the feed natural gas, process air, and steam. 2) To increase the thermal efficiency of the primary reformer, the waste heat of the flue gas needs to be utilized to a temperature as low as possible by using it to heat low-temperature fluids. Combustion air for the primary reformer is one of the low-temperature fluids. Waste heat is used to heat the combustion air from the normal temperature to temperatures of 200 to 400C, thus the fuel consumption of the primary reformer is reduced.
[Description] Structure explanation, Shape, and/or System diagram
Improved section
Fig. 1 Flow chart of ammonia plant primary reformer waste heat recovery Table 1 Energy saving effect by waste-heat recovery
[Case A] Preheating temperature of 260 Reduction in specific energy consumption Reduction in fuel consumption (heavy oil C)* Reduction in crude oil equivalent About 0.19 x 106 kcal/(NH3-t) 12,796 kL/y 13,564 kL/y [Case B] Preheating temperature of 400 About 0.28 x 106 kcal/(NH3-t) 18,857 kL/y 19,988 kL/y
(Remark*: Ammonia production 2,000t/D, operation days 330 days/year) [Economics] Equipment cost Remarks [Example sites] Investment amount: 500 million yen Improvement effect: 400 million yen/year Investment payback: 1.3 years This technology was demonstrated at Sichuan Chemical Complex in Sichuan province of China as the NEDOs Model Project for Ammonia Primary Reformer Waste Heat Recovery. [References] NEDO reports [Inquiry] Japan Chemical Industry Association / ECCJ (JIEC)
157
CA-OM-1
[Industry Classification] Chemical : Ammonia [Technology Classification] Operation & Management Outline

Ammonia production process Pre-humidification process for primary reforming
[Energy Source] Fuel [Practical Use] 1980s ~
The case is a process improvement to humidify the feed natural gas with the process condensate, as a part of the humidifying steam, by spraying into the natural gas and by vaporizing the process condensate using the heat of preheated natural gas, before entering the primary reformer of the ammonia plant. (1)For primary reforming natural gas, the natural gas is preheated to 400C before subjected to desulfurization. The process steam (40 kg/cm2G) is added to thus desulfurized natural gas to a level of S/C molar ratios of from 3.0 to 3.5. Then the natural gas is again preheated to 620C, and is fed to the catalyst tubes to perform reforming. (1)The low temperature waste heat at about 200C of the flue gas of the primary reformer is utilized. (2)The process natural gas is preheated to about 200C by the flue gas, and is desulfurized, followed by feeding to the bottom of the saturation tower. On the other hand, the process condensate is sprayed form the top of the saturation tower to make contact with the warmed natural gas to saturate with water. The saturated natural gas is used as a part of the 42 bar reforming steam. (3)After adding the steam to the natural gas to satisfy the necessary total amount of steam, the natural gas is again preheated, and is fed to the catalyst tubes of the primary reformer to perform the reforming.
Before Improvement
[Description of Improvement]
Improved section
Fig. 1 Humidification flow diagram of before the primary reforming
Table 1 Effect of energy saving by the humidification process
Effect
Remark
Reduction in energy unit requirement Increase in power unit requirement Reduction of energy (crude oil basis)
0.05 x 106 kcal/t-NH3 1 kWh/t-NH3 8,809 kL/y Production rate of 100,000 t/y
Investment amount: 250 million yen Improvement effect: 180 million yen/year Investment payback: 1.4 years The technology is applicable also to methanol plants and hydrogen plants. [References] Makers in-house technical documents [Inquiry] Japan Chemical Industry Association / ECCJ (JIEC)
Some sites adopting similar technology
158
CA-OM-2

Ammonia production process Improvement in heating feed to ammonia stripper
[Energy Source] Fuel (steam) [Practical Use] 1986
Melamine which is synthesized from urea is dissolved into aqueous ammonia in the pressurized quencher, followed by depressurized and cooled in the crystallizer to yield crystalline melamine. The improvement is energy saving through preheating the filtrate discharged from centrifugal separator in the crystallizing step for ammonia recovery.
Description of Process
Fig. 1 Process flowchart of ammonia recovery from filtrate after separating melamine
[Before improvement] The temperature of residue as the heating medium was 51C at the exit of filtrate preheater.
[After improvement] Before the existed preheater in the filtrate feed line to the distillation column, an additional preheater is inserted in series, thus the temperature of filtrate is increased.
Improved section
Fig. 2 Flowchart of ammonia recovery (before improvement) Fig. 3 Flowchart of ammonia recovery (after improvement)
Table 1 Improved effect of energy saving in the ammonia recovery step
Improved effect Reduction of steam consumption Reduction of energy (crude oil basis) 13.0 t/h 4,240 kL/y
Remark (Operating time: 4,000 h/y)
Investment amount: 7 million yen Improvement effect: 3.3 million yen/year Investment payback: 2.1 years The improvement is a typical example of widely utilizing methods for preheating raw material feed for all kinds of distillation columns. [References] [Inquiry] Collection of Energy Conservation Cases 1980, Japan Chemical Industry Association / ECCJ (JIEC) p.1021
[Example sites] Adopted at some sites.
159
CA-OM-3

Ammonia production process Carbonate removal process
The improvement is the one for energy saving in the carbonate removal process of ammonia production process. [Before improvement] (1)Conventional carbonate removal applies chemical absorption method using an absorbing liquid such as monoethanolamine (MEA) aqueous solution. The method removes CO2 contained at about 18 vol.% in the crude synthesis gas coming from the CO conversion process. (2)The regeneration heat of the solution after absorbing CO2 is about 1,000 to 2,000 kcal/Nm3-CO2. (3)With natural gas as the raw material, the quantity of removed carbonate is about 620 Nm3-CO2/t-NH3, and the process is the largest consumer of energy in the ammonia plant. [After improvement] (1)The improved technology for removing carbonate is the physical absorption type (Selexol process). The regeneration of the solution is performed by vacuum flashing and air stripping. As a result, the energy required for regeneration of the solution is significantly reduced to 22 kcal/Nm3-CO2.
Before Improvement
Improved section
Fig. 1 Flowchart of energy saving type carbonate removal process
Table 1 Improved effect in the carbonate removal process in the ammonia production process (production capacity: 300,000 t/y)
Reduced unit requirement after improvement Heat recovered as steam Increased power consumption Reduction of energy (crude oil basis) 0.6 x 106 kcal/t-NH3 10 kWh/t-NH3
Improvement effect
23,733 kL/y
Investment amount: 1,200 million yen Improvement effect: 470 million yen/year Investment payback: 2.5 years
[References] Makers in-house technical documents
160
CS-PE-1
[Industry Classification] Chemical : Caustic Soda [Technology Classification] Production Equipment Outline

Quadruple-effect concentration for diaphragm-type electrolytic caustic soda production
When the electrolytic production method of industrial salt is converted from the mercury process to the diaphragm process, the electrolyte generated in the process becomes a dilute NaOH solution containing a large amount of NaCl salt. Accordingly, it is necessary to concentrate the NaOH by a concentrator to about 50% to separate the salt in a form of crystals. This improvement enhances energy efficiency and saves energy by modifying the existing triple-effect concentration method to the quadruple-effect concentration method.
Table 1 Comparison of triple-effect evaporation and quadruple-effect evaporation
1) The electrolyte generated in the diaphragm process is a dilute solution of NaOH (about 10%). It also contains NaCl of about 15%. It is necessary to concentrate the NaOH by a concentrator to about 50% to separate the salt as crystals. 2) The existing triple-effect concentration method is modified to the quadruple-effect concentration method. The energy efficiency is improved, and the steam con[Description] sumption is reduced by 26%. The flow chart of the quadrupleeffect evaporation vessels is shown in Fig. 1. Structure 3) Comparison of triple-effect explanation, evaporation and quadruple-effect evaporation. (Refer to Table 1) Shape, and/or System diagram
Concentration of electrolyte Concentration of product
NaOH 10.3wt% NaCL 15.1wt% NaOH 50 wt% NaCL 1.1wt%

Triple-effect evaporation Temperature Concentration 142 C 45% 87 C 25% 53 C 16% -
No. 1 evaporator No. 2 evaporator No. 3 evaporator No. 4 evaporator
Quadruple-effect evaporation Temperature Concentration 158 C 43% 102 C 25% 76 C 17% 50 C 12%
Improved section
Fig. 1 Flow chart of caustic soda concentration by quadruple-effect evaporation vessels Table 2 Energy saving effect by quadruple-effect evaporation
Triple-effect type Specific steam consumption Reduction in steam consumption * Reduction in crude oil equivalent 2.7 t/t-NaOH
Quadruple effect type 2.0 t/t-NaOH
Improvement effect Reduction by 0.7 t/y 700,000 t/y 57,077 kL/y
Note*: Operating hours: 7,000 h/y [Economics] Equipment cost Remarks [Example sites] [References] [Inquiry] Many sites adopting similar Energy Saving Journal (Vol. 30, No. 9, Japan Chemica Industry Association / ECCJ(JIEC) 1978), P. 45 technology Investment amount: 4,560 million yen Improvement effect: 1,140 million yen/year Investment payback: 4 years
161
CS-PE-2

Energy saving ion exchange membrane electrolysis bath for caustic soda production
[Energy Source] Electricity [Practical Use] 1994
The newly developed electrolysis bath gives less voltage drop owing to its structure compared with a conventional multi-polar ion-exchange-membrane electrolysis bath. Accordingly it allows to increase the current density, making it an energy-saving compact NaCl electrolysis bath. Compared with a conventional type, it achieves power saving of about 6%. The current flows as indicated in Fig. 1. As the electric conductivity of Ni is six times that of Ti, a minimum level of current flows through the Ti section. Owing to this structure, the voltage drop becomes less.
Improved section
Fig. 1 Cross section of multi-polar element
[Description]
Improved section
Fig. 2 Configuration of multi-polar element Fig. 3 Flow of electrolyte
Table 1 Power saving effect of improved type compared with conventional multi-polar ion-exchange-membrane electrolysis bath
Reduction in specific power consumption Reduction in crude oil equivalent
131 DC kWh/t-NaOH 3,183 kL/y
Operating condition: production of 100,000 t-NaOH/y, current density 3 kA/m2
Investment amount: 124 million yen Improvement effect: 62 million yen/year Investment payback: 2 years The technology is economically applicable to the operation with a high current density up to 6 kA/m2. [References] [Inquiry] Soda Industry Technical Information (No. 449), Japan Chemical Industry Association / Oct. 1994 ECCJ (JIEC)
162
CS-PE-3

Ion exchange membrane NaCl electrolysis bath for caustic soda production
This technology is to switch the method employed in the NaCl electrolysis bath for caustic soda production from the asbestos membrane method to the bag ion exchange method. This improvement significantly reduced electric power consumption. [Features of ID-process NaCl electrolysis bath] (Refer to Fig. 1) 1) Caustic soda and chlorine generated by electrolysis of saline water are separated by an ion exchange membrane. 2) The ion exchange membrane is formed to a bag by which the saline water and pure water are sealed from each other more easily than a flat membrane. Improved section
Fig. 1 Schematic drawing of electrolysis bath
[Description]
[Improvement of ID-process NaCl electrolysis bath] (refer to Figs. 2 and 3) 1) The electrolysis bath was switched from the asbestos membrane method to the bag-shaped ion exchange membrane method. 2) The cathodic material of the cathodic can was switched to SUS310S. The mounting method was also modified. 3) The inner material of the can nozzle was changed to SUS310S. 4) The treatment of the periphery of the anode was modified. The thickness of the Ti spring was increased and the flatness was improved.
Structure explanation, Shape, and/or System diagram Improved section
Fig. 2 Modification of cathodic can
Fig. 3 Comparison of anode before and after improvement
Table 1 Comparison of energy saving effect between conventional membrane method and ion exchange membrane method for electrolysis bath
Conventional membrane method Improved ion exchange membrane method 34 % 0.003 % 2,338 kWh/t-NaOH 0.42 t/t-NaOH 257 kWh/t-NaOH 1.98 t/t-NaOH 22,390 kL/y Effect
NaOH concentration at electrolysis bath exit Salt concentration at electrolysis bath exit Specific power consumption Specific steam consumption Reduction in crude oil equivalent
12 % 14 % 2,595 kWh/t-NaOH 2.4 t/t-NaOH
Investment amount: 2,015 million yen Improvement effect: 447.8 million yen/year Investment payback: 4.5 years
[References] Soda Industry Technical Information (No. 449), Oct. 1994
163
CS-ME-1
[Industry Classification] Chemical : Caustic Soda [Technology Classification] Machinery & Equipment Outline

Brine preheater using recovered heat of NaCl electrolysis in caustic soda production process
This improvement is to install a preheater which preheats brine (NaCl water) fed to the electrolysis bath, using sensible heat of chlorine and hydrogen gases generated in the membrane electrolysis bath. [Before improvement] Conventionally, the feed brine was heated by steam using a carbide-made heat exchanger.
[Description]
[After improvement] 1) After the improvement, the heat is exchanged with the sensible heat of chlorine and hydrogen gases generated in the NaCl electrolytic bath (particularly membrane-type electrolysis bath), thus the steam consumption is reduced compared with the conventional steam heating. 2) Fig. 1 shows the flow diagram around the preheater. 3) The heat exchanger is a shell-and-tube type. The materials of the main parts are listed in Table 1.
Table 1 Materials of main parts of brine preheater
Shell side Chlorine gas - brine Hydrogen gas - brine TP35 (Titanium) SS40V (SS)
Tube side TTH35W (Titanium) TTH35W (SS)
Improved section
Fig. 1 Flow diagram of brine preheating syste Table 2 Heat recovery effect of brine preheater
Effect Energy recovery (in steam equivalent) Reduction in crude oil equivalent 18,000 t/y 1,468 kL/y
Remark Production rate: 55,000 t-chlorine/y (17,500 km3 of hydrogen)
[References]
[Inquiry]
Soda Industry Technical Information (No. 449), Japan Chemical Industry Association / Oct. 1994 ECCJ (JIEC)
164
CS-ME-2
[Industry Classification] Chemical : Caustic Soda [Technology Classification] Machinery & Equipment Outline

Improvement of active cathode for ion exchange membrane electrolysis for caustic soda production
This improvement is to use an active cathode. This type of cathode was developed to reduce the overvoltage at the cathode which generates large energy loss in ion-exchange-membrane NaCl electrolysis for caustic soda production. Focusing on the fact that the overvoltage at an electrode depends on the electrolysis voltage and its surface area, a new coating method was adopted, which significantly widens the surface area of the electrode. Thus, the power consumption was remarkably reduced. [Principle of ion-exchange-membrane method and breakdown of energy loss]
Table 1 Breakdown of energy loss in ion-exchange-membrane electrolysis
Reduction in specific power consumption (kWh/tNaOH) Ion-exchange-membrane resistance Anode liquid resistance Cathode liquid resistance Anode overvoltage Cathode overvoltage Conductor resistance Total 345 15 53 67 263 112 755
Rate(%) 40.3 1.8 6.1 7.9 30.7 13.2 100.0
Improved section
Fig. 1 Schematic drawing of electrolysis bath
[Description]
[Structure of active cathode] 1) Fig. 2 shows the mesh-type cathode. Fig. 3 illustrates its cross section. Special coating is applied on the stainless or nickel cathode, and the hydrogen overvoltage is reduced. 2) The coating layer is a Ni-C-S porous alloy. 3) For normal industrial-scale production, the operating current density is 20-40 a/dm3. The overvoltage of the active cathode is reduced by more than 0.2 V compared with that of a conventional one.
Improved section
Fig. 1 Mesh-type cathode Fig. 2 Schematic drawing of the cross section of cathode
Table 1 Example of energy saving (Production scale of 100,000 t-NaOH)
Reduction in specific power consumption Annual power reduction Reduction in crude oil equivalent
150 kWh/(t-NaOH) 15,000,000 kWh/y 3,645 kL/y
Investment amount: 255.1 million yen Improvement effect: 72.9 million yen/year Investment payback: 3.5 years
[References]
[Inquiry]
Some sites adopting similar tech- Collection of Energy Conservation Cases 1988, Japan Chemical Industy Asociation / nology p. 197 ECCJ (JIEC)
165
CS-OM-1
[Industry Classification] Chemical : Caustic Soda

Caustic soda production process Switching from diaphragm electrolytic process to [Technology Classification] ion exchange membrane electrolytic process Operation & Management
Outline
In the past, caustic soda production was conducted by the diaphragm process in which anode and cathode in the NaCl electrolytic bath were separated by an asbestos diaphragm from each other. There developed a process to produce high concentration and high purity caustic soda through electrolysis using ion exchange membrane. The ion exchange membrane process gives significant energy saving compared with conventional diaphragm process. [Principle of diaphragm process electrolytic bath and of ion exchange process electrolytic bath]

Fig. 1 Conceptual drawing of diaphragm process electrolytic bath Fig. 2 Conceptual drawing of ion exchange process electrolytic bath
[Description]
[Conventional process] Refer to Fig. 3 (1)Caustic soda yielded in the electrolytic bath needs further concentration and purification. NaOH concentration : about 12% NaCl concentration : about 16% (2)Content of impurities NaCl : 0.86 ~ 0.93 % Na2CO3 : 0.082 ~ 0.180 % Fe2O3 : 0.0018 %
Fig. 3 Flowchart of diaphragm process
Structure explanation, New process] Refer to Fig. 4 (3)Caustic soda yielded in the electrolytic bath Shape, and/or is the final product. NaOH concentration: about 20 to 35% System (4)Content of impurities diagram NaCl : 0.0018 0.0072 % Na2CO3 : 0.018 ~ 0.09 % Fe2O3 : 0.00009 ~ 0.008 %
Improved section
Fig. 4 Flowchart of ion exchange membrane process Table 2 Energy saving effect through the switching to ion exchange membrane process (basis: 100,000 t/y of production)
Conventional process New process average 2,100 kWh/t-NaOH average 75 kWh/t-NaOH 0.68 t/t-NaOH Effect of improvement 16% reduction 75% reduction 74% reduction 30,843 kL/y
Electric power unit requirement Steam unit requirement
for electrolysis for power
2,500 kWh/t-NaOH 200 to - 400 kWh/t-NaOH 2 ? 3.2 t/t-NaOH
Reduction of energy (crude oil basis)
Investment amount: 2,500 million yen Improvement effect: 616 million yen/year Investment payback: 4 years
[References] Chemical Engineering Journal (Vol. 56, No.9), p.634
[Inquiry] Japan Chemical Industy Asociation / ECCJ (JIEC)
Many sites adopting similar technology
166
CS-OM-2
[Industry Classification] Chemical : Caustic Soda [Technology Classification] Operation & Management Outline

Reduction of electrolytic power for NaCl electrolysis bath in caustic soda production process
In the past, caustic soda production was conducted by the diaphragm process in which anode and cathode in the NaCl electrolytic bath were separated by an asbestos diaphragm from each other. There developed a process to produce high concentration and high purity caustic soda through electrolysis using ion exchange membrane. The ion exchange membrane process gives significant energy saving compared with conventional diaphragm process. The electrolytic power (W) of NaCl electrolysis is, as shown in equation (1), proportional to the bath voltage (V), which is in turn, as shown in equation (2), nearly in a linear relation with the current (I). The production rate (P) is proportional to the product of the current and the number of baths (n) as shown in equation (3).
(1) (2) (3) Improved section
where, W is the electrolytic power (==), 670 is the electrochemical equivalent (=), V is the bath voltage, hc is the current efficiency, I is the load current (kA), a and b are the constants, P is the production rate, n is the number of baths, and K is a coefficient. 1) Equation (3) suggests that, for a certain production rate, the load current can be reduced when the number of baths is increased. Equations (1) and (2) suggest that the power is saved by this approach. However, if the current is simply reduced: - The specific steam consumption for enriching increases due to the reduced concentration of electrolyte. - The current efficiency is reduced due to the increase in liquid resistance resulted from the decrease in the electrolyte temperature. - The membrane is consumed and degraded due to the changes in the pH value in the membrane bath, and the current efficiency is reduced. As the measures to these problems, - The reduction in the electrolyte concentration is prevented by adjusting the membrane and strictly controlling the electrolytic bath. - The electrolyte temperature is increased by about 2C by preheating the feed saline water using the waste heat of generated hydrogen gas drain, thus maintaining the current efficiency.
[Description]
Table 1 Example of energy saving effect

Reduction in annual power consumption Reduction in crude oil equivalent
Effect 13,200,000 kWh/y 3,208 kL/y
Remark Reduction rate of 7.4%
Investment amount: 128 million yen Improvement effect: 64 million yen/year Investment payback: 2 years The improvement for a membrane NaCl electrolysis bath is illustrated. The technology is applicable to ionexchange-membrane NaCl electrolysis bath and electrolytic production of high-purity chromium and manganese-dioxide. [References] [Inquiry] Japan Chemical Industy Asociation / ECCJ (JIEC)
Similar technologies are adopted Collection of Energy Conservation Cases 1980, at some sites. p. 803
167
CN-ME-1
[Industry Classification] Chemical : Naphtha Cracking [Technology Classification] Machinery & Equipment

Switching quenching tower trays to packing in naphtha cracking process
[Energy Source] Electricity, Fuel [Practical Use] 1987
Outline
Power consumption by the feed gas compressor of the naphtha cracking process is reduced by increasing the suction pressure. The suction pressure is determined by the exit pressure of the cracking furnace and by the pressure difference across the quenching process. Since the increase in the exit pressure of the cracking furnace significantly reduces the ethylene yield, the pressure difference across the quenching process is reduced to save energy. [Process flow of the facility] (Refer to Fig. 1) The quenching process comprises a gasoline-fractionating column and a quenching column. 1) The pressure difference across the quenching process is 0.31 kg/cm2. The bottom oil of the quenching column is recirculated to the gasoline-fractionating column. The bottom oil-bearing hot water (quench water) of the quenching column is used as heat sources in various processes in the plant, and is recirculated to perform contact cooling after its temperature is controlled using cooling water. 2) In the both columns, the pressure difference occurs at the valve tray sections. The pressure difference occurs at each tray according to the liquid depth. If the valve trays are changed to packing, the pressure difFig. 1 Flow chart of naphtha-cracking quenching ference is decreased and the heat transfer coefficient process is increased, thus the top reflux is decreased and the bottom temperature is increased. 4) As a result, the heat source of the de-ethanizing column can be switched from low-pressure steam to quench water, so the steam consumption is reduced. [Before improvement] [After improvement]
[Description]
Improved section
Fig. 3 Tray packing section in quenching column(after improvement) Table 1 Comparison of operating conditions before and after improvement
Before improvement -Pressure difference in gasoline-fractionating column -Pressure difference across quenching column -Inlet pressure of feed gas compressor -Driving force of feed gas compressor, etc. 0.07 kg/cm2 0.05 kg/cm2 0.49 kg/cm2 12,700 kW/h 86 C 8.6 t/h After improvement 0.01 kg/cm2 0.01 kg/cm2 0.59 kg/cm2 12,030 kW/h 88 C 2.7 t/h
Fig. 2 Quenching column (before improvement)
Temperature of quench water Reboiler steam
Table 2 Energy saving effect by changing trays to packing
Hourly reduction Reduction in power consumption Reduction in steam consumption Reduction in crude oil equivalent 670 kW/h 5.9 t/h
Annual reduction (7,000 h/y) 4,690,000 kWh/y 41,300 t/y 4,508 kL/y
[References]
Many sites adopting similar Collection of Energy Conservation Cases 1988, p. 1173 technology
168
CN-ME-2

Installation of turbo-expander in top gas line of demethanizing column in naphtha cracking process
Outline
This improvement is a measure to overcome capacity shortage of a refrigerant ethylene compressor under increased ethylene production. In order to further reduce the pressure from the conventional level and lighten the load to the compressor, a turbo-expander is installed in the top gas line and the low-temperature heat is recovered for energy saving. The conventional flow is given below.
Before Improvement
Fig. 1 Flow chart around demethanizing column (before improvement)
1) The top gas temperature of the demethanizing column, which was formerly changed under the isenthalpic condition, is now lowered to -128C by using a turbo-expander, and further lowered to -136C by isentropic change. 2) This improvement increases the heat recovery to 2.14 x 106 kcal/h, reduces the steam consumption at the [Description refrigerant ethylene compressor by 4.5 t/h, and reduces the steam consumption at the refrigerant propylene of compressor by 3.2 t/h. Improvement] 3) The process flow with the turbo-expander installed is shown below. Structure explanation, Shape, and/or System diagram
Improved section
Fig. 2 Flow chart around demethanizing column after turbo-expander is installed Table 1 Energy saving effect by installing turbo-expander
After improvement Remark (Operating hours: 8,000 h/y)
Cold heat recovery Reduction in steam consumption at compressors Reduction in crude oil equivalent
2.14 x 106 kcal/h 7.7 t/h 6,874 kL/y
Investment amount: 687 million yen Improvement effect: 137.4 million yen/year Investment payback: 5 years
[References]
[Inquiry]
Collection of Energy Conservation Cases 1993, Japan Chemical Industry Association / ECCJ (JIEC) p. 761
169
CN-ME-3

Cold heat recovery from demethanizing column bottom liquid in naphtha cracking process
Outline
In the naphtha cracking process, the bottom liquid of the demethanizing column is at a temperature of -30C and is fed to the ethylene rectificating column at a vapor/fluid ratio of 0.11. Since the increase in the vapor/fluid ratio of the feed does not affect much to the efficiency of the ethylene rectificating column, the cold heat of the bottom liquid is utilized to reduce the power of the propylene refrigerator for energy saving. The conventional process flow is shown below.
Before Improvement
Fig. 1 Flow chart of demethanizing column and ethylene rectification column
1) Two aluminum-made heat exchanger is Newly installed: one to the top vapor section of the depropanizing column, the other to the feed chiller (refrigerator) of the demethanizing column. The bottom liquid of the demethanizing column is flashed in the adiabatic mode using two control valves, and the cold heat is recovered, thus reducing the power of the propylene refrigerator. [Description 2) The recovered power of the propylene refrigerator is 830 kWh/h. of 3) The flow after improvement is shown below. Improvement] Structure explanation, Shape, and/or System diagram
Improved section
Fig. 2 Flow chart of cold heat recovery from bottom liquid of demethanizing column Table 1 Refrigerator power saving effect
After improvement Remark Operation of 8,000 h/y
Energy saving effects [Economics] Equipment cost Remarks [Example sites] Adopted at some sites.
Reduction in power by recovering cold heat Reduction in crude oil equivalent
6,640,000 kWh/y 1,614 kL/y
[References] Collection of Energy Conservation Cases 1987, p. 618
170
CN-ME-4

Combustion air preheating for boilers using cooling tower bottom hot water in naphtha cracking process
Outline
In a naphtha cracking plant, hot water at the bottom of the cooling tower is cooled by process fluid to 60C, and further cooled to 35-50C using the cooling water (TW) before sending back to the cooling tower. On the other hand, at the power plant boilers, the combustion air is heated to 240C using the 13 kg/cm2 steam and the boiler flue gas before sent to the boilers.
[Flow for utilizing process waste heat at boilers] (Refer to Fig. 1) 1) An air-preheater using waste heat from circulating hot water of the naphtha cracking plant was installed ahead of the forced draft fan (FDF) for No. 1 and No. 2 boilers. Steam is no more used for preheating. 2) This improvement reduced the steam consumption by 13 t/h. [Description]
Improved section
Fig. 1 Flow chart of combustion air preheating using process waste heat of cooling tower bottom hot water Table 1 Energy saving effect by reducing combustion-air preheating steam for boilers
Improvement effect Reduction in steam consumption Reduction in crude oil equivalent 104,000 t/y (13 t/h) 8,480 kL/y
Remark Operating hours: 8,000 h/y
[Example sites] [References] [Inquiry] Many sites adopting similar Collection of Energy Conservation Cases 1980, Japan Chemical Industry Association / technology ECCJ (JIEC) p. 1021
171
CN-ME-5
[Industry Classification] Chemical : Naphtha Cracking [Technology Classification] Machinery & Equipment Outline

Hot water heating by distillation column top vapor
The top vapor of the CO2 stripper in this plant is at about 94C, and the top vapor of the MEG distillation column is at about 105C. Both vapors are cooled by cooling water. On the other hand, in the P plant in the same industrial complex, the bottom temperature of the rectificating column is at about 60C, and the reboiler is heated by steam. This improvement is to circulate hot water along with the waste heat of the top vapor of the rectificating column in the B plant, and utilize the waste heat as a heat source of the reboiler of the P plant. [Energy flow with B and P plants] (Refer to Fig. 1)
Fig. 1 Flow chart of heat among ethylene-oxide plant, B and P plants
[Description]
1) It reduces the overall heat transfer coefficient to convert the cooling water to hot water at the top condenser of the CO2 stripper. Accordingly, the internal structure of the condenser was modified. 2) As for the MEG distillation column, the pressure was changed from 25 to 36 Torr, and the top temperature was changed from 105 to 117C. After these modifications, a top heat exchanger was installed. 3) A condenser was installed at the B plant. A reboiler and a hot water tank were installed at the P plant.
Improved section
Fig. 1 Use of waste heat of top vapor of distillation column at reboiler by hot-water circulation Table 1 Energy saving effect by utilizing top vapor waste heat of distillation column

Reduction in steam consumption Reduction in crude oil equivalent
Improvement effect 37,180 t/y 3,032 kL/y
Remark
[References]
Many sites adopting similar Energy Saving Journal (Vol. 37, No. 2, 1985), technology P. 39
172
CN-OM-1
[Industry Classification] Chemical : Naphtha Cracking [Technology Classification] Operation & Management Outline

Control of excess air ratio at cracking furnace in naphtha cracking process
At this plant, a gas turbine generator was introduced, and its flue gas is used as combustion air for the cracking furnace. Since the cracking furnace is operated under negative pressure, air is sucked into it. This improvement for energy saving is to control the excess air ratio using an oxygen analyzer mounted to each cracking furnace. [Relation between fuel gas flow rate and theoretical oxygen volume] (Refer to Fig. 1) [Control of excess air ratio] The theoretical oxygen volume necessary for combustion is computed based on the molecular weight and feed rate of the fuel, and compared with the oxygen volume actually consumed for combustion. The feed rate of the air is controlled based on the theoretical oxygen volume.
Fig. 1 Relation between the molecular weight and calorific value of the fuel gas, and the theoretical oxygen volume
[Description]
Improved section
Fig. 2 Flow chart for using gas turbine flue gas as combustion air Table 1 Energy saving effect by controlling excess air ratio of cracking furnace

Reduction in energy consumption Reduction in crude oil equivalent
Improvement effect 41.2 x 109 kcal/y 4,454 kL/y
Remark (Equivalent to 15 cracking furnaces)
[References] [Inquiry] Collection of Energy Conservation Cases 1992, Japan Chemical Industry Association / ECCJ (JIEC) p. 811
173
CN-OM-2

Change of feed step for depropanizing column in naphtha cracking process
Conventionally the bottom liquid of the de-ethanizing column and the bottom liquid of the condensate stripper in the naphtha cracking process were joined and fed to the depropanizing column via the cooler. This improvement is to separately feed the bottom liquid of the condensate stripper to a lower step of the depropanizing column, thus eliminating the use of cooling water for the cooler, and reducing steam consumption at the reboiler of the depropanizing column.
Table 1 Main components of bottom liquid of de-ethanizing column and condensate stripper
De-ethanizing column Main components Operating pressure Transfer method C3 C4 C5 77.0 % 8.6 % 0.6 % 27 kg/cm2 Pressure transfer
Condensate stripper 23.4 % 49.2 % 22.4 % 10 kg/cm2 Pump up
Depropanizing column
10.5 kg/cm2
[Description]
1) Conventionally, the bottom liquid of the de-ethanizing column and the condensate stripper were jointly fed to No. 19 step of the depropanizing column. 2) The temperature profile in the depropanizing column is as shown in Fig. 1. After the improvement, the bottom liquid of the condensate stripper is fed to the lower No. 34 step. 3) At the same time, cooling water supply to the cooler in the feed line of the bottom liquid of the de-ethanizing column is stopped. Thus, the steam consumption by the reboiler of the depropanizing column is reduced.
Improved section
Fig. 1 Temperature profile of depropanizing column Fig. 2 Feed system to depropanizing column
Table 2 Energy saving effect by changing feed step to depropanizing column

Improvement effect Reduction in energy consumption Reduction in crude oil equivalent 19.600 t/y (2.8 t/h) 1.598 kL/y Remark (Operating hours: 7,000 h/y)
[Inquiry] Many sites adopting similar Collection of Energy Conservation Cases 1979, Japan Chemical Industry Association / ECCJ (JIEC) technology p. 765
[References]
174
CN-OM-3

Pressure control of ethylene rectification column by suction pressure of propylene refrigerator in naphtha cracking process
This improvement is to reduce the refrigerator power by improving the control method of the propylene refrigerator of the top condenser of the ethylene rectification column. This improvement was made at the time of introducing a decentralized control system (DCS) to the naphtha cracking plant. [Pressure control method of ethylene rectification column] (Refer to Fig. 1) 1) Before the improvement, the pressure of the ethylene rectification column was controlled by the liquid level of refrigerant propylene in the top condenser. 2) On the other hand, the suction pressure of the propylene refrigerator was controlled by the revolution speed of the compressor.
Before Improvement
Improved section
Fig. 1 Pressure control method of ethylene rectification column
1) A function to control the suction pressure of the refrigerator was added to the system to control the pressure of the ethylene rectification column within the framework of the decentralized control system (DCS). Thus the heat transfer area of the condenser Structure is now utilizd to the maximum degree. explanation, 2) As a result, the suction pressure of the refrigerator was changed from 0.60 to 0.68 Shape, and/or kg/cm2G, and the power of the propylene refrigerator was reduced by 250 kW. System diagram [Description of Improvement] Improved section
Fig. 2 Suction pressure control method of propylene refrigerator Table 1 Energy saving effect of pressure control of ethylene rectification column
Reduction effect Reduction in refrigerator power Reduction in crude oil equivalent Reduced by 250 kWh/h
Remark Operation hours of 7,000 h/y
425 kL/y
[References]
[Inquiry]
Many sites adopting similar Collection of Energy Conservation Cases 1988, Japan Chemical Industry Association / technology p. 1173 ECCJ (JIEC)
175
CN-OM-4

Naphtha cracking process Energy saving in ethylene cracker
[Energy Source] Fuel (gas) [Practical Use] 1979
Operation technology on uniform and low oxygen combustion of fuel gas for heating the ethylene cracker.
Ethylene cracker heats raw material naphtha to temperatures of from 800 to 850C to decompose into ethylene (thermal cracking). The cracker is an upright type with long depth, and has a radiation zone at lower part provided with many burners (112 units) of short-flame radiation type at lower side walls, and a convection zone at upper part (for preheating raw material and steam). The current combustion control values are: intrafurnace pressure at top of the radiation zone to a reduced pressure by 3 mm H2O; and exhaust gas O2 concentration of 1 to 3% (at exit of convection zone). Those control variables are checked by sampling from a single point over the whole furnace. The fuel consumption for heating is 2,190 Nm3/h per furnace.
Observation of distribution of O2 content in vertical and horizontal directions in the furnace revealed the following. (1)Lateral O2 content distribution is not uniform. 1.5 ~ 1.7 Left side: O2 [Description] Right side: O2 0.2 ~ 0.3 (2)Difference in O2 content exists in vertical direction. 7.0 ~ 5.0 Lower burner section: O2 Upper burner section: O2 1.0 ~ 0.7 Structure Exit of convection zone: O2 1.2 ~ 1.0 explanation, (3) Actions Shape, and/or - Primary air valve opening for burner is adjusted. - Primary air valve for each of lowermost row of burnSystem ers is opened to a minimum necessary degree to prevent burning. diagram - For the third row and upper burners, also the sec ondary air valve is kept slightly open. - Draft is adjusted to 3 to 3.5, somewhat stronger degree.
Many burners are arranged on the side walls, thus the side walls function as the radiation plane.
Through the above-described improvement (actions), the following-listed effects appeared. (1)Horizontal distribution of O2 content becomes almost uniform. (2)Vertical distribution of O2 content is also improved as shown in the right figure. Energy saving (3)Fuel consumption is reduced as follows. - Reduction by 30 Nm3/h effects Before improvement 2190 Nm3/h After improvement 2160 Nm3/h Reduction 30 Nm3/h - Effect as amount: about 7 million yen (as 33 yen/Nm3)
Improved section
Investment amount: 20 million yen Improvement effect: 7 million yen/year Investment payback: 2.8 years This is the uniform O2 content combustion technology in the case that many burners are arranged in a single furnace. For the case of individual burners, refer to the Energy Saving Handbook, Equipment Common to All Industries, Low O2 Burners. [References] Collection of Energy Conservation Cases 1981, p. 105, ECCJ [Inquiry] Japan Chemical Industry Association / ECCJ (JIEC)
176
CB-ME-1
[Industry Classification] Chemical : BTX [Technology Classification] Machinery & Equipment Outline

Recovery of top vapor heat of ortho-xylene separation column in aromatics production process
The top condenser of the ortho-xylene separating column in the aromatics production process is of an aircooling type. The waste heat of the top vapor is dissipated from the air-fin cooler. The dissipated heat is as large as 46,000,000 kcal/h and the temperature is 153C. This improvement is to recover this waste heat. [Balance of waste energy by form]
Before Improvement
Fig. 1 Waste energy balance at ortho-xylene separation column
[Outline of heat recovery system] (Refer to Fig. 2) 1) Through studying the use of a heat pump for generating a high-temperature heat source and the Ranking cycle for recovering the power, power generation by a low-pressure steam turbine was adopted. 2) The system comprises an evaporator, a feed-water heater, a steam turbine, a condenser, a condensate pump, and a generator. [Description of Improvement] Structure explanation, Shape, and/or System diagram
Improved section
Fig. 2 Flow chart of waste-heat-recovery generator for ortho-xylene separation column Table 1 Energy saving effect by heat-recovery generator
Recovered energy
Remark 4,500 - 6,500 kW 7,500 h/y
Average power generation capacity Total power generation Reduction in crude oil equivalent
5,500 kW 41,250 MWh/y 10,024 kL/y
Investment amount: 720 million yen Improvement effect: 700 million yen/year (including the stoppage of one pump) Investment payback: 1 year
[Inquiry] Energy Saving Journal (Vol. 35, No. 13, 1983), Japan Chemical Industry Association / ECCJ (JIEC) P. 105
[References]
177
CB-ME-2
[Industry Classification] Chemical : BTX [Technology Classification] Machinery & Equipment

Waste heat recovery from heating furnace flue gas in BTX production
Outline
This process carries out secondary hydrogenation purification of cracked gasoline generated as a by-product in an ethylene plant. The heating furnace (recycle heater) heats the unreacted hydrogen from 340 to 500C. The heating furnace was modified from natural draft type to forced draft type, thus improving its thermal efficiency from 74 to 89.8%. At the same time, the heat of flue gas is utilized to generate steam. Thus, waste heat is recovered with a significant energy saving effect. [Before improvement]
[Description]
Fig. 1 Flow chart of cracked-gasoline secondary hydrogenation process
Structure explanation, [After improvement] Shape, and/or System diagram
Improved section
Fig. 2 Flow chart of steam generation by recovered flue gas heat of heating furnace (recycle heater) Table 1 Energy saving effect by steam generation by heating-furnace flue gas
Improvement effect Total 1,100 kL/y (in fuel oil C equivalent) 1,166 kL/y
Reduction in steam consumption Steam generation by recovered heat Reduction in crude oil equivalent
0.21 x 106 kcal/h 1.51 t/h
Investment amount: 200 million yen Improvement effect: 23.2million yen/year Investment payback: 8.6 years
178
CB-ME-3
[Industry Classification] Chemical : BTX Machinery & Equipment

[Energy Source]
Steam turbine power generation using waste heat of Electricity [Technology Classification] distillation column top vapor in BTX production process [Practical Use]
1980 At this plant, power is generated in-house using a bleeding-condensing turbine. Steam for production processes is the bleed from the turbine. Power balance is maintained by adjusting the condensing power generation. However, along with the progress in energy saving, steam consumption in the processes was significantly reduced, and the condensing power generation nearly reached the upper limit. On the other hand, energy of distillation column top vapor of the xylene production process was not recovered. Therefore, a new condensing turbine was installed to recover power from the process, thus the steam to be generated by the old in-house power generator was reduced, and the operation of one of the boilers was stopped. - Case study for utilizing top vapor waste heat of distillation column (Table 1)
Type 1 Absorption refrigeration 2 Low-pressure steam recompression 3 Heat pump 4 Low-pressure steam turbine Waste heat recovery method Top vapor - Cold water generation Top vapor - Low-pressure vapor generation - (Compression) Medium-pressure steam generation Top vapor - Low-pressure steam generation - Turbine drive (power, electricity generation) Top vapor - Low-pressure steam generation - Turbine drive (power, electricity generation) Economy OK OK Some OK Prior adoptions Many A few None Many
Outline
Improvement Study
[Description]
1) The top vapor (153C, 45 x 106 kcal/h) of the distillation column for separating ortho-xylene from mixed xylene in the xylene production process was formerly cooled by an air-fin cooler (AFC). 2) The 4th case among those studied was adopted to recover waste heat. The system comprises an evaporator generating low-pressure steam (1.72 kg/cm2G) in parallel with the existing AFC, a condensing turbine power generator, and a feed-water heater. 3) Specification of the facility Condensing turbine: 3-stage impulse-type turbine with adiabatic efficiency of 72% Generator capacity: 6,600 kW 4) System flow (Refer to Fig. 1)
Improved section
Fig. 1 System flow chart of steam-turbine power generation using top vapor of distillation column Table 2 Energy saving effect
Improvement effect Recovered energy in heavy oil equivalent Reduction in crude oil equivalent 11,300 kL/y 11,978 kL/y
Remark (Fuel oil C basis)
[References]
[Inquiry] Energy Saving Journal (Vol. 32, No. 12, 1980), Japan Chemical Industry Association / ECCJ (JIEC) P. 43
179
CB-ME-4
[Industry Classification] Chemical : BTX [Technology Classification] Machinery & Equipment

Combustion air preheating using heating furnace flue gas in BTX production process
Outline
This plant has three heavy-oil/gas fired reboilers for the distillation column and one gas fired furnace for the reaction-system charge heater. All of them are of a horizontal natural draft type. Accordingly, their flue gas temperatures were as high as 400 to 500C, and their thermal efficiencies were as low as 70 to 75%. This improvement achieved the thermal efficiency of 88% by lowering the flue gas temperature through installing preheaters for combustion air and employing mechanical draft.
Before Improvement
Fig. 1 Combustion system of heating furnaces (before improvement)
1) The natural draft system was modified to a system using forced draft fans (FDFs) and induced draft fans (IDFs). Rotary[Description type air preheaters are installed. of 2) As a measures to suppress NOx emissions, conventional burners were changed Improvement] to low-NOx burners which assure stable combustion even under a low excess-air ratio. The low-NOx burner type: Voltmetric Structure burner of sonic atomizing type explanation, 3) The result of the improvement is shown in Table 1. Shape, and/or System diagram
Table 1 Energy saving and environmental improvement data

Before improvement Energy saving effect SOx emissions NOx emissions 2.29 m3N/h 10.4 m3N/h 1.19 m3N/h 7.1 m3N/h After improvement Effect Reduction by 0.94 kl/h Reduction by 48% Reduction by 32%
Improved section
Fig. 2 Flow chart of improvement by combustion air preheating using heating furnace flue gas Table 2 Energy saving effect by combustion air preheating
Improvement effect Remark (in fuel oil C equivalent)
Recovered energy Reduction in crude oil equivalent *
8.5 x 10 kcal/h (0.94 kL/h) 6,975 kL/y
Note*: Heating furnace operating hours: 7,000 h/y [Economics] Equipment cost Remarks [Example sites] Many sites adopting similar technology [References] [Inquiry] Collection of Energy Conservation Cases 1979, Japan Chemical Industry Association / ECCJ (JIEC) p. 1263 Investment amount: 100 million yen Improvement effect: 140 million yen/year Investment payback: 0.7 year
180
CB-OM-1
[Industry Classification] Chemical : BTX [Technology Classification] Operation & Management

Change of washing system in amine desulfurization process for BTX production
[Energy Source] Fuel (steam), Water [Practical Use] 1984
Outline
At this plant, sulfur-bearing gas generated as a by-product of BTX production by reforming is desulfurized. A survey of the current operation showed that the sulfur concentration in feed naphtha was in a range of 1/4 to 1/ 14 of the designed value. However, the circulation rate of amine as the absorbent of hydrogen sulfide was maintained at the excessive design level. This improvement is to reduce the circulation rate of amine, and reduce the steam rate to the reboiler of the amine regeneration column, eliminating a significant amount of unnecessary energy input. [Operating condition] - The design value of the sulfur concentration in feed naphtha : 1,400 ppm Current operation data: 100 ~ 350 ppm - The circulation rate of amine (monomethanolamine) used to absorb hydrogen sulfide was at the design level. [Description of the process flow] (Refer to Fig. 1) 1) The circulation rates of amine at V301, V302, and V303 were adjusted to optimal values according to the respective feed gas flow rate of each column. 2) The return water from V301, which was a cause of poor water quality, was re-routed so as to be directly fed to V308. This change reduced the pure water feed rate. 3) As a result, steam for the reboilers of V304 and V108 was reduced.
Before Improvement
[Description of Improvement] Structure explanation, Shape, and/or System diagram
Fig. 1 Flow chart of amine desulfurization process Table 1 Energy saving effect by reducing amine circulation rate
Improved section
Improvement effect
Remark
Reduction in steam consumption Reduction in crude oil equivalent
4,200 t/y 342 kL/y
[References]
Many sites adopting similar Collection of Energy Conservation Cases 1985, p. 1001 technology
181
CB-OM-2
[Industry Classification] Chemical : BTX [Technology Classification] Operation & Management Outline

Reboiler heating by waste heat of top vapor of distillation column in BTX production process
This BTX production plant produces benzene, toluene, and xylene from light oil generated as a by-product of coke production. This improvement is to utilize heat of condensation of top vapor of the distillation column, heat held by condensate of steam used in the reboiler.
Before Improvement
Fig. 1 Flow chart of BTX production around distillation columns (before improvement)
[Flow after improvement] (Refer to Fig. 2) 1) By increasing the heat transfer area of the heat exchanger for the top vapor of the crude benzene column by three fold, the heat of condensation of the top vapor is utilized for preheating the feed crude light oil. In addition, the heat of condensation of the top vapor of the crude toluene column and the heat held by the condensate of reboiler steam are utilized as the heat source of the reboiler of the pure benzene column. 2) To do this, a circulation pump for the reboiler liquid of the pure benzene column and a drain heat exchanger are newly installed.
Improved section
Fig. 2 Improved flow for reboiler heating by top-vapor waste heat of distillation columns Table 1 Energy saving effect by waste heat recovery
Improvement effect Reduction in steam consumption Reduction in crude oil equivalent 11,860 t/y 967 kL/y
Remark
182
CB-OM-3
[Industry Classification] Chemical : BTX [Technology Classification] Operation & Management Outline

Waste heat recovery from heating furnace flue gas in BTX production
[Energy Source] Fuel (general) (steam) [Practical Use] 1979
A unit to strip (separate) H2S dissolved in oil after hydrogenation of sulfur compounds (mainly thiophene) in a benzene derivative production process. 1. The unit is a multi-stage deaerator to remove H2S by heating the oil with steam. 2. The operating pressure in a conventional system is 7.5 kgf/cm2G with heating steam of 10 kgf/cm2G. 3. This unit is operated at 3.0 kgf/cm2G with heating steam of 5.2 kgf/cm2G. 4. Thus, the unit enables to reduce steam consumption and steam pressure. 1. The safe operation range of the stripper is an area surrounded by the blowing (upperlimit), pulsating (lower limit), and flooding. 2. The requirements for modification are the following two items. The cross-sectional area of the downcomer at each stage shall be sufficiently large in relation to the amount of liquid flowing down in the column, that is, the treatment capacity. The gap between the bottom of the downcomer and the tray, and the gap betweenthe downcomer and the inlet weir shall be adequate, and the pressure drop shall not be excessively high. 3. Improvements to be made on a conventional stripper are; To enlarge the cross-sectional area of the downcomer and the gap between the downcomer and the inlet weir. To enlarge the tray spacing (reduction of number of stages). To change the tray to a low pressure-loss type (bubble cap tray to perforated tray). 4. Configurations of strippers before and after the modification are shown below.
(Before modification) (After modification)
[Description]
Improved section Modifications The downcomer length was shortened by 17 mm. The inlet weir was distanced from the downcomer by 18 mm. The inlet weir was raised by 2 mm due to the fabrication convenience. At a capacity of 300 t/d, the steam consumption, the steam pressure, and the stripping pressure are the following. Steam consumption Steam pressure Stripping pressure (kg/h) (kgf/cm2G) (kgf/cm2G) Before modification 660 10 7.5 After modification 535 5.2 3.0 Effect 125 (accounting for 7,100,000 per year including the benefit of lowered steam pressure) Investment amount: 15 million yen Improvement effect: 7.1 million yen/year Investment payback: 2 years
[References] Collection of Energy Conservation Cases 1981, Firs volume
183
CB-OM-4
[Industry Classification] Chemical : BTX [Technology Classification] Operation & Management

Control of reflux ratio of distillation column using on-line analyzer
Outline
Since the operation control of the benzene distillation column in this plant was done by analog instruments, changes in feed rate and composition varied the toluene concentration in the product benzene, which raised problems in quality. The improvement is the introduction of decentralized control system (DCS) to the plant, and the adoption of reflux ratio control of distillation column under the on-line control, thus attains the reduction of steam consumption in reboiler. The operation is under a condition of excess value of reflux ratio of distillation column aiming to prevent the toluene content in benzene from largely fluctuate owing to the changes of benzene concentration resulted from fluctuation of feed rate of crude benzene to the benzene distillation column caused by upstream influence (disturbance) or from fluctuation of composition of feed. Furthermore, the bottom temperature of the column is set to higher level than normally expected value to prevent entering benzene into the residue. [Flow after improvement] Refer to Fig. 1 (1)The GC analysis values of feed are entered to the decentralized control system via an advanced control system (ACS), and the control loop is changed to Fig. 1. 1)The quantity of benzene (FC-7) in the feed is determined using the feed analyzer (GC-1) and the flow meter (GC-1), thus controlling the quantity of crude benzene (FC-1). 2)Instead of the control of temperature inside of the distillation column, the internal reflux ratio control (RC1) is adopted, and AC-1 is employed in the superior loop to control the toluene concentration in benzene to a constant level. 3)To the superior group of the temperature inside of the column TC-1, AC-2 is added to control the benzene concentration in the bottom liquid at a constant level. (2)The result is the stabilized dispersion of toluene concentration, the reduction in reflux ratio, and the reduction in steam consumption in the reboiler.
Before Improvement
Improved section
Fig. 1 Control system of benzene distillation column after improvement Table 1 Effect of control of reflux ratio of distillation column
Before improvement After improvement 18010 ppm 470 kg/t-Bz Reduction by 101 kg/t-Bz; (20%) Effect
Toluene content in benzene Reduction of steam unit requirement Reduction of energy (crude oil basis)
13050 ppm 508 kg/t-Bz
184
CG-PE-1
[Industry Classification] Chemical : General [Technology Classification] Production Equipment

Gelatin drying system using heat pump in pharmaceutical production line
[Energy Source] Electricity [Practical Use] 1980s ~
Outline
Gelatin which is widely used in photograph films, drugs, and foods is an extremely hygroscopic material, and the drying of gelatin consumes large quantity of energy. The system is a case of energy saving as well as improving the product quality by switching the conventional steam heat source hot air drying method to the heat pump method. - Flow diagram of steam heating drying process - Flow diagram of heat pump drying process
Improved section [Improved heat pump drying system] (Fig. 4) - Closed system of heat energy employs recycle of heat not to generate waste heat.
[Description]
Improved section Energy saving effects [Economics] Equipment cost Remarks [Example sites] Adopted at many sites. [References] Energy Saving Journal (Vol. 42, No. 4, 1990), ECCJ Version [Inquiry] Japan Chemical Industry Association / ECCJ (JIEC) - Energy cost is reduced by 50%. An actual plant result: Conventional method: 52 million yen/year Heat pump method: 26 million yen/year Investment amount: 80 million yen Improvement effect: 26 million yen/year Investment payback: 3 years
185
CG-PE-2
[Industry Classification] Chemical : General [Technology Classification] Production Equipment

[Energy Source] Electricity, Fuel
Powder detergent drier utilizing turbine flue gas
[Practical Use] 1990
Outline
This improvement significantly reduced fuel consumption by a heating furnace in a powder-detergent production line. When planning in-house power generation for peak power demand in the plant, a power generation system in which all the gas discharged from the gas turbine is recovered for reuse was adopted. The recovered heat is used as heat sources for driers and other facilities for producing powder detergents for clothing. [Energy balance of gas turbine generator] (Refer to Fig. 1) [Relation among fuel types, atomizing-air volume, and dust generation] (Refer to Fig. 2) When planning to use flue gas directly, its effect on the product quality needs to be checked.
Fig. 1 Energy balance of gas turbine
Fig. 2 Relation among fuel types, atomizing-air volume, and dust generation
[Description]
[Gas-turbine specification] Gas-turbine generator: 750 kW, simple open cycle, single-axis type Flue-gas temperature: 300-500C
Detergent
Improved section
Fig. 3 Flow chart of direct utilization of gas turbine flue gas for drier
Energy saving Gas-turbine energy efficiency: power generation (about 20%), waste heat recovery (about 75%), total 95% (Refer to Fig. 1) effects [Economics] Equipment cost Remarks [Example sites] Some sites adopting similar technology. [References] Collection of Energy Conservation Cases 1989, p.1273 [Inquiry] Japan Chemical Industry Association / ECCJ (JIEC) Investment amount: 30 million yen Improvement effect: 10 million yen/year Investment payback: 3 years
186
CG-ME-1
[Industry Classification] Chemical : General [Technology Classification] Machinery & Equipment

Ethanol recovery unit using steam recompression heat pump at alcohol distillation column
Outline
This improvement is to utilize a high-temperature heat pump for recovering waste heat of the alcohol distillation column. The heat of condensation of top vapor of the distillation column, which was formerly wasted into cooling water, is recompressed by a screw compressor (VRC, MRC), and utilized to heat the bottom liquid of the column. [Example of ethanol recovery from aqueous ethanol solution] 1) As shown in Fig. 1, the vapor having a composition near to that of azeotrope (ethanol: 95.6 wt.%, 78.15C, 760 mmHg) is taken out from the column top, and the steam (73C, 265.3 mmHg) is generated by the condenser/evaporator. The steam is heated to 816 mmHg (saturation temperature of 102C) using a screw compressor (compression ratio of 3.08). 2) Since the facility gives a nearly zero alcohol concentration at the bottom of the column, the discharged steam can be directly injected, and no reboiler is necessary.
[Description]
Improved section
Fig. 1 Heat recovery system by steam recompression using heat pump at alcohol distillation column
Table 1 Energy saving effect by heat pump VRC

Conventional system Heat pump VRC Reduction effect
Steam consumption Power consumption Annual energy consumption Consumption in crude oil equivalent
1,600 kg/h 163 kWh 11,200 t/y 913 kL/y 1,141,000 kWh/y 277 kL/y Reduction of 636 kL/y
(Operating hours: 7,000 h/y) [Economics] Equipment cost Remarks [Example sites] Buyo Gas Corporation [References] OHM (No. 6, 1988), P. 49 [Inquiry] Japan Chemical Industry Association / ECCJ (JIEC) Investment amount: 52 million yen Improvement effect: 12.8 million yen/year Investment payback: 4 years
187
CG-ME-2

Reduction of waste water to be incinerated using reverse osmosis membrane in phenol production process
Outline
Since the waste water generated in a phenol production plant contains phenol, acetone, and polymers of these, the biological treatment is difficult, and all of the waste water is incinerated by incinerators. Fuel consumed to treat the waste water accounts for about one third of the total consumption of fuel in the plant. This improvement is to reduce this fuel consumption.
Description of Process
Fig. 1 Incineration of waste water of phenol plant
[Flow of reverse osmosis membrane treatment] (Refer to Fig. 2) 1) Waste water to be treated is 228 t/d from the oxidizer system, 125 t/d from the distillation system, and 72 t/ d from other systems. As the property of waste water from each system differs, several kinds of membranes were tested. 2) It was decided that only the waste water from the distillation system is to be processed by the reverse osmosis membrane (RO membrane) after preliminary treatment. As a result, the volume of concentrated liquid to be incinerated was reduced to about one fourth. The treated liquid can be reused as a process water as its phenol content was reduced,. 3) For reference, Table 1 shows the observed data of RO-membrane treatment of waste water from the distillation system.
Table 1 Observed data of RO-membrane treatment of waste water from distillation system
Item Water throughput (t/d) COD (ppm) Phenol (ppm) Color
Feed liquid 125 7,000 500 Brown
Treated liquid 94 200 50 Transparent
Concentrated liquid 31 27,400 2,000 Black-brown
Fig. 2 Flow chart of RO-membrane treatment of waste water from distillation system Table 2 Energy saving effect by RO membrane
Improved section
Improvement effect Reduction of auxiliary-fuel consumption Reduction in crude oil equivalent 1,307 kL/y 1,385 kL/y
Remark (Fuel oil C)
[Example sites] [References] [Inquiry] Some sites adopting similar tech- Collection of Energy Conservation Cases 1987, Japan Chemical Industry Association / nology p. 1685 ECCJ (JIEC)
188
CG-ME-3
[Industry Classification] Chemical : General [Technology Classification] Machinery & Equipment Outline Before Improvement

Improvement of oxygen enrichment process for bulk pharmaceutical production
[Energy Source] Electricity [Practical Use] Around 1994
In a conventional process for producing pharmaceuticals, the oxygen enrichment process adopted a vacuum concentrator using a steam ejector. This improvement saved significant energy by switching the vacuum concentrator to a membrane (ultra-filtration membrane) concentrator. Conventional vacuum concentration using steam for oxygen enrichment had following problems. 1) Instantaneous power failures or equipment troubles increased the liquid temperature, and generated a large amount of poor-quality products. 2) It required many types of equipment for the purposes such as heating, cooling, and evacuating, and they consumed a large amount of energy. In addition, unmanned operation was not possible. Evacuation-concentration system [Before improvement]
Ultra-filtration membrane system
[After improvement]
Improved section
Table 1 Comparison of energy saving effect and environmental improvement
Before improvement Facility capacity Reduction in power consumption Reduction in crude oil equivalent 75 kW 18,000 kWh/Y
After improvement 15 kW 3,000 kWh/Y
Reduction of energy 60 kW 15,000 kWh/Y 3.6 kL/y
Investment amount: 61 million yen Improvement effect: 32.7 million yen/year Investment payback: 1.9 years
[References] Collection of Improvement Cases at Excellent Energy Management Plants (1995)
Tokyo Tanabes Ashikaga Plant
189
CG-ME-4

Power generation by turbo-expander in telephthalic acid production process
Outline
In the feed-oxidizing reaction process for telephthalic-acid production, a large amount of non-reactive nitrogen contained in the air is emitted to the atmosphere. The temperature of the emitted flue gas varies with seasons: about 20C in winter and about 60C in summer. This improvement significantly saved energy by recovering the energy of the flue gas, which had formerly been dissipated to the atmosphere, using a gas expander (expansion turbine). [Selection of energy recovery system]
Table 1 Selection of a system to recover energy from flue gas
Energy recovery system Gas exp (1) compresander + Steam sor exp (2) Gas presander + Turbo com sor (3) Gas expander + Small power generator
Recoverable energy 5kg/cm2G steam 13.8t/h Electricity: 1,740kW Steam: 3.7t/h Electricity: 2,600kW Steam: 4.0t/h
Merit (million yen/year) 100 136 176
Investment (million yen) 450 290 280
Invesment effect (Investment/Effect) 4.1 2.1 1.6
[Description]
1) The flue gas has the energy of 36,000 m3/h and the pressure of 20 kg/cm2G. 2) Gas expander specification Expansion turbine: three-stage impulse-type (with heaters at inlet and intermediate stage) Generator : induction generator Output : 2,600 kWh/h 3) Power generation system (Refer to Fig. 2)
Improved section
Fig. 2 Power generation system by gas expander (expansion turbine) Table 1 Energy saving effect by gas expander
Improvement effect Power generation Increase of steam consumption Reduction in crude oil equivalent 20,800 Mcal/y 32,000 t/y 2,445 kL/y
Remark (2,600 kW) (4 t/h)
Investment amount: 280 million yen Improvement effect: 170 million yen/year Investment payback: 1.6 years - The turbine rotor shall be made of SUS materials. [References] [Inquiry] Energy Saving Journal (Vol. 32, No. 2, 1980), Japan Chemical Industry Association / ECCJ (JIEC) P. 31
190
CG-ME-5

Waste heat recovery from solvent separator vapor using absorption heat pump in butadiene production process
Outline
In this process, steam is introduced to the separator to heat and separate the solvent from the feed. The temperature of vapor leaving the separator was about 90C, and this heat of condensation was wasted into the cooling water at the cooler. This improvement for energy saving is to recover the waste heat in a form of hot water using a heat pump, vaporize it in a flash tank, and reuse the steam at the separator. The absorption heat pumps are classified into Class 1 and Class 2 as shown in Table 1 by the application method of waste heat.
Table 1 Classification and features of heat pumps
Driving power Class 1 (cycle) Class 2 (cycle) Steam (5 to 10 kg/cm2G) or fuel Waste heat (60 or more)
Low-temperature heat source Waste heat, environment Waste heat (60 or more)
Usable heat About 170% of the driving power in thermal equivalent Less than 50% of the waste heat used
Generated heat temperature range 80 - 120 C
Cooling water
Not necessary
160 or less
Necessary
[Description]
1) A Class-2 absorption-type heat pump is installed in parallel with the existing cooler. Heat of condensation at the cooler is 4.3 x 106 kcal/h. 2) The absorption heat pump recovers the waste heat of the cooler in a form of hot water (133C), from which steam (127C) is generated in the flash tank. The generated steam is supplied to the solvent separator. The vapor condensed in the heat pump is separated into solvent and water in the drain tank. The separated water is reused as make-up hot water for the heat pump.
Improved section
Fig. 1 Flow chart of Class-1 absorption-type heat pump Fig. 2 Flow chart of Class-2 absorption-type heat pump applied to solvent separation process
Table 2 Energy saving effect by waste heat recovery using heat pump
Improvement effect Reduction in steam consumption Increase in power consumption * Reduction in crude oil equivalent 24,000 t/y 234 x 103 kWh/y 1,900 kL/y
Remark Total (in heavy oil equivalent) 1,792 kL/y
[References] Energy Saving Journal (Vol. 36, No. 7, 1984), P. 15
191
CG-ME-6
[Industry Classification] Chemical : General

Low temperature catalyst combustor
[Energy Source] Fuel (general)
[Practical Use] [Technology Classification] 1970s Machinery & Equipment 1) A catalyst to oxidize waste gas containing organic matters, tar generated in a furnace and hydrocarbons at a low temperature of 350C or below. 2) Oxidization decomposition allows to apply the catalyst for deodorizing, effective use of oxidization heat, Outline and cleaning of waste gas, etc. 3) Low temperature combustion suppresses the thermal NOx generation Principle & Mechanism 1) The supporting metals are Pt, Pd, or Rh. 2) The catalyst effect enhances oxidization at a low temperature level (150 to 350C depending on the type of gas). 3) The operating condition is space velocity of 20,000 to 40,000 l/h, and catalyst bed height of 15 to 25 cm. 1) The catalyst is used in a shape of grain, honeycomb, foam, or fiber, depending on the operating condition. 2) Following is an example of a catalyst system.
[Description]
Substance
Operating temperature (C)
Concentration before treatment (ppm)
Concentration after treatment (ppm)
Improved section
Energy saving effects [Economics] Equipment cost Remarks [Example sites]
Compared with a direct heating (high temperature oxidization) waste gas treatment facility, the fuel cost is decreased to a level of 30 to 35%. Investment amount: 50 million yen Improvement effect: 15 million yen/year Investment payback: 3.3 years Deodorizing and removal of harmful substances from waste gas of a chemical plant, oxidization cleaning of unburnt gas and tar in an incinerator. [References] [Inquiry] The Agency of Natural Resources and Energy, Japan Chemical Industry Association / "Energy Conservation Setsubi Souran," P245, ECCJ (JIEC) The Energy Conservation Center, Japan, 1986.
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Section 3 Chemical Industry Process Flow 3-1 Ammonia 3-2 Caustic Soda 3-3 Naphtha Cracking 3-4 BTX

Chemical (Ammonia) : Production Process and Energy Saving Technology

Grassification (reforming) process

Gas refining process

Chemical (Caustic soda) : Production Process and Energy Saving Technology

Caustic soda production process

Item No. CS-PE-3 CS-PE-2 CS-ME-1 CS-ME-2 CS-OM-1

Item No. CS-PE-1

Chemical (Naptha Cracking) : Production Process and Energy Saving Technology

Naptha cracking production process

Chemical(BTX) : Production Process and Energy Saving Technology

Energy Conservation Directory

[Practical Use] After 1960

Principle & Mechanism

Structure explanation, Shape, and/or System diagram

[Economics] Equipment cost Remarks [Example sites]

Energy Conservation Directory

Fig. 1. Heat-exchanger-type primary reformer

Energy saving effects

[Economics] Equipment cost Remarks

[Example sites] Adopted at many sites.

Energy Conservation Directory

Structure explanation, Shape, and/or System diagram

Energy saving effects

Reduction in unit requirement after the improvement 0.14 x 106 kcal/t-NH3

[Economics] Equipment cost Remarks [Example sites]

[References] Makers in-house technical documents

[Inquiry] Japan Chemical Industry Association / ECCJ (JIEC)

Adopted at some sites.

Energy Conservation Directory

Energy saving effects

Reduction in unit requirement after the improvement 0.17 x 106 kcal/t-NH3

[Economics] Equipment cost Remarks [Example sites]

Adopted at some sites.

Energy Conservation Directory

Structure explanation, Shape, and/or System diagram

Energy saving effects

(at operation rate of 100,000 t/y)

Effect of the improvement

[Economics] Equipment cost Remarks [Example sites]

Energy Conservation Directory

CO oxidizer in ammonia production process

[Practical Use] 1971~

Principle & Mechanism

Structure explanation, Shape, and/or System diagram

Energy saving effects

Reduced unit requirement after improvement 0.07 x 106 kcal/t-NH3

Effect of improvement 2,851 kL/y

[Economics] Equipment cost Remarks [Example sites]

Adopted at some sites.

Energy Conservation Directory

Energy saving effects

Table 1 Energy saving effect

[Economics] Equipment cost Remarks [Example sites]

[Inquiry] Japan Chemical Industry Association / ECCJ (JIEC)

Energy Conservation Directory

Principle & Mechanism

[Description] Structure explanation, Shape, and/or System diagram

Fig. 1 Schematic cross section of separation membrane module

- Energy saving effect Energy saving effects

Energy Conservation Directory

Principle & Mechanism

Energy saving effects

[Economics] Equipment cost Remarks [Example sites]