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Approaches to Optimise Heat Recovery

Traditional Approach Based on Experience Mathematical Method Thermodynamic Method

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Traditional Approach
Largely based on Heuristics OR Previous Design Experience Several alternatives need to be generated and Simulated to Establish the Best Possibility of Sub-Optimal Design

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Mathematical Method
Formulate the design as a Mathematical Optimization Problem Requires High Degree of Mathematical Skill and Programming Effort Little OR no Physical Insight - Use of Brute Force

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Thermodynamic Method (Pinch Technology)

User-Driven approach in the Development of Energy and Process System Set Energy and Capital Targets before Design Analysis Based on Physical Insight

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Pinch Technology Approach

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General Process Plant

Makeup Light Ends

Heat Exchanger Network

Stripper Reactor Feed Product

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Example of Application

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A Typical PFD
Reactor Steam

Steam

Feed

CW

Product

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Reactor

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Design Comparison for Simple Process

Reactor Steam Steam

Steam

Feed Product CW Feed Product

Steam = CW = Area =

1722 654 629

Steam = CW = Area =

1068 0 533

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Pinch Technology Tools

Composite Curves Grand Composite Curves Area Vs. Energy Plot

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Consider This Simple Process...

Feed 80 T 200 Steam 200

Reactor

Product 200 CW Steam 90

90 80

CW

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Process Heat Exchange Reduces Both Stream and Cooling Water

T 200 Steam

Curves are Shifted Horizontally towards each other

90

Recovered Heat = X
80

CW

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Improved Design...
Reactor 20

Stream Feed 80 CW Product 90

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Energy / Capital Tradeoff

Total Capital Energy

T Min.

Opt.

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Pinch Technology: Experience Base

PETROCHEMICALS
Acetic Acid Amines Aromatics BTX Butadiene Caprolactum Cyclohexane Ethylene Phenol Pthalic Anhydride Polymers Styrene Vinyl Chloride Monomer

BULK INORGANICS
Ammonia Chlor - Alkali Fertilisers General Chemicals Nitric Acid Soda ASH Sulphuric Acid

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Urea

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Case Study - 1 Crude Preheat Train Objective Throughput Increase

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Basis of Study
Crude Basis - Lightest Crude (Highest Furnance Absorbed Duty) Retain Furnance Duty Minimum Changes for Quick Implementation Pay Back less than One Year Utilities not a Constraint

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Preheat Train Already well Integrated by an Independent Consultant What Can We Do Further?

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Scope for Energy Savings

Hot Utility Target less than the Existing Furnace Duty by 1.8 Mmkcal/hr. Is That All?

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WHAT IF REBOILER DUTIES ARE TREATED AS UTILITIES?

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Pinch Analysis Conclusions

Cross Pinch Heat Transfer

Heat Transfer from RCO above Pinch to Crude (To Preflash Tower) Below Pinch

Criss Cross Heat Transfer

Heat Transfer from HSD Pump around to Stabiliser Reboiler

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Summary
Crude Preheat Temperature of 276C Improvement by 6C Potential for Increased Throughput by 12% Simple Payback of 9 Months

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Case Study - 2 Low Level Heat Recovery

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Crude Unit Revamp

Objectives Maximise Throughput Improve Product Separation Increase Fired Heater Efficiency

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Objectives for Pinch

Crude Throughput Increase By: 15% Retain Present Furnace Use of HP Stream to be Avoided Preheat Temperature to Preflash: 240C Preheat Temperature to Crude Column: 360C

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Steps for Revamp

Heat Duty Throughput, Preheat, Pump Around

Optimisation of Preflash, Main Column, Stabliser

Targeting Composite & Grand Composite Curve Maximum Energy Recovery

Practical Design

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Prima Facie - Furnace is Sufficient Can We Do Better?

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Summary
Potential for Low Level Heat Recovery Demonstrated Processes Requirements Completely Met No Change in Furnace Duty