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APPLICATION OF EXERGY AND PINCH ANALYSIS ON OLEOCHEMICAL

FRACTIONATION PROCESSES

LEE CHEE HONG AND ZAINUDDIN ABD. MANAN

Department of Chemical Engineering, University Technology of Malaysia,
81310 Skudai, JohorBahru, JohorDT.
E-mail: chlee @celcom.net.my: zain @ fkkksa. Mm.m\

The energy conservation and efficiency using combined exery-pinch analysis of this paper is based
on the oleochemical fractionation plant. Oleochemical is a chemical component that is derived from
palm/vegetable/animal oils (e.g. fatty acids, fatty alcohol, glycerine). Since oleochemical processes
usually operate under relatively high temperature and low-pressure conditions, large amount of high-
quality energy may be lost during the process operations. It is, therefore important for engineers and
scientists to prevent these losses, in order to save operating costs and reduce environmental
emissions. This paper presents the process simulation model developed for the oleochemical plant
that provides detailed mass and energy balances, thermodynamics and transport properties for the
process streams for the purpose of the exergy and pinch analysis studies. Exergy analysis is a tool
that, based on the First and Second Law of Thermodynamics enables a designer to identify the
location, type, and magnitude of real work loss [1]. Exergy analysis can guide steps to improve
energy inefficiencies, one of which is through the use of pinch analysis technique which focuses on
the optimal design of heat recovery network and utility systems [5].

1 INTRODUCTION

To date, there has been no publication on exergy and energy studies for oleochemical
processes [7]. The exergy method of analysis is based on the second law of
thermodynamics and the concept of irreversible production of entropy [1]. Pinch
Technology is a useful systematic method that primarily involves the 1sl law and 2nd law
of thermodynamics. Its application enables engineers to gain the maximum potential
energy recoverable from a process and provides guidelines to provide an optimal heat-
recovery network design to achieve this objective [2]. This insight also able to predict and
optimize the overall utility consumption and process structure early during the design
stage [3].
This paper focuses on the development of a steady state model of an oleochemical
fractionation process. This model, which has reconcilled with plant operation data,
consists of complete mass and energy balance data, will be used in the main part of our
research, i.e. in proposing energy-efficient oleochemical plant using a combination of
exergy-pinch analysis techniques.

2 BACKGROUND CONCEPT

2.1 The concept of exergy

Exergy or formerly called work availability is a therrnodynamic function of state like
enthalpy and entropy; it's defined as the availability of work in the gas, fluid or mass as a
result of its nonequilibrium condition relative to some reference condition [1]. Exergy
function is in general defined as:
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Ex = ( H - H c ) - T o ( S - S 0 ) Eq.(l).

Conventionally, heat balance calculation only involves the heat rejected in energy
efficiency analysis, this is an inappropriate approach to calculate energy efficiency
without considering the exergy (2nd law) losses. Recall the first law of thermodynamics:

W = H , - H 0 + Q(To) Eq.(2).

Second law of thermodynamics entropy balance:

AS = dCWT Eq. (3)

QTO = T 0 ( S , - S „ ) Eq.(4).

Combined Eq. (2). and Eq (4), we could obtain an maximum work (or exergy) as shown
in Eq. (1). Equation (1) above can only apply for constant pressure and temperature
conditions, for finite temperature and pressure condition, it needs to be developed to
produce an appropriate equation.

At finite AT, and P constant:

AEx = AH \-To* Eq. (5).

{T2-Tt j

At finite AP, and T constant­

ly =nflrin^- ^ (°)-

2.2 The concept of pinch analysis

Pinch technology has become accepted as a general process design tool since its initial
development in the seventies as a heat exchanger networks design tool. The term 'Pinch
Technology' has been introduced more recently in the context of more general systems
such as refrigeration systems, heat and power co-generation systems, distillation and heat
recovery processes etc. [2].
A Pinch Analysis starts with the heat and material balance for the process. Using
Pinch Technology, it is possible to identify appropriate changes in the core process
conditions that can have an impact on energy savings [5]. After the heat and material
balance is established, targets for energy saving can be set prior to the design of the heat
exchanger network. The Pinch Design Method ensures that these targets are achieved
during the network design [11].

3 STEADY STATE MODEL DEVELOPMENT

3.1 Process Description

Palm kernel oil (PKO) is fed into the first column, the lighter fatty acids get distilled in
the packed column under vacuum and heavier acids remains at the bottom of the column.
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The top lighter fraction is cooled and pumped put to storage as finished product. The
bottom fraction of the first column is pumped to the second column as feed and undergoes
the same process as in the first column. The other individual components are recovered in
the same manner as in the preceding column and the process is repeated in the third and
the fourth columns.

3.2 Steady State Model development of Fractionation Process

Aspen Plus™ steady state simulation has been successfully carried out, all simulated
results have matched and met the plant operation data. This model produces complete
thermodynamic properties, mass and energy flows, transport phenomenon and physical
properties of each component in every single stream.

3.3 Component properties estimation

Property databases for oleochemicals (chemicals derived from palm/vegetable oil) are
normally incomplete in most commercial process simulators. Thus, databases for these
chemicals need to be supplemented or supplied by user.
For the oleochemical process under study, some crucial information that is required
for component and stream property estimation, include the components structural
formula, normal boiling point (TB) and molecular weight (MW) [3]. Property Constant
Estimation System (PCES), module in Aspen Plus® simulator estimates the property
parameters required by physical property model, including, all pure component
thermodynamic and transport property model parameters [3].

4 EXERGY ANALYSIS ON THE OLEOCHEMICAL PLANT

4.1 Exergy A nalysis of Heat Exchanger Processes

Most of the heat exchangers in this process operate in high temperature (>200 °C), in
exergy analysis, the higher process temperature, the lesser efficient of the process.

(T/r 0 <xl/r|) Eq.(7)

Therefore, it's important for this research to implement exergy analysis especially in
all the heat exchangers of fractionation process. If the heat exchanging process undergoes
a constant P process, apply Eq (5) to calculate the AEx, while for finite AT and AP
conditions, combine both Eq (4) and Eq (5) to produce its AEx.

4.2 Exergy Analysis of Separation Processes

In nature, separation processes require extra potential or exergy, we could see the overall
exergy balance from this relation, Exergymixlure < Exe^y^,*,,*,,,, where Potential =
exergycomp0nent - iixergy „,;,(,„
We should include these 'potential' during the overall exergy lost calculation, which
we noted as AEx,*. All the output exergy are subtracted from the input exergy streams to
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produce column exergy lost This value can be used to find out the degree of inefficient of
columns.

E x l o s t = A E x f e e d + AEXreboUe, - AEXcond^se, - A E x ^ - A E x ^ ™ - AEXoe Eq.(8).

The exergy and energy can be calculated using the equations above for each point
(stream) of the process, after all, the results can be tabulated, from this table, one can
identify the location, magnitudes and types of exergy loss during the fractionation
process, this method, namely point method of exergy analysis, gives a initial picture to
designer or engineer to have a rough idea on energy recovery and optimization exercise.
As a result of the exergy analysis (Table 1), the fractionation plant requires input
exergy of 13349.0 MJ/hr, the exergy loss occoured is 6512.8 MJ/hr, this gives an overall
plant exergy efficiency of 51.2 %.
From this analysis can illustrate the real work losses in the process, the contributor
for these exergy losses could be came from heat transfer through temperature gradient,
irreversibility of process, heat transfer through pressure drop and temperature drop. All
these exergy losses couldn't not be discovered if the energy analysis are based on the 1st
law heat balance. Some minor exergy losses including flow friction, machine inefficiency
etc, however, are assume negligible.
Table 1. Summary of exergy calculation

Input Exergy Exergy Loss Exergetic

MJ/hr MJ/hr Percentage
%
13349.01 6511817 51.21124

5 PINCH ANALYSIS

The main utility that utilized by fractionation plant is low pressure steam, there are only
two cold streams in this plant. High boiling point of the heavy key components require
more energy to reboil, this condition occurs during the reboiling process in the columns,
all this four reboilers operate at the temperature ranging from 213°C - 275 °C, which is
above the pinch temperature. Meanwhile, all the condenser of this plant operate below the
pinch temperature, according to "golden rules" of pinch technology, [11], no transfer heat
across the pinch, therefore, only a relatively small quantity of energy could be integrated
for this plant.
Figure 1 shows that only three cold streams can be integrated with hot streams, three
interchangers are needed in this case, the integration of these stream saves up to 656.7 kW
cooling and 437.7 kW of heating utilities. The capital investment analysis will be done
according to total energy saved from the integration. Nevertheless, a huge amount of
external heating (4303.436 kW) is still require to reboil the bottom products for the four
column respectively. For condensers, the external cooling of 2459.278 kW that released
could be transfer to water to produce low-pressure steam for other usage, such as
preheating. The reasons why not all the hot streams (included condensers) can be
integrated with the cold streams, as mentioned earlier, including [2].
i) integration is not practical, where the cpcoid > cphc and Tcoid (i„i«) > T^, (inlet)
ii) not economic, it requires large exchanger area to achieve the integration.
iii) low heat duty of the hot stream.
iv) Crossing pinch heat transfer.
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Below Pinch PINCH Above Pinch

410J)kVvV 223.14 223.14 ..—.— 0 —r

223.14 223.14
27.7 kW
223.14 223.14 . _ ._ . 4 ,,
r 223.14 223.14 .— _. ^ «
4. 223.14 223.14 656.7 kW

External Heating External Cooling

Figure 1. Heat exchanger networks representation

6 ACKNOWLEDGEMENTS

I would like to extend a gratitude to Dr. Zainuddin Bin Abdul Manan, my research project
supervisor for his assistance and tireless effort in helping me during this research. Without
his valuable guidance and support, this manuscript would not have been accomplished. To
oleochemical plant management and staffs, thanks for their co-operation and helps during
the collection and extracting of plant operation data. Last but not least, I like to express
my thanks to En. Kamal bin Baderon, who helped me in operating Aspen Plus.

7 REFERENCES

[1] John E. Ahern, 1980, The Exergy Method of Energy Systems Analysis.
New York, Wiley-interaction Publication.
[2] Linnhoff B, D.W. Townsend, D. Boland, G.F. Hewitt, B.E.A. Thomas,
A.R.Guy, and R.H. Marsland, 1982, User Guide on Process Integration
for the Efficient Use of Energy, IChemE, Rugby, U.K.
[3] Aspen Technology Inc., 1992, Aspen Plus™ User Manual Volume 1
Release 9. Massachusetts, USA, Aspen Tech.
[4] Smith, J.M., 1987, Introduction to Chemical Engineering
Thermodynamics. 4th Ed. New York, McGraw-Hill Book Company.
[5] Linnhoff, B. and Eastwood, A., December 1987, Process Integration
using Pinch Technology, Boston : 108th ASME Winter Meeting.
[6] Dale, J., 1984, Energy Audits Manual, MD, USA: Government
Institutes, Inc.
[7] Ademe-ADB Study Team., October 1993., Energy Conservation Study
in Malaysia, Training Workshop for Energy Auditors, Kuala Lumpur.
[8] Vikas R. Dhole and Jian P.Z., Applying Combined Pinch and Exergy
Analysis to Closed Cycle Gas Turbine System Design, CPI, UMIST,
Manchester.
[9] Kaiser, V. 1993, Industrial Energy Management, Paris, Edition
Technip.
[10] Aspen Technology Inc., 1990, Process Integration using Pinch
Technology, Technical Articles, Massachusetts, USA, Aspen Tech.
[11] Smith, R. 1995, Chemical Process Design. New York, McGraw-Hill
Book Company.