ESL-IE-09-05-35

Exergy Analysis of the Steam Network in Tehran Oil Refinery and evaluation with
New Scenario
Hassan Khodaei JA Ramin Taheri seresht Reza Arghandeh
Energy system Lab Chairman of the Board of Directors Electrical & Computer Engineering
K.N.Toosi University,Mechanical Dep Yasun Farayand Co. Mississippi State University
Tehran, Iran Tehran, Iran MS 30759

Figure 1 shows the opportunities of optimization in

steam networks.
ABSTRACT in this paper, we complete the lost works such as
The importance of energy crisis and global warming optimization and estimation of carbon dioxide
necessitates to present strategies in order to decrease emission through the steam generator sources with
the amount of emissions as well as fuel consumption in calculating the amount of exergy destruction in the
large and complex industries such as refining and exist case and the best case [1], [6] .As a result of
petrochemical. In this paper, the steam network in calculations, we can find new ways to reduce energy
Tehran oil finery is selected as a case study, after loses with increasing the efficiency of devices in steam
simulation and optimization of the steam network the
best scenario is selected regarding to minimum total
annualised cost with considering minimum carbon
dioxide reduction. From the exergy analysis it can be
notified that the main parts of Exergy losses occurs in
the boilers in the exist model. in the best scenario that
is selected with considering different functions, the
amount of exergy losses decrease significantly because
of retrofit in the steam generation sources as well as
variation of the types of fuel consumption. The final
results are: decrease the amount of exergy destruction
in the retrofit scenarios consequently, reduce total
annualised cost as well as reduce carbon dioxide
emission. networks.

Keywords: Crude oil refinery, Exergy Analysis, Steam

Network, Retrofit, Optimization Figure 1: The opportunities of optimization in steam
networks [1]-[2].
1. INTRODUCTION
Refinery steam network is considered as a unit that 2. A REVIEWS OF PAPERS IETC 2008
consumes energy greatly. The main objective of the
Gas
network is to produce the steam, which is required in Scen Boil 1 Boil 2 Boil 3 Boil 4 HRSG St Tr
Tur
different site processes. The amount of fuel 1 9 9 9 9 - - 9
consumption in steam networks is enormously high, 2 9 9 8 8 9 9 9
because of boilers and other fuel-consuming 3 9 9 8 8 9 9 9
components existence. Hence, reduction of energy 4 9 9 8 8 9 9 8
consumption saves total operating costs significantly. 5 9 9 8 8 9 9 8
In addition, it is possible to reduce total annualized
6 9 9 9 9 - - 9
cost through introducing new scenarios, which
improve the networks performance.
Different approaches are proposed to optimize steam 2.1 Scenario Suggestion
networks, which can be categorized as: (1) Using Table 1: The scenarios proposed to modify the steam
renewable energy; (2) Promoting the network's network.
components performance; (3) Selling or buying the
power exported or imported that it depends on 2.1 Simulation of Tehran Oil Refinery Steam Network
political and geographical strategies of countries; (4)
Steam coupling between the networks and adjacent After presenting the scenarios, the steam network is
power plants; (5) Using heat recovery steam simulated in STAR [3] software environment. The
generating systems and gas turbines instead of old simulation results such as total annualized cost, fuel
boilers and so on. heat load of all processes and equipment as well as
unused heat load will be used to the optimization

Proceedings of the Thirty-First Industrial Energy Technology Conference, New Orleans, LA, May 12-15, 2009

phase. Figure 2 shows simulation of the scenario 1 and
6. Figure 3 illustrates the scenarios 2 to 5 simulated in
the software.
Figure 2: Steam network of Tehran oil refinery
(Northern site) [4],[5],[6].
Figure 3: The steam network of Tehran oil refinery
modified according to the new scenarios (2-5) [5],[6]
2.2 Optimization
The objective function of optimization is to minimize
total annualized costs. Some parameters can be limited
during the optimization such as gas turbine power, the
amount of the steam produced in HRSG as well as fuel
ratio. The optimization approach is based upon fixed
header conditions e.g. temperature and pressure. The
steam system model is first simulated and the
pressures and temperatures of the steam main fixed.
The model is then optimized using a linear program
with the temperatures of the mains fixed. Re
simulation of the model then allows the temperature of
the steam mains to be determined. These temperatures
are then fixed, the model re optimized using a linear
program and re simulated, and so on utile convergence
is achieved [4]-[1]. During optimization, the amount
of the steam consumed through the refinery units is
fixed. The letdown stations are used to increase
degrees of freedom. It is not allowed to vary driver
turbines power in order to connect directly them to a
drive such as pumps and compressors. The cost of
Proceedings of the Thirty-First Industrial Energy Technology Conference, New Orleans, LA, May 12-15, 2009
ESL-IE-09-05-35
steam is calculated according to the fuel cost and other
costs of headers [4]-[1]. The cost of each steam level
is the cost of the next highest level mines the value of
the power generated from the expansion from the next
highest level. If there are utility boilers generating
steam into the lower pressure steam mains, then the
cost of operating these boilers must also be added to
the cost of steam at that level [4].
2.3 Analysis of Tehran Oil Refinery Steam Network
Considering CO2 Emission
Carbon dioxide as a greenhouse gas plays a vital role
in global warming. Studies show that it is responsible
for about two-thirds of the enhanced greenhouse
effect. In order to meet the environmental regulations
as agreed in the Kyoto Protocol, the chemical process
industries are challenged to reduce their greenhouse
emissions, in particular CO2 emissions [7].
The results of simulation (Figure 12) and optimization
(Figure 13) indicate that the amount of TAC with and
without CO2 tax has reduced dramatically after
optimization in all proposed scenarios. The scenario 5
is the best, from viewpoint of TAC (with and without
CO2 tax).
Figure 4: The amount of fuel consumption in the
proposed scenarios in both simulation and
optimization state
Figure 5: Total annualized cost of the proposed
scenarios after optimization
 ESL-IE-09-05-35

I&Turbine= E&in − E&out = ∑(m

& e)in −W&out − ∑(m
& e)out (5)

3. EXERGY ANALYSIS OF THE STEAM

NETWORK IN TEHRAN OIL REFINERY Where, Wout is the shaft work produced [8]-[9].

Regarding to the previous results, now we calculate

the amount of Exergy destruction between the exist 4. RESULTS
case and the scenario 5 as the best scenario. In this paper, the amount of exergy destruction and
3.1 exergy definition and correlation losses are calculated for the steam and the gas
turbines as well as HRSG and expansion valves. The
Exergy is the maximum theoretical useful work amount of exergy losses and destruction are calculated
attainable from an energy carrier under the conditions for the scenario 1 as the exist case and the scenario 5
imposed by an environment at given pressure p0 and as the best scenario after optimization, that are shown
temperature T0, and with given amounts of chemical in Table 2. The results imply that the amount of exergy
elements. The purpose of an Exergy analysis is losses and destruction have reduced remarkably in the
generally to identify the location, the source, and the optimum state of scenario 5.
magnitude of true thermodynamic inefficiencies in the
plant. Disregarding kinetic and potential energy
changes the specific flow exergy of a fluid at any cycle
state is given by: Table 2: the amounts of Exergy destruction in the
Components Exergy Destruction (MW)
e = h – ho –To(s – so) (1)
Exist Case Scenario 5
HRSG 0 60.56
The reversible work as a fluid goes from an inlet state
to an exit state is given by the Exergy change between Gas Turbine 0 2.73
these two states. That is: Compressor 0 0.96
Chamber 0 16.62
e2-e1 =h2 - h1 –To(s2 - s1) (2) Boiler 1 39.86 55.90
Boiler 2 39.86 0.00
Where, the subscripts 1 and 2 represent the inlet and Boiler 3 39.90 0.00
the exit state for a flowing fluid. Boiler 4 39.87 0.00
A. Combustor Vent 0.02 4.72
The exergy destruction in boiler is calculated as:
Let-down 1 0.08 0.24
Let-down 2 0 1.44
I&Combuster = E& in − E& out = ∑ ( m& e ) in − ∑ ( m& e ) out (3) Let-down 3 0.075 0.95
Steam Turbine 1 2.74 0.00
Where, Ein is the sum of fuel and air exergy input to Steam Turbine 2 2.74 0.00
the combustion chamber. Eout is exergy of combustion, Steam Turbine 3 1.69 0.00
which is produced in combustor [8]-[9]. Driver Turbine 1 0.04 0.04
Another form of exergy is associated with the heat
Driver Turbine 2 0.04 0.04
transfer out of or into a control surface called thermal
Driver Turbine 3 0.17 0.17
exergy ( E& Q ) defined as [10]: Driver Turbine 4 0.14 0.14
. . ⎛ T ⎞ Driver Turbine 5 0.03 0.03
ExQ = Q⎜⎜1 − 0 ⎟⎟ (4)
⎝ TCS ⎠ Driver Turbine 6 0.31 0.31
Where, Tcs is the uniform temperature at the control Total Exergy Destruction 167.59 144.87
surface. Total Exergy Loss 36.49 10.30
B. Turbines Total 204.08 155.16
Exergy destruction in steam and gas turbines is exist case and the scenario 5 as a the best selected
defined as: scenario.

Proceedings of the Thirty-First Industrial Energy Technology Conference, New Orleans, LA, May 12-15, 2009
 ESL-IE-09-05-35

Exist Sc Best Sc

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60
50
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30
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Figure 6: A comparison between the exist scenario and the best selected scenario as a view point of Exergy analysis.
Ein(out) Sum of fuel and air Exergy Inp(Out)
5. CONCLUSION CO2 Carbon dioxide
After simulation and optimization of Tehran oil Greek
refinery steam network, the following results were symbols
obtained for the proposed scenarios. Scenario 5 was ∑ Summation
selected as the best-optimized scenario. The Other symbols
comparison showed that the amount of TAC has
reduced by 31%, without consideration of carbon 9 Active devices
dioxide tax. In addition, when the carbon dioxide tax 8 Deactivate devices
is taken into account, the amount of TAC reduces by - Not exist device
33%. Besides, scenario 5 remarkably reduces the
amount carbon dioxide production by 97% in References
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Proceedings of the Thirty-First Industrial Energy Technology Conference, New Orleans, LA, May 12-15, 2009
 ESL-IE-09-05-35

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Proceedings of the Thirty-First Industrial Energy Technology Conference, New Orleans, LA, May 12-15, 2009