Department of Energy and Process Engineering TEP 4215 - Energy Utilization and Process Integration in Industrial Plants, or for short: “Energy and Process” • The Objective is to convey u Systems Thinking and Systematic Methods for: § Analysis and Design (and partly Operation) of § Processes and Utility Systems, with focus on § Efficient Use of Energy while considering § Economy, Operation and (to some extent) Environment • Requirements to be able to join the Course u None (meaning previous courses), but it is an advantage to have some basic knowledge about the following: § heat exchangers, distillation columns, evaporators § turbines, heat pumps and “simple” thermodynamics u Fall 98: 100 students from 8 departments in 4 faculties !! u From Spring 2009: Compulsory for the “PuP” Program Truls Gundersen 10.01.10
Department of Energy and Process Engineering TEP 4215 - Energy and Process • The Course Content is primarily u System based Strategy for Design of integrated Process Plants with corresponding Utility Systems u Systematic Methods for Analysis and Design of § Reactor Systems (very limited and not in depth) § Thermally driven Separation Systems , such as (primarily) Distillation and (to a much less extent) Evaporation § Heat Exchanger Networks and Correct Heat Integration § Utility Systems (heating, cooling and power) u The Thermodynamically based Pinch Analysis u Brief Introduction to the use of Optimization u Environmental Issues related to Energy Usage u New Design and Retrofit of Existing Plants Truls Gundersen 10.01.10
Department of Energy and Process Engineering TEP 4215 - Energy and Process • The Curriculum for the Course is: u R. Smith: “Chemical Process Design and Integration”, 2nd ed., John Wiley & Sons, January 2005. Alternative Text Book: u I.C. Kemp: “Pinch Analysis and Process Integration”, Elsevier, Butterworth Heinemann, December 2006. u T. Gundersen: “Basic Concepts for Heat Recovery in Retrofit Design of Continuous Processes”, Ch. 6 in “A Process Integration Primer”, IEA, 2000 (18 pages). u Lectures and Assignments. u Assignments are Examination oriented (most are previous Ex Q’s) u Examination will test Understanding through Calculation Examples. This requires Training established by working with Assignments. • Home Page: http://www.ivt.ntnu.no/ept/fag/tep4215/ Truls Gundersen 01.01.10
Department of Energy and Process Engineering TEP 4215 - Plan for Assignments with Guidance Ass. Topic Supervised Deadline 1 Sequence of Distillation Columns 22.01 29.01 2 Minimum Energy Requirements and Pinch 29.01 05.02 3 Design of Heat Exchanger Networks (1) 05.02 12.02 4 Optimization of Heat Exchanger Networks 12.02 26.02 5 Retrofit Design of Heat Exchanger Networks 26.02 05.03 6 Indirect Integration of Plants using Steam 05.03 12.03 7 Integration of Distillation Columns 12.03 09.04 8 Optimal Use of Heat Pump 09.04 16.04 9 Area in Heat Exchanger Networks 16.04 23.04 10 Heat Integration and Forbidden Matches 23.04 30.04 11 Design of Heat Exchanger Networks (2) 30.04 none Guidance: One Ph.D. Student (?), 6 Student Assistants and the Lecturer Truls Gundersen 12.01.13
Norway as an Energy Nation Natural Gas Production (GSm 3 ) Norway: 1997: 43.0 (1.9%) − 2007: 89.7 (3.1%) Process, Energy and System World Production (2007): 2940 GSm 3 Russia USA 20.7% 42.4% Canada ”others” Iran Norway Algerie UK 18.6% Others 6.2% 2.8% 3.8% 2.5% 3.1% Introduction and Background T. Gundersen E-stat 1
Norway as an Energy Nation Oil Production (mill. tonnes) Norway: 1997: 156.2 (4.6%) − 2007: 118.8 (3.0%) Process, Energy and System World Production (2007): 3905.9 mill. tonnes 12.6% Saudi Arabia 12.6% Russia 49.1% USA Iran China Mexico 8% Norway 5.4% Others 4.8% 3.0% Introduction and Background T. Gundersen E-stat 2
Energy Production (PJ) in Norway in 2007 (Total: 9 512.7 PJ − Export: 8 474.6 PJ (89.1%) Process, Energy and System 6.0% Crude Oil Natural Gas Hydro Power LNG Gasoline Coal Bio Energy 38.8% + 48.4% = 87.2% P(eta) = 10 15 Introduction and Background T. Gundersen E-stat 3
Energy Consumption in Norway by Sector in 2007 (Total: 813.5 PJ) Process, Energy and System Other Sectors: Private household (20.0%), Community Consumption (13.7%) and Fishing/Agriculture (3.6%) 35.1% 37.3% Industry & Mining Transportation 27.6% Other Sectors T(erra) = 10 12 The Course “Energy & Process” makes Sense !! Introduction and Background T. Gundersen E-stat 4
Energy Consumption (TWh) in Norwegian Industry in 2007 (Total: 80.66 TWh) Process, Energy and System Aluminum 29.6% Chemical Pulp & Paper Petrochemical Food Industry Iron & Steel Minerals Wood Ware 12.0% 17.6% Mining 13.6% Others Introduction and Background T. Gundersen E-stat 5
Energy Consumption, Fossil Fuels and the Impacts on the Environmental Process, Energy and System • Emissions include: u Greenhouse Gases u Acid Gases u Particles • Options to mitigate: u Carbon Capture and Storage (CCS) u Fuel Switch u Renewables u Energy Efficiency • The Cleanest Energy? Introduction and Background T. Gundersen E-stat 6
The IEA Definition of Process Integration Process, Energy and System "Systematic and General Methods for Designing Integrated Production Systems, ranging from Individual Processes to Total Sites, with special emphasis on the Efficient Use of Energy and reducing Environmental Effects" P R O C E S S From an Expert Meeting I N T E G R A T I O N IEA in Berlin, October 1993 OECD Definitions and Relations T. Gundersen Intro 1
Process Synthesis - Definition “Process Synthesis is a Systematic approach Process, Energy and System to the selection and interconnection of unit operations and to the specification of their operating conditions , in order to develop a conceptual flowsheet that produces desired products from available raw materials, in a safe and environmentally acceptable way, with maximum profit , while the plant exhibits flexibility , operability and controllability ” Definitions and Relations T. Gundersen Intro 2
Process Integration & Systems Engineering Process, Energy and System Systems Engineering (SE) (Cybernetics) Process Systems Engineering (PSE) (SE applied to Process Systems) Process IPD - Integrated LCA - Life Integration Process Design Cycle Analysis and Synthesis (disciplines) (time) (space) (software) Definitions and Relations T. Gundersen Intro 3
Terms in Perspective Process, Energy and System Energy Conservation Heat Integration Process Integration Process Synthesis Definitions and Relations T. Gundersen Intro 4
Process as a “Converter” Mechanical Energy Process, Energy and System Com Exp Steam Steam HP HP MP MP Energy LP LP Cooling Cooling Material Product(s) Raw Material(s) Byproduct(s) Introduction to Process Design T. Gundersen Intro 5
A “Generic” Process Process, Energy and System Gas Recycle Purge Feed Product Feed Separation Reactor Treatment System Liquid Byproduct Recycle Introduction to Process Design T. Gundersen Intro 6
Conseptual Design and the “Onion” R Process, Energy and System S H U R S R = Reactor System H S = Separation System H = Heat Integration U U = Utility System Decomposition Interactions Introduction to Process Design T. Gundersen Intro 7
Process Example with elements of R/S/H/U Gas Recycle Purge Process, Energy and System Compressor H 2 Feed Flash REACTOR Drum Toluene Feed Toluene Recycle Fuel Gas TOLUENE COL. BENZENE COL. STABILIZER Benzene Diphenyl Introduction to Process Design T. Gundersen Intro 8
4-way Trade-off in Process Design Energy Capital Process, Energy and System Steam, Cooling water Investment in Refrigeration, etc. Equipment, Interest Topology Process parameters Ex.: Δ T min Operation Raw Materials Conversion, Losses Flexibility, Safety Selectivity, Yield and Controllability Introduction to Process Design T. Gundersen Intro 9
Project Life Cycle Technology Process Detailed Process Idea Definition Package Design Redesign Process, Energy and System Commercial Commercial Endorsement Plant Plant Operation Plant Dis- Justification Completion and Maintenance assembling Research Engineering Operation Process Process Functional Detailed Plant Conception Simulation Design Design Construction w Laboratory w Rigorous w PFD + P&ID w Equipment w Project Control w Pilot Plant Simulation w Functional Design Time w Synthesis w Parameter Performance w Piping Materials w Structural Optimization Specs w Layout Labor Optimization w Stream w Major Equipm. w Isometrics Schedule w Flowsheeting Compositions w Costing w Structural Density w Costing Conditions w Instrumentation w Electrical w Cost Control w Duty Sizing Performance w Civil Specifications w Mechanical Phases and corresponding Technical Activities Introduction to Process Design T. Gundersen Intro 10
Motivating Example Reactor Process, Energy and System Traditional ST Recycle Design ST Sepa- Q ST = 1722 kW rator CW Q CW = 654 kW Area = 629 m 2 Units = 6 stk. Feed Product Motivation T. Gundersen Intro 11
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