Chapter 24: Energy Conservation

Rules of Thumb for Chemical Engineers, 5th Edition

by Stephen Hall

Units of Measure:
Exchange Rate ($/Euro)
1.35

SI

US

Units (US or SI)

2
2

Problem Statement:
Estimate the average cost of plant steam

Inputs
Boiler Fuel:

Gas

Energy Costs ($)

Power
Gas
No. 2 Fuel Oil
No. 6 Fuel Oil
Propane
Coal
Biomass

kWh
KCF
gal
gal
gal
ton
ton

Water
Feed Temp

200

Boiler
Efficiency
Pressure
Temperature

psig
F

82%
100
350

Sat Temp - HP steam

Enthalpy - feed
Enthalpy - steam
Fuel Cost

F
Btu/lb
Btu/lb
Klb steam

338
168
1,198
$ 11.01

Generation Cost

Klb steam

$ 14.31

$ 0.08
$ 9.00
$ 2.30
$ 2.80
$ 1.85
$ 200.00
$ 300.00

=
=
=
=
=
=
=

$ 23.45
$ 8.74
$ 16.43
$ 18.30
$ 20.20
$ 7.41
$ 18.18

Output

Data
Fuel Oil
No. 2 Fuel Oil
No. 6 Fuel Oil
Propane
Gas
Coal
Biomass

Btu/gal
140,000
153,000
91,600
1,030 Btu/cf
27,000,000 Btu/ton
16,500,000 Btu/ton

Result

per million Btu

per million Btu
per million Btu
per million Btu
per million Btu
per million Btu
per million Btu

per million Btu

per million Btu
per million Btu
per million Btu
per million Btu
per million Btu
per million Btu

25.00
23.75
1.60
22.50
2.20
2.55

2.70
3.30
3.00
140
150

125

120

2.40

2.00

2.25

1.90

2.10

1.80

2.40

160

1.70

1.95

1.60
2.10

2.70
2.40

1.80

90

100

100

2.10

75

80

1.80

60
30

50

1.50

1.50

1.65

1.40

1.50

1.30

1.35

1.20

1.20

1.10

1.20

60

1.00

1.05

1.20
25
40
$ / bbl heavy crude, 14API
0.90
(150,000 BTU/gal)
20
$ / bbl light crude, 30API
0.60
(140,000 BTU/gal)
0.30
$ / bbl No. 6 Fuel
(153,000 BTU/gal)
$ / gal No.2 Fuel Oil
(140,000 BTU/gal)
$ / gal naphtha, 65API
(115,000 BTU/gal)

21.25
1.40
1.30

18.75

1.20

17.50

1.10

16.25

1.00

15.00

0.90
0.80

0.90

0.80

0.75
0.60

0.30

0.60

0.45

0.50

10.00
0.60
8.75
0.50
7.50
0.40
6.25

0.40

0.30

0.30

0.15

0.20

$ / gal butane
(103,300 BTU/gal)
$ / gal propane
(91,600 BTU/gal)

12.50
11.25

0.70

0.60

13.75

0.70

0.90
0.90

20.00

1.50

1.80
120

1.50

2.10

0.30

5.00

0.20

3.75

0.10

2.50

0.10

1.25

$ / gal ethane
(66,000 BTU/gal)
$ / MMBTU
Natural Gas

0.00

Inputs
Boiler hp
Steam pressure
Steam temp
Feedwater temp

hp
psig
F
F

Calculations
Enthalpy, feed Btu/lb
Enthalpy, steam Btu/lb
Production
lb/h

300
100
350
200

168
1,198
9,757

Result

Inputs

Result

Steam Pressure
psig
Orifice Diameter
inch
Steam Flow Reduction Factor
Steam Cost
$/Klb

10
0.250
0.66
$ 11.01

Steam Loss

28.0
$ 0.31
$ 52
$ 2,695

lb/h
$/h
$/wk
$/yr

Result

Inputs
Cold Streams

2
Stream
ID

Name
1 Raw Crude
10 Desalted Crude

Hot Streams

Minimum temperature
Maximum temperature
Temperature increment

10
Stream
ID
1
3
4
6
8
9
11
13
14
16

Name
Atmos Bottom Pump Around
Atmos Mid Pump Around
Atmos Top Pump Around
Atmos Tower Overheads
Atmospheric Gas Oil Product
Diesel Side Product
Kerosene Side Product
Vacuum Residual
Vacuum Gas Oil Pump Around
Vacuum Gas Oil Product

deg F
deg F
deg F

0.0
800.0
35.0

Flow
lb/min
12,000
12,000

T1
deg F
65.0
259.0

T2
deg F
265.0
665.0

Flow
lb/min
3,600
8,200
8,200
9,500
1,500
3,000
2,500
2,600
15,600
4,000

T1
deg F
626.9
550.1
327.6
281.3
524.6
475.2
376.3
693.0
481.8
341.5

T2
deg F
518.0
403.1
185.0
107.6
363.6
150.0
90.0
383.9
310.0
200.0

0.0

Output
Cold Stream Segments
Duty, MBtu/h
Stream
ID

Name
1 Raw Crude
10 Desalted Crude

CP
Mbtu/h-F
0.6
0.8
-

0
-

35
3
-

Sum
Cumulative

187

187

3
190

Hot Stream Segments

Stream
ID
1
3
4
6
8
9
11
13
14
16

Name
Atmos Bottom Pump Around
Atmos Mid Pump Around
Atmos Top Pump Around
Atmos Tower Overheads
Atmospheric Gas Oil Product
Diesel Side Product
Kerosene Side Product
Vacuum Residual
Vacuum Gas Oil Pump Around
Vacuum Gas Oil Product

CP
Mbtu/h-F
0.2
0.4
0.3
0.5
0.1
0.2
0.1
0.1
0.6
0.2
-

Sum
Cumulative

50
-

0
50.0

35
50.0

700

Cp
Btu/lb-F
0.71
0.73
0.71
0.84
0.71
0.92
0.46
0.52
0.67
0.69

70
21
-

Duty
MBtu/h
119.0
327.9
Duty
MBtu/h
16.7
52.5
49.7
83.6
10.3
53.7
19.8
25.3
107.6
23.6
-

105
21
-

600

Temperature, F

Cp
Btu/lb-F
0.83
1.12

500
400
300
200
100
Cold Target

0
0

100

200

300

400

Enthalpy, Mbtu/h

140
21
-

175
21
-

210
21
-

245
12
17
-

280
28
-

315
28
-

350
28
-

21
211

21
231

21
252

21
273

21
294

29
323

28
351

28
379

28
407

70
1.0
-

105
15.6
2.4
-

140
16.8
4.1
2.4
-

175
8.7
16.8
5.8
2.4
1.7
-

210
12.2
16.8
5.8
2.4
5.8
-

245
12.2
16.8
5.8
2.4
5.8
-

280
12.2
0.6
5.8
2.4
3.1
5.8
-

315
4.4
5.8
2.4
21.9
4.4
-

350
1.4
5.8
1.8
0.1
21.9
-

1.0
51.0

18.0
69.1

23.4
92.4

35.4
127.9

43.1
170.9

43.1
214.0

30.0
244.0

38.9
282.9

31.0
313.9

135.68

120.64

118.08

103.48

81.24

58.99

49.84

39.77

37.06

Hot Target

Pinch Area

Hot CC
Cold CC

400

500

600

700

lpy, Mbtu/h

385
28
-

420
28
-

455
28
-

490
28
-

525
28
-

560
28
-

595
28
-

630
28
-

665
-

28
436

28
464

28
492

28
521

28
549

28
577

28
605

28
634

634

385
6.0
2.2
5.8
2.9
21.9
-

420
12.5
2.2
5.8
2.9
21.9
-

455
12.5
2.2
3.3
2.9
16.8
-

490
1.1
12.5
2.2
2.9
-

525
5.4
9.0
2.9
-

560
5.4
2.9
-

595
4.9
2.9
-

630
2.9
-

665
2.3
-

38.8
352.7

45.3
398.0

37.7
435.8

18.6
454.4

17.2
471.6

8.2
479.8

7.8
487.6

2.9
490.4

2.3
492.7

26.49

9.45

9.62

20.69

40.72

61.23

86.64

112.61

700
-

735
-

770
-

805
-

840

634

634

634

634

700
-

735
-

770
-

805
-

492.7

492.7

492.7

492.7

140.88

140.88

140.88

140.88

(140.88)

840