11 Chapter3 Section3 Chemical Industry Page137 192

Section 3
Chemical Industry
Process Flow
3-1 Ammonia
3-2 Caustic Soda
3-3 Naphtha Cracking
3-4 BTX
137
Chemical (Ammonia) : Production Process and Energy Saving Technology
Grassification (reforming) process CO conversion process Gas refining process Synthesis process
Item No. Technology Item/Title Item No. Technology Item/Title

Item No. Technology Item/Title
CA-PE-6 CO oxidizer in ammonia production process CS-PE-3 Ion exchange membrane NaCl electrolysis bath for
CA-PE-2 Heat exchanger type primary reformer for waste
Item No. Technology Item/Title CA-ME-3 High pressure water power recovery turbine in caustic soda production
heat recovery in ammonia production process
ammonia production process CA-ME-4 Installation of pre-reformer in ammonia reforming
CA-ME-4 Installation of pre-reformer in ammonia reforming CA-PE-5 Isothermal CO converter for ammonia production
CA-OM-3 Ammonia production process: Carbonate removal process
process CA-OM-1 Humidification process prior to primary reforming
CA-ME-5 Primary reformer waste heat recovery unit for process CA-ME-1 Waste heat recovery unit for synthesis gas
in ammonia production process compressor exit gas in ammonia production
ammonia plant
process
CA-ME-2 Membrane separation hydrogen recovery unit in
ammonia production process
CS-ME-2 Improvement of active cathode for ion exchange
membrane electrolysis for caustic soda production

CS-OM-2 Reduction of electrolytic power for NaCl
electrolysis bath in caustic soda production process
138 -139
Chemical (Caustic soda) : Production Process and Energy Saving Technology
Caustic soda production process
Item No. Technology Item/Title Item No. Technology Item/Title

CS-PE-3 Ion exchange membrane NaCl electrolysis bath for CS-PE-1 Quadruple-effect concentration for diaphragm-type
caustic soda production electrolytic caustic soda production
CS-PE-2 Energy saving ion exchange membrane electrolysis
bath for caustic soda production
CS-ME-1 Brine preheater using recovered heat of NaCl
electrolysis in caustic soda production process
CS-ME-2 Improvement of active cathode for ion exchange
membrane electrolysis for caustic soda production
CS-OM-1 Caustic soda production process: Switching from
diaphragm electrolytic process to ion exchange
membrane electrolytic process
CS-OM-2 Reduction of electrolytic power for NaCl electrolysis
bath in caustic soda production process
140 -141
Chemical (Naptha Cracking) : Production Process and Energy Saving Technology
Naptha cracking production process

CN-ME-1 Switching quenching tower trays to packing in naphtha cracking process
CN-ME-2 Installation of turbo-expander in top gas line of demethanizing column
in naphtha cracking process
CN-ME-3 Cold heat recovery from demethanizing column bottom liquid in naphtha
cracking process
CN-ME-4 Combustion air preheating for boilers using cooling tower bottom hot
water in naphtha cracking process
CN-ME-5 Hot water heating by distillation column top vapor
CN-OM-1 Control of excess air ratio at cracking furnace in naphtha cracking
process
CN-OM-2 Change of feed step for depropanizing column in naphtha cracking
process
CN-OM-3 Pressure control of ethylene rectification column by suction pressure of
propylene refrigerator in naphtha cracking process
CN-OM-4 Naphtha cracking process: Energy saving in ethylene cracker
142 - 143
Chemical(BTX) : Production Process and Energy Saving Technology

CB-ME-1 Recovery of top vapor heat of ortho-xylene separation
column in aromatics production process
CB-ME-2 Waste heat recovery from heating furnace flue gas in
BTX production
CB-ME-3 Steam turbine power generation using waste heat of
distillation column top vapor in BTX production
process
CB-OM-1 Change of washing system in amine desulfurization
process for BTX production
CB-OM-2 Reboiler heating by waste heat of top vapor of
distillation column in BTX production process
CB-OM-4 Control of reflux ratio of distillation column using
on-line analyzer
144 -145
Data Sheets
3-1 Ammonia
3-2 Caustic Soda
3-3 Naphtha Cracking
3-4 BTX
3-5 General
146
CA-PE-1 Energy Conservation Directory
[Industry Classification] [Energy Source]
Chemical : Ammonia Fuel (general) Steam
[Technology Classification] Multi-effect evaporator [Practical Use]
Production Equipment After 1960
Outline An evaporator used for vaporizing aqueous solution containing nonvolatile substances in a chemical plant.
1. The saturation temperature of generated vapor is lower than the boiling point of the solution, corresponding
Principle to the boiling point rise.
2. In the next evaporator in which the pressure is further reduced, the boiling point of the solution is lower
& than the saturation temperature of the vapor generated in the preceding stage.
Mechanism 3. The vapor generated in the preceding stage is used as the heat source of the next evaporator with reduced
pressure. Vaporizers in which pressure is reduced from the preceding stage are installed in a train to use the
vapor generated in preceding stage.
This type of facility is called a multi-effect evaporator.
[Description] 1. For a multi-effect evaporator with n-stage, the consumption of heating steam is theoretically 1/n times.
2. If the number of stages is increased at aspecific temperature difference, the temperature difference per stage
becomes small, thus the heat transfer area increases.
3. Accordingly, the number of stages less than 6 is generally adopted, taking into account of the investment and
Structure operating cost.
4. Figure shows a multi-effect (2-stage) distillation flow scheme.
explanation,
Shape, and/or
System
diagram
Improved section
Fig. 1 Liquid supplying method example of multi-effect evaporator
The steam consumption becomes 0.7 to 0.8 times the steam consumption of a single stage evaporator divided
by the number of stages. That is, the general formula given below determines the steam consumption.
Energy saving Q = Qs/kn

where, Q : steam consumption for a n-stage evaporator
effects Qs : steam consumption for a single stage evaporator
n : number of stages
k : effectivity factor (normally 0.7 to 0.8)
[Economics] Investment amount: 130 million yen

Equipment Improvement effect: 40 million yen/year
Investment payback: 3.2 years
cost
Production of nonvolatile products such as NaCl and NaOH.
Remarks Production of concentrated fruit juice.
Concentration and solidification of nonvolatile matters in waste liquid.
Desalination of sea water.
[Example sites] [References] [Inquiry]
Energy Conversion Forum, "Energy Utilization Japan Chemical Industry Association /
Engineering," P190, Ohm Sha, 1980. ECCJ (JIEC)
147
Chemical : Ammonia Heat exchanger type primary reformer for Fuel (natural gas)
[Technology Classification] waste heat recovery in ammonia production process [Practical Use]
Production Equipment 1990s -
By using the reactor in the reforming process of an ammonia plant, the high-temperature process waste heat at
Outline the exit of the secondary reformer is utilized as the reaction heat for the endothermic reaction in the primary
reforming process to achieve energy saving.
Principle 1) Process waste heat of about 1,000˚C at the exit of the secondary reformer is utilized as the reaction heat
(endothermic reaction) in the primary reformer.
& 2) The principle is to use the primary reformer as a heat-exchanger-type reactor. The heat transfer tubes are
Mechanism filled with Ni-based catalyst. The exit gas of the secondary reformer flows through the shell side, and works
as heating fluid.
[Structure of heat-exchanger-type reactor] (Refer to Fig. 1)
1) The primary reformer is used as a heat-exchanger-type reactor.
The heat transfer tubes are filled with Ni-based catalyst, and the
exit gas of the secondary reformer flows through the shell side as
heating fluid.
2) The catalyst tubes are of a double-tube type, where inner tubes
are inserted into outer tubes. The mixture of preheated feed natu-
ral gas and steam flows through an annular space filled with cata-
[Description] lyst between the outer tube and the inner tube.
3) The mixture flows downward through the catalyst bed while be-
ing reacted, then turns upward inside of the inner tube to enter
the secondary reformer.
Structure 4) Each outer tube is surrounded by a sheath tube, and the hot gas
explanation, from the secondary reformer flows through the annular space
between these tubes.
Shape, and/or
System [Improved process flow] (Refer to Fig. 2)
diagram
Fig. 1. Heat-exchanger-type primary reformer
Improved section
Fig. 2 Improved reforming process flow of ammonia plant
Table 1 Energy saving effect by heat-exchanger-type primary reformer (production capacity: 2,000 t/D)
Energy saving Improvement effect Remark
effects Reduction in specific energy consumption 0.15 x 106 kcal/NG3-t

Accounting for about 10% of the fuel supplied
to the primary reformer
Reduction in energy consumption 10,102 x 103 m3/y Operation days 330 d/y
Reduction in crude oil equivalent 10,708 kL/y

Investment payback: 1 year
cost
Remarks
Adopted at many sites. Makers’ in-house technical documents Japan Chemical Industry Association /
“Chemical Process” p. 50, 51, Tokyo Kagaku ECCJ (JIEC)
Dojin
148
Chemical : Ammonia Ammonia plant Fuel (natural gas)
[Technology Classification] High conversion synthesis reactor [Practical Use]
Production Equipment 1970s ~
The facility is an energy saving type reactor which is placed between the reactors of synthesis process of
Outline ammonia plant and which effectively recovers the heat of exit gas while controlling the reaction heat to main-
tain the reaction temperature at an adequate level through the heat exchange with the reactor inlet gas.
Principle 1) There are two methods for removing reaction heat in the ammonia synthesis reactor: the indirect cooling
method that employs a heat exchanger having the structure that is applied in this case; and the quenching
& method which uses unreacted synthesis gas directly for cooling.
Mechanism 2) Conventionally-applied quenching method has a simple structure facility. The method has, however, disad-
vantages that the ammonia concentration which was increased by the synthesis reaction is diluted by the
cooling gas and that the temperature at exit of the reactor is lowered.
3) Owing to the drawbacks, recent ammonia synthesis plants have adopted a new synthesis reactor of indirect
cooling method.
[Features of the high conversion synthesis reactor (indirect cooling reactor)]
1) The method uses the inlet gas of the reactor to cool the hot exit gas at each catalyst bed through a heat
exchanger. Thus, the disadvantages of cool gas quenching method are solved.
[Description] 2) The indirect cooling reactor gives the exit gas temperatures of the reactor from about 300˚C to 450 - 500˚C,
which temperature allows effective use of the reaction heat to generate high pressure steam and superheated
steam. The method achieves energy saving of about 0.14 x 106 kcal/t-NH3 of unit requirement compared
with that of conventional quenching method.
Structure 3) Fig. 1 shows an example of indirect cooling high conversion synthesis reactor.
explanation,
Shape, and/or
System
diagram
Improved section
Fig. 1 Schematic drawing of cross section of indirect cooling high conversion synthesis reactor
Table 1 Improvement in unit requirement of high conversion synthesis reactor (production rate of 300,000 t/y)
Reduction in unit requirement after

Energy saving Effect of improvement
the improvement
effects
Heat recovered to steam 0.14 x 106 kcal/t-NH3
Reduction of energy (crude oil basis) 5,708 kL/y
[Economics]
Investment amount: 150 million yen
cost Investment payback: 1.5 years
Remarks
Adopted at some sites. Makers’ in-house technical documents Japan Chemical Industry Association / ECCJ (JIEC)
149
Chemical : Ammonia Ammonia plant Fuel (natural gas)
[Technology Classification] Low pressure difference synthesis reactor [Practical Use]
Outline The improvement is related to an energy saving reactor of ammonia synthesis process, in which the direction of
gas flow within the reactor catalyst bed is controlled to reduce the pressure loss.
Principle A feature of the ammonia synthesis process is unavoidably forming a synthesis loop. The pressure difference in
the synthesis loop reaches to a range of from 7 to 14 kg/cm2. With the use of a low pressure difference type
& synthesis reactor, energy saving resulted from reduced pressure difference and packing of small sized synthetic
Mechanism catalyst particles owing to the reduction of pressure difference are available. Since the catalyst of small particle
size has high activity, the conversion increases and the driving energy for circulator and refrigerator decreases.
[Features of low pressure difference reactor]
1) Conventional synthesis reactor employs Table 1 Comparison of gas flow directions and
axial gas flow direction through the cata- of power consumption
lyst bed, which induces pressure differ- Power consumed for
ences of from 7 to 14 kg/cm2. The new Reduced power
[Description] circulation
design of reactor which uses the gas flow
Axial direction flow 44 kWh/t-NH3
directions of radial, cross sectional, and
axial-radial significantly reduces the pres- Cross sectional direction flow 39 kWh/t-NH3 5 kWh/t-NH3
Structure sure difference. Reduction of pressure dif- Radial direction flow 37 kWh/t-NH3 7 kWh/t-NH3
explanation, ference reduces the power consumption of
the circulator. (Refer to Table 1.) Axial-radial direction flow 32 kWh/t-NH3 12 kWh/t-NH3
Shape, and/or 2) The developed low pressure difference re-
System actor allows to reduce the catalyst particle
size from 6 - 12 mm to 1.5 - 3 (6) mm,
diagram thus the catalyst activity is improved the
conversion at exit of reactor is improved,
and the exit ammonia concentration is in-
creased.
3) Increased conversion reduces the circula-
tion gas rate, thus decreases the power con-
sumption of the circulator.
4) Increased ammonia concentration at exit
of the synthesis reactor increases the con-
densation temperature, increases the con-
densed generated ammonia by water cool-
ing, thus decreases the condensed refrig-
erant ammonia and decreases the power
consumption of the refrigerator.
Improved section
Fig. 1 Schematic cross sectional drawing of radial direction flow reactor
Table 2 Reduction in unit requirement in a pressure difference reactor

Energy saving Reduction in unit requirement after
Effect of improvement
effects the improvement
Heat recovered to steam 0.17 x 106 kcal/t-NH3
[Economics] Investment amount: million yen

Equipment Improvement effect: million yen/year
Investment payback: years
cost
Remarks
150
Chemical : Ammonia Ammonia plant Electricity
[Technology Classification] Isothermal CO converter [Practical Use]
Outline The converter is a reactor with built-in heat exchanger to implement the CO conversion in the ammonia plant at
a single stage and to recover the reaction heat.
Principle 1) The secondary reformer exit gas contains about 13 vol.% of CO.
The CO is converted to H2 by the reaction of
& CO + H2O = CO2 + H2
Mechanism The reaction is advantageous in terms of chemical equilibrium at lower temperatures.
1) Conventionally, an adiabatic reactor filled with Fe-Cr catalyst (usually) is operated to conduct two stage
reactions: namely, the high temperature conversion operated at temperatures of from 370 to 430˚C, and the
low temperature conversion operated at temperatures of from 200 to 230˚C.
2) The facility adopts an isothermal reactor to carry out the reaction in a single stage at about 250˚C.
[Description] The reaction heat generated by the CO conversion in the reactor is recovered by generating medium pres-
sure steam in a built-in heat exchanger.
3) Fig. 1 shows the reactor used in the CO conversion process in the ammonia plant.
Structure
explanation,
Shape, and/or
System
diagram
Improved section
Fig. 1 Reactor used in the CO conversion process
Table 1 Effect of improvement of energy unit requirement during ammonia production

(at operation rate of 100,000 t/y)
Energy saving
Unit requirement after the
effects Effect of the improvement
improvement
Heat recovered as steam 0.1 x 106 kcal/t-NH3
[Economics]
Equipment Improvement effect: 2,560 million yen/year
Remarks The facility is also applicable to hydrogen plants.

“Energy Saving Journal (Vol. 31, No. 8, 1979),” Japan Chemical Industry Association / ECCJ (JIEC)
151
Chemical : Ammonia Fuel (natural gas)
CO oxidizer in ammonia production process [Practical Use]
[Technology Classification]
Production Equipment 1971~
Outline The improvement relates to the CO conversion step in ammonia plant, particularly to the unit which conducts
two stage reactions at high and low temperature levels, (CO + H2O = CO2 + H2), followed by oxidizing the
residual CO with air on a Pd catalyst to obtain CO2.
Principle [Pd metal catalyst]
The catalyst selectively oxidizes CO remained at 0.3 to 0.5 vol.% after the CO conversion, into CO2 gas. Since
& the treatment reduces CO amount, the amount of CH4 generated in downstream methanation stage decreases,
Mechanism which improves the purity of the syn-gas.
1) The CO remained after the conversion is converted to CH4 in the downstream methanation stage. The CO
is, however, accumulated in the synthesis reaction to hinder the reaction.
2) The unit oxidizes CO into CO2 using a catalytic reaction, which CO2 is removed in succeeding carbonate
removing stage. Increased purity of syn-gas decreases the amount of purge gas in the synthesis stage. As a
[Description] result, the H2 loss also decreases.
3) Fig. 1 shows the ammonia production flow diagram with the addition of the CO oxidizer.
Structure
explanation,
Shape, and/or
System
diagram
Improved section
Fig. 1 Flow diagram of CO conversion in ammonia production process
Table 1 Improvement in energy unit requirement in CO converter (at production rate of 300,000 t/y)
Energy saving
effects Reduced unit requirement Effect of improvement
after improvement
Recovered energy 0.07 x 106 kcal/t-NH3
Reduction of energy 2,851 kL/y
[Economics]
Remarks The facility is also applicable to hydrogen plants.

152
CA-ME-1 Energy Conservation Directory
Chemical : Ammonia Waste heat recovery unit for synthesis gas Fuel
[Technology Classification] compressor exit gas in ammonia production process [Practical Use]
Machinery & Equipment 1984
In an ammonia plant, in-process heat recovery from compressed gas out of the synthesis-gas compressor was
not applied because the heat exchanger hinders temperature control in the succeeding process. For effective use
Outline of the heat exchanger, the boiler feed water is injected into the process gas, thus the temperature control be-
comes possible. Feed steam to the reboiler of the CO2 regenerator is decreased as well owing to the increase in
the heating value.
Feed gas generated in the reformer
was purified, compressed by the am-
monia synthesis-gas compressor from
24 kg/cm2 to 150 kg/cm2 , and fed.
Before A heat exchanger to preheat the
methanator feed gas was installed as
Improvemet the intercooler of this compressor.
The heat exchanger was, however, not
used because it gives bad influence
to the control of the inlet temperature
of the low-temperature converter of
the succeeding process. It also short-
ens the catalyst life. Thus the heat of
compression was discarded into cool-
ing water. (Refer to Fig. 1) Improved section
Fig. 1 Flow chart of synthesis gas purification and compression process
1) When the heat is exchanged with the compressor exit gas, the inlet temperature of the low-temperature
converter increases from 214˚C to 238˚C. The boiler feed water at 130˚C is injected into the process gas to
[Description change the sensible heat to the latent heat. In this manner, the heating value increases without raising the
temperature, which is maintained at the set level of 214˚C. (Refer to Fig. 2)
& 2) This improvement increases the supply rate of latent heat to the process reboiler of the CO 2 regenerator.
Improvement] Accordingly, the load of feed steam to the steam reboiler can be decreased.
Structure
explanation,
Shape, and/or
System
diagram
Improved section
Fig. 2 System to inject boiler feed water to low-temperature converter
Table 1 Energy saving effect

Energy saving
Amount of steam reduction Effect
effects
Recovered heat of boiler feed water at heat
1,664 MMkcal/h Total 1,372 kL/y
exchanger
(in heavy oil equivalent)
Reduction in steam supply to steam reboiler 3.572 t/h

Investment payback: 2 years
cost
Remarks
Mitsui Toatsu Chemicals’ “Collection of Energy Conservation Cases Japan Chemical Industry Association / ECCJ (JIEC)
Osaka plant 1985,” p. 1223
153
Chemical : Ammonia Membrane separation hydrogen recovery unit Fuel (natural gas)
[Technology Classification] in ammonia production process [Practical Use]
Machinery & Equipment 1979 ~
The membrane separation unit is an energy saving unit which does not employ any moving parts and does not
Outline need any complex operation while consuming minimum energy, because the separation is carried out using the
pressure of the gas itself as the driving force.
[Features of the membrane separation process]
1) The process attains high hydrogen recovery rate in a high-pressure process, and is suitable for a process for
Principle producing hydrogen of the concentration of 90-99%.
2) After installed, the throughput can be readily changed responding to the operating conditions.
& 3) The process has no moving part, and saves energy. Its maintenance is easy.
Mechanism 4) The product hydrogen has a low pressure owing to the permeation treatment.
5) Condensation of the heavy fraction in feed gas results in the decrease in the hydrogen permeation rate. To
prevent it, an adequate pre-treatment is required.
6) The investment cost is low.
[Structure of hydrogen separation membrane]
1) The gas separation membrane used for hydrogen gas recovery is made of a non-porous polymer which has
excellent properties in the heat resistance, pressure durability, chemicals resistance, separation coefficient
[Description] and permeation rate.
2) The membrane element is either a hollow type having approximate diameters of 0.1-0.5 mm or a flat mem-
brane wound in a spiral form. These elements are packed in a pressure vessel to form a module. (Refer to
Structure
Fig. 1.)
explanation,
Shape, and/or
System
diagram
Improved section
Fig. 1 Schematic cross section of separation membrane module
- Energy saving effect

Table 1 Improvement effect in specific consumption by membrane separation hydrogen recovery
Energy saving (production rate of 300,000 t/y)
effects Reduction in specific consumption after
Improvement effect
improvement
Heat recovered as steam 0.14 x 106 kcal/t-NH3
- Additional effect: From the same volume of natural gas, the production is increased by 4-6% compared
with conventional process.
cost
Remarks
Adopted at some sites. “Oil Refinery Process (Japan Petroleum Society)” Japan Chemical Industry Association / ECCJ (JIEC)
Kodansha
154
Chemical : Ammonia High pressure water power recovery turbine in Fuel (natural gas)
[Technology Classification] ammonia production process [Practical Use]
Machinery & Equipment 1980s ~
Outline This improvement is to utilize a high-pressure water turbine in order to recover power from the high-pressure
liquid which absorbed carbon-dioxide in the carbon-dioxide removal process of an ammonia plant.
[Power recovery system using high-pressure water turbine and power recovery calculation formula]
Principle
&
Mechanism
[Before the improvement]

[Description] 1) In the carbon-dioxide removal process, a large quantity of absorbent liquid is supplied to the top of the
absorbing column under a pressure of about 30 kg/cm2 to remove about 15 vol.% of CO2 contained in the
crude gas coming from the reforming process and the CO conversion process.
2) The liquid which absorbed CO2 is sent to the regenerating column after the pressure is reduced from 30 to 1
Structure kg/cm2 by a pressure-reducing valve.
explanation, [After the improvement]
Shape, and/or 1) The facility employs a power recovery turbine instead of the pressure-reducing valve, and utilizes the pres-
sure to drive the feed pump for the absorbent liquid.
System 2) The facility comprises an electric motor with shafts on both sides, which are directly connected to a power
diagram recovery turbine and to a absorbing liquid feed pump via clutches.
Improved section
Fig. 1 Flow diagram of waste heat recovery of primary reformer of ammonia plant
Table 1 Energy saving effect by power recovery turbine

Energy saving After improvement Production and operation conditions
effects Reduction in specific energy consumption 6

Reduction by 0.04 x 10 kcal/(NH3-t) Production rate 1,000 t/d
Reduction in crude oil equivalent 1,794 kL/y Operation days 330 d/y
[Economics]
Remarks
Adopted at many sites. “Hydrocarbon Processing (Aug.1992) Japan Chemical Industry Association / ECCJ (JIEC)
155
Chemical : Ammonia Installation of pre-reformer in Fuel (natural gas)
[Technology Classification] ammonia reforming process [Practical Use]
This technology is a process improvement aiming at energy saving by installing a pre-reformer in the reforming
Outline stage of the ammonia production process.
Before
- The conventional process adopted natural gas reforming by the primary reformer.
Improvemet
1) Using high-temperature (600˚C or more) waste heat of the primary reformer flue gas, the mixture of feed
natural gas and reaction steam is heated up to 620˚C.
[Description 2) The heated mixture is sent to the primary reformer, where the feed natural gas is cracked by steam on a Ni
& catalyst to yield H2, CO, and CO2.
3) Part of the primary reforming reaction is carried out in the pre-reformer (adiabatic reformer) which is also
Improvement] filled with a Ni catalyst. Since the reaction heat (endothermic reaction) is supplemented by the sensible heat
of the mixture, the exit gas temperature is lowered by 60-80˚C.
4) The reactor exit gas is reheated by the flue gas, which is then fed to the primary reformer.
Structure 5) Installation of the pre-reformer allows to reduce the capacity of the primary reformer by 10%.
explanation,
Shape, and/or
System
diagram
Fig. 1 Flow chart of reforming process with pre-reformer Improved section
Table 1 Energy saving effect by pre-reformer

Improvement effect Remark
Energy saving Reduction in specific energy consumption 0.15 x 106 kcal/NH3-t

Accounting for about 10% of the fuel
supplied to the primary reformer
effects
Reduction in energy consumption * 5,051 x 103 m3/y

(Note *: Production capacity of 2,000 t/d, operating days of 330 d/y)
[Economics]
Remarks
“Hydrocarbon Processing (Aug. 1992)” Japan Chemical Industry Association / ECCJ (JIEC)
156
Chemical : Ammonia Primary reformer waste heat Fuel (natural gas)
[Technology Classification] recovery unit for ammonia plant [Practical Use]
This unit preheats the combustion air by hot flue gas generated by combustion, and supplies the heat to the
Outline endothermic reaction (reforming reaction) in the heating-furnace-type primary reformer of an ammonia plant.
1) In the primary reformer, fuel is combusted outside of catalyst tubes to supply heat to the reforming reaction
(endothermic reaction) in the catalyst tubes. The waste heat of the flue gas (about 1,000˚C) generated by
Principle combustion is used to heat the feed natural gas, process air, and steam.
& 2) To increase the thermal efficiency of the primary reformer, the waste heat of the flue gas needs to be utilized
to a temperature as low as possible by using it to heat low-temperature fluids.
Mechanism Combustion air for the primary reformer is one of the low-temperature fluids. Waste heat is used to heat the
combustion air from the normal temperature to temperatures of 200 to 400˚C, thus the fuel consumption of
the primary reformer is reduced.
[Description]
Structure
explanation,
Shape, and/or
System
diagram
Improved section
Fig. 1 Flow chart of ammonia plant primary reformer waste heat recovery
Table 1 Energy saving effect by waste-heat recovery

[Case A] [Case B]
Preheating temperature of 260 Preheating temperature of 400
Energy saving
Reduction in specific energy consumption About 0.19 x 106 kcal/(NH3-t) About 0.28 x 106 kcal/(NH3-t)
effects
Reduction in fuel consumption (heavy oil C)* 12,796 kL/y 18,857 kL/y
Reduction in crude oil equivalent 13,564 kL/y 19,988 kL/y
(Remark*: Ammonia production 2,000t/D, operation days 330 days/year)

cost
Remarks This technology was demonstrated at Sichuan Chemical Complex in Sichuan province of China as the NEDO’s
Model Project for Ammonia Primary Reformer Waste Heat Recovery.

NEDO reports Japan Chemical Industry Association /
ECCJ (JIEC)
157
CA-OM-1 Energy Conservation Directory
Chemical : Ammonia Ammonia production process Fuel
[Technology Classification] Pre-humidification process for primary reforming [Practical Use]
Operation & Management 1980s ~
The case is a process improvement to humidify the feed natural gas with the process condensate, as a part of the
Outline humidifying steam, by spraying into the natural gas and by vaporizing the process condensate using the heat of
preheated natural gas, before entering the primary reformer of the ammonia plant.
(1)For primary reforming natural gas, the natural gas is preheated to 400˚C before subjected to desulfurization.
Before The process steam (40 kg/cm2G) is added to thus desulfurized natural gas to a level of S/C molar ratios of
Improvement from 3.0 to 3.5. Then the natural gas is again preheated to 620˚C, and is fed to the catalyst tubes to perform
reforming.
(1)The low temperature waste heat at about 200˚C of

the flue gas of the primary reformer is utilized.
[Description (2)The process natural gas is preheated to about 200˚C
of by the flue gas, and is desulfurized, followed by
feeding to the bottom of the saturation tower.
Improvement] On the other hand, the process condensate is
sprayed form the top of the saturation tower to
make contact with the warmed natural gas to satu-
Structure rate with water. The saturated natural gas is used
as a part of the 42 bar reforming steam.
explanation, (3)After adding the steam to the natural gas to satisfy
Shape, and/or the necessary total amount of steam, the natural
gas is again preheated, and is fed to the catalyst
System tubes of the primary reformer to perform the re-
diagram forming.
Improved section
Fig. 1 Humidification flow diagram of before the primary reforming
Table 1 Effect of energy saving by the humidification process
Effect Remark
Energy saving
Reduction in energy unit requirement 0.05 x 106 kcal/t-NH3
effects Production rate of
Increase in power unit requirement 1 kWh/t-NH3
100,000 t/y

cost
Remarks The technology is applicable also to methanol plants and hydrogen plants.

Some sites adopting similar technology Makers’ in-house technical documents Japan Chemical Industry Association /
ECCJ (JIEC)
158
Chemical : Ammonia Ammonia production process Fuel (steam)
[Technology Classification] Improvement in heating feed to ammonia stripper [Practical Use]
Operation & Management 1986
Melamine which is synthesized from urea is dissolved into aqueous ammonia in the pressurized quencher,
Outline followed by depressurized and cooled in the crystallizer to yield crystalline melamine. The improvement is
energy saving through preheating the filtrate discharged from centrifugal separator in the crystallizing step for
ammonia recovery.
Description
of
Process
Fig. 1 Process flowchart of ammonia recovery from filtrate after separating melamine
[Before improvement] [After improvement]

[Description
The temperature of residue as the heating medium Before the existed preheater in the filtrate feed line to
of the distillation column, an additional preheater is in-
was 51˚C at the exit of filtrate preheater.
Improvement] serted in series, thus the temperature of filtrate is in-
creased.
Structure
explanation,
Shape, and/or
System
diagram
Improved section
Fig. 2 Flowchart of ammonia recovery Fig. 3 Flowchart of ammonia recovery

(before improvement) (after improvement)
Table 1 Improved effect of energy saving in the ammonia recovery step
Energy saving Improved effect Remark

effects Reduction of steam consumption 13.0 t/h (Operating time: 4,000 h/y)

Equipment Improvement effect: 3.3 million yen/year
cost
The improvement is a typical example of widely utilizing methods for preheating raw material feed for all kinds
Remarks of distillation columns.
Adopted at some sites. “Collection of Energy Conservation Cases 1980,” Japan Chemical Industry Association /
p.1021 ECCJ (JIEC)
159
Chemical : Ammonia Ammonia production process Fuel (natural gas)
[Technology Classification] Carbonate removal process [Practical Use]
Operation & Management 1980s ~
The improvement is the one for energy saving in the carbonate removal process of ammonia production pro-
Outline cess.
[Before improvement]
(1)Conventional carbonate removal applies chemical absorption method using an absorbing liquid such as
Before monoethanolamine (MEA) aqueous solution. The method removes CO2 contained at about 18 vol.% in the
Improvement crude synthesis gas coming from the CO conversion process.
(2)The regeneration heat of the solution after absorbing CO2 is about 1,000 to 2,000 kcal/Nm3-CO2.
(3)With natural gas as the raw material, the quantity of removed carbonate is about 620 Nm3-CO2/t-NH3, and the
process is the largest consumer of energy in the ammonia plant.
[After improvement]
(1)The improved technology for removing carbonate is the physical absorption type (Selexol process). The
regeneration of the solution is performed by vacuum flashing and air stripping. As a result, the energy
required for regeneration of the solution is significantly reduced to 22 kcal/Nm3-CO2.
[Description
of
Improvement]
Structure
explanation,
Shape, and/or
System
diagram
Improved section
Fig. 1 Flowchart of energy saving type carbonate removal process
Table 1 Improved effect in the carbonate removal process in the ammonia production process
(production capacity: 300,000 t/y)
Reduced unit requirement after
Energy saving Improvement effect
improvement
effects Heat recovered as steam 0.6 x 106 kcal/t-NH3
Increased power consumption 10 kWh/t-NH3
[Economics] Investment amount: 1,200 million yen

cost
Remarks

Adopted at some sites. Makers’ in-house technical documents Japan Chemical Industry Association /
ECCJ (JIEC)
160
CS-PE-1 Energy Conservation Directory
Chemical : Caustic Soda Quadruple-effect concentration for diaphragm-type Fuel (steam)
[Technology Classification] electrolytic caustic soda production [Practical Use]
Production Equipment 1977
When the electrolytic production method of industrial salt is converted from the mercury process to the dia-
phragm process, the electrolyte generated in the process becomes a dilute NaOH solution containing a large
Outline amount of NaCl salt. Accordingly, it is necessary to concentrate the NaOH by a concentrator to about 50% to
separate the salt in a form of crystals. This improvement enhances energy efficiency and saves energy by
modifying the existing triple-effect concentration method to the quadruple-effect concentration method.
1) The electrolyte generated in the Table 1 Comparison of triple-effect evaporation and

diaphragm process is a dilute
solution of NaOH (about 10%). quadruple-effect evaporation
It also contains NaCl of about Concentration of electrolyte NaOH 10.3wt% NaCL 15.1wt%
15%. It is necessary to concen- Concentration of product NaOH 50 wt% NaCL 1.1wt%
trate the NaOH by a concentra-
tor to about 50% to separate the Quadruple-effect evaporation Triple-effect evaporation
salt as crystals. Temperature Concentration Temperature Concentration
2) The existing triple-effect concen- No. 1 evaporator 158˚ C 43% 142˚ C 45%
tration method is modified to the No. 2 evaporator 102˚ C 25% 87˚ C 25%
quadruple-effect concentration No. 3 evaporator 76˚ C 17% 53˚ C 16%
method. The energy efficiency
No. 4 evaporator 50˚ C 12% - -
[Description] is improved, and the steam con-
sumption is reduced by 26%.
The flow chart of the quadruple-
effect evaporation vessels is
Structure shown in Fig. 1.
3) Comparison of triple-effect
explanation, evaporation and quadruple-effect
Shape, and/or evaporation. (Refer to Table 1)
System
diagram
Improved section
Fig. 1 Flow chart of caustic soda concentration by quadruple-effect evaporation vessels
Table 2 Energy saving effect by quadruple-effect evaporation

Energy saving Triple-effect type Quadruple effect type Improvement effect
effects Specific steam consumption 2.7 t/t-NaOH 2.0 t/t-NaOH Reduction by 0.7 t/y
Reduction in steam consumption * 700,000 t/y
Note*: Operating hours: 7,000 h/y

[Economics]
Investment amount: 4,560 million yen
Equipment Improvement effect: 1,140 million yen/year
cost Investment payback: 4 years
Remarks
Many sites adopting similar “Energy Saving Journal (Vol. 30, No. 9, Japan Chemica Industry Association /
technology 1978),” P. 45 ECCJ(JIEC)
161
Chemical : Caustic Soda Energy saving ion exchange membrane Electricity
[Technology Classification] [Practical Use]
electrolysis bath for caustic soda production 1994
Production Equipment
The newly developed electrolysis bath gives less voltage drop owing to its structure compared with a conven-
tional multi-polar ion-exchange-membrane electrolysis bath. Accordingly it allows to increase the current
Outline density, making it an energy-saving compact NaCl electrolysis bath. Compared with a conventional type, it
achieves power saving of about 6%.
The current flows as indicated in Fig.

1. As the electric conductivity of Ni is
six times that of Ti, a minimum level
of current flows through the Ti section.
Principle Owing to this structure, the voltage
drop becomes less.
&
Mechanism
Improved section Fig. 1 Cross section of multi-polar element
[Description]
Structure
explanation,
Shape, and/or
System
diagram
Improved section
Fig. 2 Configuration of multi-polar element Fig. 3 Flow of electrolyte
Table 1 Power saving effect of improved type compared with conventional multi-polar
Energy saving ion-exchange-membrane electrolysis bath
effects Reduction in specific power consumption 131 DC kWh/t-NaOH Operating condition:
production of 100,000 t-NaOH/y,
Reduction in crude oil equivalent 3,183 kL/y current density 3 kA/m2
[Economics]
Remarks The technology is economically applicable to the operation with a high current density up to 6 kA/m2.
Adopted at some sites. “Soda Industry Technical Information (No. 449),” Japan Chemical Industry Association /
Oct. 1994 ECCJ (JIEC)
162
Chemical : Caustic Soda Ion exchange membrane NaCl electrolysis bath for Electricity
[Technology Classification] caustic soda production [Practical Use]
This technology is to switch the method employed in the NaCl electrolysis bath for caustic soda production
Outline from the asbestos membrane method to the bag ion exchange method. This improvement significantly reduced
electric power consumption.
[Features of ID-process NaCl electrolysis bath]
(Refer to Fig. 1)
Principle 1) Caustic soda and chlorine generated by elec-

trolysis of saline water are separated by an ion
& exchange membrane.
Mechanism 2) The ion exchange membrane is formed to a bag
by which the saline water and pure water are
sealed from each other more easily than a flat
membrane.
Improved section
Fig. 1 Schematic drawing of electrolysis bath
[Improvement of ID-process NaCl electrolysis bath] (refer to Figs. 2 and 3)
1) The electrolysis bath was switched from the asbestos membrane method to the bag-shaped ion exchange
membrane method.
2) The cathodic material of the cathodic can was switched to SUS310S. The mounting method was also modi-
fied.
[Description] 3) The inner material of the can nozzle was changed to SUS310S.
4) The treatment of the periphery of the anode was modified. The thickness of the Ti spring was increased and
the flatness was improved.
Structure
explanation,
Shape, and/or
System
diagram
Improved section
Fig. 2 Modification of cathodic can Fig. 3 Comparison of anode before and after improvement
Table 1 Comparison of energy saving effect between conventional membrane method
and ion exchange membrane method for electrolysis bath
Conventional membrane Improved ion exchange
Effect
method membrane method
NaOH concentration at electrolysis bath exit 12 % 34 %

Energy saving
Salt concentration at electrolysis bath exit 14 % 0.003 %
effects
Specific power consumption 2,595 kWh/t-NaOH 2,338 kWh/t-NaOH 257 kWh/t-NaOH
Specific steam consumption 2.4 t/t-NaOH 0.42 t/t-NaOH 1.98 t/t-NaOH
[Economics] Investment amount: 2,015 million yen

cost
Remarks
163
CS-ME-1 Energy Conservation Directory
Chemical : Caustic Soda Brine preheater using recovered heat of NaCl Fuel (steam)
electrolysis in caustic soda production process 1992
Machinery & Equipment
This improvement is to install a preheater which preheats brine (NaCl water) fed to the electrolysis bath, using
Outline sensible heat of chlorine and hydrogen gases generated in the membrane electrolysis bath.
Conventionally, the feed brine was heated by steam using a carbide-made heat exchanger.
[After improvement]
[Description] 1) After the improvement, the heat is exchanged with the sensible heat of chlorine and hydrogen gases gener-
ated in the NaCl electrolytic bath (particularly membrane-type electrolysis bath), thus the steam consump-
tion is reduced compared with the conventional steam heating.
2) Fig. 1 shows the flow diagram around the preheater.
Structure 3) The heat exchanger is a shell-and-tube type. The materials of the main parts are listed in Table 1.
explanation,
Shape, and/or Table 1 Materials of main parts of brine preheater
System Shell side Tube side

diagram Chlorine gas - brine TP35 (Titanium) TTH35W (Titanium)
Hydrogen gas - brine SS40V (SS) TTH35W (SS)
Improved section
Fig. 1 Flow diagram of brine preheating syste
Table 2 Heat recovery effect of brine preheater
Energy saving Effect Remark
effects Energy recovery (in steam equivalent) 18,000 t/y Production rate: 55,000 t-chlorine/y (17,500
Reduction in crude oil equivalent 1,468 kL/y km3 of hydrogen)

cost
Remarks
164
CS-ME-2 Energy Conservation Directory
Chemical : Caustic Soda Improvement of active cathode for ion exchange Electricity
[Technology Classification] membrane electrolysis for caustic soda production [Practical Use]
This improvement is to use an active cathode. This type of cathode was developed to reduce the overvoltage at
Outline the cathode which generates large energy loss in ion-exchange-membrane NaCl electrolysis for caustic soda
production. Focusing on the fact that the overvoltage at an electrode depends on the electrolysis voltage and its
surface area, a new coating method was adopted, which significantly widens the surface area of the electrode.
Thus, the power consumption was remarkably reduced.
[Principle of ion-exchange-membrane method and breakdown of energy loss]
Table 1 Breakdown of energy loss in ion-exchange-membrane electrolysis

Principle Reduction in specific power
Rate(%)
consumption (kWh/tNaOH)
& Ion-exchange-membrane resistance 345 40.3
Mechanism Anode liquid resistance 15 1.8
Cathode liquid resistance 53 6.1
Anode overvoltage 67 7.9
Cathode overvoltage 263 30.7
Conductor resistance 112 13.2
Total 755 100.0
Improved section
Fig. 1 Schematic drawing of electrolysis bath

[Structure of active cathode]
1) Fig. 2 shows the mesh-type cathode. Fig. 3 illustrates its cross section. Special coating is applied on the
[Description] stainless or nickel cathode, and the hydrogen overvoltage is reduced.
2) The coating layer is a Ni-C-S porous alloy.
3) For normal industrial-scale production, the operating current density is 20-40 a/dm3. The overvoltage of the
Structure active cathode is reduced by more than 0.2 V compared with that of a conventional one.
explanation,
Shape, and/or
System
diagram
Improved section
Fig. 1 Mesh-type cathode Fig. 2 Schematic drawing of the cross section of cathode
Table 1 Example of energy saving (Production scale of 100,000 t-NaOH)

Energy saving
Reduction in specific power consumption 150 kWh/(t-NaOH)
effects
Annual power reduction 15,000,000 kWh/y
[Economics] Investment amount: 255.1 million yen

cost
Remarks
Some sites adopting similar tech- “Collection of Energy Conservation Cases 1988,” Japan Chemical Industy Asociation /
nology p. 197 ECCJ (JIEC)
165
CS-OM-1 Energy Conservation Directory
[Industry Classification] Caustic soda production process [Energy Source]
Chemical : Caustic Soda Electricity
Switching from diaphragm electrolytic process to
Operation & Management ion exchange membrane electrolytic process 1988
In the past, caustic soda production was conducted by the diaphragm process in which anode and cathode in the
Outline NaCl electrolytic bath were separated by an asbestos diaphragm from each other. There developed a process to
produce high concentration and high purity caustic soda through electrolysis using ion exchange membrane.
The ion exchange membrane process gives significant energy saving compared with conventional diaphragm
process.
[Principle of diaphragm process electrolytic bath and of ion exchange process electrolytic bath]
Principle
&
Mechanism
Fig. 1 Conceptual drawing of diaphragm Fig. 2 Conceptual drawing of ion exchange process
process electrolytic bath electrolytic bath
[Conventional process] Refer to Fig. 3
(1)Caustic soda yielded in the electrolytic bath
needs further concentration and purification.
NaOH concentration : about 12%
NaCl concentration : about 16%
(2)Content of impurities
[Description] NaCl : 0.86 ~ 0.93 %
Na2CO3 : 0.082 ~ 0.180 %
Fe2O3 : 0.0018 %
Structure Fig. 3 Flowchart of diaphragm process

explanation, New process] Refer to Fig. 4 Improved section
(3)Caustic soda yielded in the electrolytic bath
Shape, and/or is the final product.
System NaOH concentration: about 20 to 35%
(4)Content of impurities
diagram NaCl : 0.0018 0.0072 %
Na2CO3 : 0.018 ~ 0.09 %
Fe2O3 : 0.00009 ~ 0.008 %
Fig. 4 Flowchart of ion exchange membrane process
Table 2 Energy saving effect through the switching to ion exchange membrane process
(basis: 100,000 t/y of production)
Conventional process New process Effect of improvement
Energy saving Electric power unit for electrolysis 2,500 kWh/t-NaOH average 2,100 kWh/t-NaOH 16% reduction
requirement
effects for power 200 to - 400 kWh/t-NaOH average 75 kWh/t-NaOH 75% reduction
Steam unit requirement 2 ? 3.2 t/t-NaOH 0.68 t/t-NaOH 74% reduction
[Economics]
Investment amount: 2,500 million yen
Remarks
Many sites adopting similar “Chemical Engineering Journal (Vol. 56, Japan Chemical Industy Asociation /
technology No.9),” p.634 ECCJ (JIEC)
166
CS-OM-2 Energy Conservation Directory
Chemical : Caustic Soda Reduction of electrolytic power for NaCl electrolysis Electricity
[Technology Classification] bath in caustic soda production process [Practical Use]
In the past, caustic soda production was conducted by the diaphragm process in which anode and cathode in the
Outline NaCl electrolytic bath were separated by an asbestos diaphragm from each other. There developed a process to
produce high concentration and high purity caustic soda through electrolysis using ion exchange membrane.
The ion exchange membrane process gives significant energy saving compared with conventional diaphragm
process.
The electrolytic power (W) of NaCl electrolysis is, as shown in equation (1), proportional to the bath voltage
(V), which is in turn, as shown in equation (2), nearly in a linear relation with the current (I).
The production rate (P) is proportional to the product of the current and the number of baths (n) as shown in
equation (3).
Principle (1)
&
Mechanism (2)
(3) Improved section
where, W is the electrolytic power (==), 670 is the electrochemical equivalent (=), V is the bath voltage, hc is
the current efficiency, I is the load current (kA), a and b are the constants, P is the production rate, n is the
number of baths, and K is a coefficient.
1) Equation (3) suggests that, for a certain production rate, the load current can be reduced when the number of
baths is increased. Equations (1) and (2) suggest that the power is saved by this approach. However, if the
current is simply reduced:
[Description] - The specific steam consumption for enriching increases due to the reduced concentration of electrolyte.
- The current efficiency is reduced due to the increase in liquid resistance resulted from the decrease in the
electrolyte temperature.
Structure - The membrane is consumed and degraded due to the changes in the pH value in the membrane bath, and the
current efficiency is reduced.
explanation, As the measures to these problems,
Shape, and/or - The reduction in the electrolyte concentration is prevented by adjusting the membrane and strictly control-
ling the electrolytic bath.
System - The electrolyte temperature is increased by about 2˚C by preheating the feed saline water using the waste
diagram heat of generated hydrogen gas drain, thus maintaining the current efficiency.
Table 1 Example of energy saving effect

Energy saving
Effect Remark
effects
Reduction in annual power consumption 13,200,000 kWh/y Reduction rate of 7.4%
[Economics]
The improvement for a membrane NaCl electrolysis bath is illustrated. The technology is applicable to ion-
Remarks exchange-membrane NaCl electrolysis bath and electrolytic production of high-purity chromium and manga-
nese-dioxide.

Similar technologies are adopted “Collection of Energy Conservation Cases 1980,” Japan Chemical Industy Asociation /
at some sites. p. 803 ECCJ (JIEC)
167
CN-ME-1 Energy Conservation Directory
Chemical : Naphtha Cracking Switching quenching tower trays to packing in Electricity, Fuel
[Technology Classification] naphtha cracking process [Practical Use]
Power consumption by the feed gas compressor of the naphtha cracking process is reduced by increasing the
suction pressure. The suction pressure is determined by the exit pressure of the cracking furnace and by the
Outline pressure difference across the quenching process. Since the increase in the exit pressure of the cracking furnace
significantly reduces the ethylene yield, the pressure difference across the quenching process is reduced to save
energy.
[Process flow of the facility] (Refer to Fig. 1)
The quenching process comprises a gasoline-fractionating column and a quenching column.
1) The pressure difference across the quenching process
is 0.31 kg/cm2. The bottom oil of the quenching col-
umn is recirculated to the gasoline-fractionating col-
Principle umn. The bottom oil-bearing hot water (quench wa-
ter) of the quenching column is used as heat sources
& in various processes in the plant, and is recirculated to
Mechanism perform contact cooling after its temperature is con-
trolled using cooling water.
2) In the both columns, the pressure difference occurs at
the valve tray sections. The pressure difference oc-
curs at each tray according to the liquid depth. If the
valve trays are changed to packing, the pressure dif- Fig. 1 Flow chart of naphtha-cracking quenching
ference is decreased and the heat transfer coefficient
process
is increased, thus the top reflux is decreased and the
bottom temperature is increased.
4) As a result, the heat source of the de-ethanizing column can be switched from low-pressure steam to quench
water, so the steam consumption is reduced.
[Before improvement] [After improvement]
[Description]
Structure
explanation, Improved section
Shape, and/or
Fig. 3 Tray packing section in quenching column(after improvement)
System
Table 1 Comparison of operating conditions before and after improvement
diagram
Before improvement After improvement
-Pressure difference in gasoline-fractionating column 0.07 kg/cm2 0.01 kg/cm2
-Pressure difference across quenching column 0.05 kg/cm2 0.01 kg/cm2
-Inlet pressure of feed gas compressor 0.49 kg/cm2 0.59 kg/cm2
-Driving force of feed gas compressor, etc. 12,700 kW/h 12,030 kW/h
Fig. 2 Quenching column Temperature of quench water 86˚ C 88˚ C
(before improvement) Reboiler steam 8.6 t/h 2.7 t/h
Table 2 Energy saving effect by changing trays to packing

Hourly reduction Annual reduction (7,000 h/y)
Energy saving
Reduction in power consumption 670 kW/h 4,690,000 kWh/y
effects
Reduction in steam consumption 5.9 t/h 41,300 t/y
[Economics]
Remarks
Many sites adopting similar “Collection of Energy Conservation Cases 1988,” Japan Chemical Industry Association /
technology p. 1173 ECCJ (JIEC)
168
Chemical : Naphtha Cracking Installation of turbo-expander in top gas line of Electricity
[Technology Classification] demethanizing column in naphtha cracking process [Practical Use]
This improvement is a measure to overcome capacity shortage of a refrigerant ethylene compressor under
increased ethylene production. In order to further reduce the pressure from the conventional level and lighten
Outline the load to the compressor, a turbo-expander is installed in the top gas line and the low-temperature heat is
recovered for energy saving.
The conventional flow is given below.
Before
Improvement
Fig. 1 Flow chart around demethanizing column (before improvement)
1) The top gas temperature of the demethanizing column, which was formerly changed under the isenthalpic
condition, is now lowered to -128˚C by using a turbo-expander, and further lowered to -136˚C by isentropic
change.
[Description 2) This improvement increases the heat recovery to 2.14 x 106 kcal/h, reduces the steam consumption at the
refrigerant ethylene compressor by 4.5 t/h, and reduces the steam consumption at the refrigerant propylene
of compressor by 3.2 t/h.
Improvement] 3) The process flow with the turbo-expander installed is shown below.
Structure
explanation,
Shape, and/or
System
diagram
Improved section
Fig. 2 Flow chart around demethanizing column after turbo-expander is installed

Table 1 Energy saving effect by installing turbo-expander
After improvement Remark

Energy saving
effects Cold heat recovery 2.14 x 106 kcal/h (Operating hours:
Reduction in steam consumption at compressors 7.7 t/h 8,000 h/y)
[Economics]
Remarks
p. 761 ECCJ (JIEC)
169
Chemical : Naphtha Cracking Cold heat recovery from demethanizing column Electricity
[Technology Classification] bottom liquid in naphtha cracking process [Practical Use]
In the naphtha cracking process, the bottom liquid of the demethanizing column is at a temperature of -30˚C and
is fed to the ethylene rectificating column at a vapor/fluid ratio of 0.11. Since the increase in the vapor/fluid
Outline ratio of the feed does not affect much to the efficiency of the ethylene rectificating column, the cold heat of the
bottom liquid is utilized to reduce the power of the propylene refrigerator for energy saving.
The conventional process flow is shown below.
Before
Improvement
Fig. 1 Flow chart of demethanizing column and ethylene rectification column
1) Two aluminum-made heat exchanger is Newly installed: one to the top vapor section of the depropanizing
column, the other to the feed chiller (refrigerator) of the demethanizing column. The bottom liquid of the
demethanizing column is flashed in the adiabatic mode using two control valves, and the cold heat is recov-
ered, thus reducing the power of the propylene refrigerator.
[Description 2) The recovered power of the propylene
refrigerator is 830 kWh/h.
of 3) The flow after improvement is shown
Improvement] below.
Structure
explanation,
Shape, and/or
System
diagram
Improved section
Fig. 2 Flow chart of cold heat recovery from bottom liquid of demethanizing column
Table 1 Refrigerator power saving effect
After improvement Remark

Energy saving
Reduction in power by recovering cold heat 6,640,000 kWh/y Operation of 8,000 h/y
effects
[Economics]
Remarks
p. 618 ECCJ (JIEC)
170
Chemical : Naphtha Cracking Combustion air preheating for boilers using cooling Fuel (steam)
[Technology Classification] tower bottom hot water in naphtha cracking process [Practical Use]
In a naphtha cracking plant, hot water at the bottom of the cool-

ing tower is cooled by process fluid to 60˚C, and further cooled
to 35-50˚C using the cooling water (TW) before sending back to
the cooling tower. On the other hand, at the power plant boilers,
the combustion air is heated to 240˚C using the 13 kg/cm2 steam
Outline and the boiler flue gas before sent to the boilers.
[Flow for utilizing process waste heat at boilers] (Refer to Fig. 1)
1) An air-preheater using waste heat from circulating hot water of the naphtha cracking plant was installed
ahead of the forced draft fan (FDF) for No. 1 and No. 2 boilers. Steam is no more used for preheating.
2) This improvement reduced the steam consumption by 13 t/h.
[Description]
Structure
explanation,
Shape, and/or
System
diagram
Improved section
Fig. 1 Flow chart of combustion air preheating using process waste heat of cooling tower bottom hot water
Table 1 Energy saving effect by reducing combustion-air preheating steam for boilers
effects
Reduction in steam consumption 104,000 t/y (13 t/h) Operating hours: 8,000 h/y
[Economics]
Remarks
171
Chemical : Naphtha Cracking Fuel (steam)
Hot water heating by distillation column top vapor [Practical Use]
The top vapor of the CO2 stripper in this plant is at about 94˚C, and the top vapor of the MEG distillation
column is at about 105˚C. Both vapors are cooled by cooling water. On the other hand, in the “P” plant in the
Outline same industrial complex, the bottom temperature of the rectificating column is at about 60˚C, and the reboiler
is heated by steam. This improvement is to circulate hot water along with the waste heat of the top vapor of the
rectificating column in the “B” plant, and utilize the waste heat as a heat source of the reboiler of the “P” plant.
[Energy flow with B and P plants] (Refer to Fig. 1)
Principle
&
Mechanism
Fig. 1 Flow chart of heat among ethylene-oxide plant, B and P plants

1) It reduces the overall heat transfer coefficient to convert the cooling water to hot water at the top condenser
of the CO2 stripper. Accordingly, the internal structure of the condenser was modified.
2) As for the MEG distillation column, the pressure was changed from 25 to 36 Torr, and the top temperature
was changed from 105 to 117˚C. After these modifications, a top heat exchanger was installed.
3) A condenser was installed at the B plant. A reboiler and a hot water tank were installed at the P plant.
[Description]
Structure
explanation,
Shape, and/or
System
diagram
Improved section
Fig. 1 Use of waste heat of top vapor of distillation column at reboiler by hot-water circulation
Table 1 Energy saving effect by utilizing top vapor waste heat of distillation column
Energy saving
effects
Reduction in steam consumption 37,180 t/y
[Economics]
Remarks
Many sites adopting similar “Energy Saving Journal (Vol. 37, No. 2, 1985),” Japan Chemical Industry Association /
technology P. 39 ECCJ (JIEC)
172
CN-OM-1 Energy Conservation Directory
Chemical : Naphtha Cracking Control of excess air ratio at cracking furnace in Fuel
At this plant, a gas turbine generator was introduced, and its flue gas is used as combustion air for the cracking
furnace. Since the cracking furnace is operated under negative pressure, air is sucked into it. This improve-
Outline ment for energy saving is to control the excess air ratio using an oxygen analyzer mounted to each cracking
furnace.
[Relation between fuel gas flow rate and theoretical

oxygen volume] (Refer to Fig. 1)
[Control of excess air ratio]
The theoretical oxygen volume necessary for combus-
tion is computed based on the molecular weight and
feed rate of the fuel, and compared with the oxygen
Principle volume actually consumed for combustion. The feed
& rate of the air is controlled based on the theoretical
oxygen volume.
Mechanism
Fig. 1 Relation between the molecular weight and calorific

value of the fuel gas, and the theoretical oxygen volume
[Description]
Structure
explanation,
Shape, and/or
System
diagram
Improved section
Fig. 2 Flow chart for using gas turbine flue gas as combustion air
Table 1 Energy saving effect by controlling excess air ratio of cracking furnace
Energy saving
effects
Reduction in energy consumption 41.2 x 109 kcal/y (Equivalent to 15 cracking furnaces)
[Economics]
Remarks
p. 811 ECCJ (JIEC)
173
Chemical : Naphtha Cracking Change of feed step for depropanizing column in Fuel (steam)
Conventionally the bottom liquid of the de-ethanizing column and the bottom liquid of the condensate stripper
in the naphtha cracking process were joined and fed to the depropanizing column via the cooler. This improve-
Outline ment is to separately feed the bottom liquid of the condensate stripper to a lower step of the depropanizing
column, thus eliminating the use of cooling water for the cooler, and reducing steam consumption at the
reboiler of the depropanizing column.
Table 1 Main components of bottom liquid of de-ethanizing column and condensate stripper
De-ethanizing column Condensate stripper Depropanizing column
Principle
& C3 77.0 % 23.4 %
Main components C4 8.6 % 49.2 %
Mechanism C5 0.6 % 22.4 %
Operating pressure 27 kg/cm2 10 kg/cm2 10.5 kg/cm2
Transfer method Pressure transfer Pump up
1) Conventionally, the bottom liquid of the de-ethanizing column and the condensate stripper were jointly fed to
No. 19 step of the depropanizing column.
2) The temperature profile in the depropanizing column is as shown in Fig. 1. After the improvement, the
bottom liquid of the condensate stripper is fed to the lower No. 34 step.
[Description] 3) At the same time, cooling water supply to the cooler in the feed line of the bottom liquid of the de-ethanizing
column is stopped. Thus, the steam consumption by the reboiler of the depropanizing column is reduced.
Structure
explanation,
Shape, and/or
System
diagram
Improved section
Fig. 1 Temperature profile of depropanizing column Fig. 2 Feed system to depropanizing column
Table 2 Energy saving effect by changing feed step to depropanizing column

Energy saving
effects
Reduction in energy consumption 19.600 t/y (2.8 t/h) (Operating hours: 7,000 h/y)
Reduction in crude oil equivalent 1.598 kL/y

cost
Remarks
174
Pressure control of ethylene rectification column by
Chemical : Naphtha Cracking Fuel (steam)
suction pressure of propylene refrigerator in [Practical Use]
Operation & Management naphtha cracking process 1991
This improvement is to reduce the refrigerator power by improving the control method of the propylene refrig-
Outline erator of the top condenser of the ethylene rectification column. This improvement was made at the time of
introducing a decentralized control system (DCS) to the naphtha cracking plant.
[Pressure control method of ethylene rectification column] (Refer to Fig. 1)
1) Before the improvement, the pressure of the ethylene rectification column was controlled by the liquid level
of refrigerant propylene in the top condenser.
2) On the other hand, the suction pressure of the propylene refrigerator was controlled by the revolution speed
of the compressor.
Before
Improvement
Improved section
Fig. 1 Pressure control method of ethylene rectification column
1) A function to control the suction pressure

[Description of the refrigerator was added to the system
of to control the pressure of the ethylene rec-
tification column within the framework of
Improvement] the decentralized control system (DCS).
Thus the heat transfer area of the condenser
Structure is now utilizd to the maximum degree.
explanation, 2) As a result, the suction pressure of the re-
frigerator was changed from 0.60 to 0.68
Shape, and/or kg/cm2G, and the power of the propylene
System refrigerator was reduced by 250 kW.
diagram
Improved section
Fig. 2 Suction pressure control method of propylene refrigerator
Table 1 Energy saving effect of pressure control of ethylene rectification column

Energy saving Reduction effect Remark
effects
Reduction in refrigerator power Reduced by 250 kWh/h
Operation hours of 7,000 h/y
Reduction in crude oil equivalent 425 kL/y

cost
Remarks
175
[Industry Classification] Naphtha cracking process [Energy Source]
Chemical : Naphtha Cracking Fuel (gas)
[Technology Classification] Energy saving in ethylene cracker [Practical Use]
Operation technology on uniform and low oxygen combustion of fuel gas for heating the ethylene cracker.
Outline
Ethylene cracker heats raw material naphtha to temperatures of from 800 to 850˚C to decompose into ethylene
Principle (thermal cracking). The cracker is an upright type with long depth, and has a radiation zone at lower part
provided with many burners (112 units) of short-flame radiation type at lower side walls, and a convection zone
& at upper part (for preheating raw material and steam). The current combustion control values are: intrafurnace
Mechanism pressure at top of the radiation zone to a reduced pressure by 3 mm H2O; and exhaust gas O2 concentration of 1
to 3% (at exit of convection zone). Those control variables are checked by sampling from a single point over the
whole furnace. The fuel consumption for heating is 2,190 Nm3/h per furnace.
Observation of distribution of O2 content in vertical and
horizontal directions in the furnace revealed the follow-
ing.
(1)Lateral O2 content distribution is not uniform.
[Description] Left side: O2 1.5 ~ 1.7
Right side: O2 0.2 ~ 0.3
(2)Difference in O2 content exists in vertical direction.
Lower burner section: O2 7.0 ~ 5.0
Structure Upper burner section: O2 1.0 ~ 0.7
Exit of convection zone: O2 1.2 ~ 1.0
explanation, (3) Actions
Shape, and/or - Primary air valve opening for burner is adjusted.
- Primary air valve for each of lowermost row of burn-
System ers is opened to a minimum necessary degree to pre-
diagram vent burning.
- For the third row and upper burners, also the sec
ondary air valve is kept slightly open.
- Draft is adjusted to 3 to 3.5, somewhat stronger de-
gree. Many burners are arranged on the side walls,
thus the side walls function as the radiation
plane.
Through the above-described improvement (actions), the fol-

lowing-listed effects appeared.
(1)Horizontal distribution of O2 content becomes almost uni-
form.
(2)Vertical distribution of O2 content is also improved as shown
in the right figure.
Energy saving (3)Fuel consumption is reduced as follows.
- Reduction by 30 Nm3/h Improved section
effects Before improvement 2190 Nm3/h
After improvement 2160 Nm3/h
Reduction 30 Nm3/h
- Effect as amount: about 7 million yen (as 33 yen/Nm3)

cost
This is the uniform O2 content combustion technology in the case that many burners are arranged in a single
Remarks furnace. For the case of individual burners, refer to the Energy Saving Handbook, Equipment Common to All
Industries, “Low O2 Burners”.
“Collection of Energy Conservation Cases Japan Chemical Industry Association /
1981,” p. 105, ECCJ ECCJ (JIEC)
176
CB-ME-1 Energy Conservation Directory
Chemical : BTX Recovery of top vapor heat of ortho-xylene Electricity
[Technology Classification] separation column in aromatics production process [Practical Use]
The top condenser of the ortho-xylene separating column in the aromatics production process is of an air-
Outline cooling type. The waste heat of the top vapor is dissipated from the air-fin cooler. The dissipated heat is as large
as 46,000,000 kcal/h and the temperature is 153˚C. This improvement is to recover this waste heat.
[Balance of waste energy by form]
Before
Improvement
Fig. 1 Waste energy balance at ortho-xylene separation column

[Outline of heat recovery system] (Refer to Fig. 2)
1) Through studying the use of a heat pump for generating a high-temperature heat source and the Ranking
cycle for recovering the power, power generation by a low-pressure steam turbine was adopted.
2) The system comprises an evaporator, a feed-water heater, a steam turbine, a condenser, a condensate pump,
and a generator.
[Description
of
Improvement]
Structure
explanation,
Shape, and/or
System
diagram
Improved section
Fig. 2 Flow chart of waste-heat-recovery generator for ortho-xylene separation column

Table 1 Energy saving effect by heat-recovery generator
Recovered energy Remark
Energy saving
Average power generation capacity 5,500 kW 4,500 - 6,500 kW
effects
Total power generation 41,250 MWh/y 7,500 h/y

Equipment Improvement effect: 700 million yen/year (including the stoppage of one pump)
Investment payback: 1 year
cost
Remarks
“Energy Saving Journal (Vol. 35, No. 13, 1983),” Japan Chemical Industry Association /
P. 105 ECCJ (JIEC)
177
Chemical : BTX Waste heat recovery from heating furnace flue gas Fuel (steam)
in BTX production 1983
This process carries out secondary hydrogenation purification of cracked gasoline generated as a by-product in
an ethylene plant. The heating furnace (recycle heater) heats the unreacted hydrogen from 340 to 500˚C. The
Outline heating furnace was modified from natural draft type to forced draft type, thus improving its thermal efficiency
from 74 to 89.8%. At the same time, the heat of flue gas is utilized to generate steam. Thus, waste heat is
recovered with a significant energy saving effect.
[Description]
Fig. 1 Flow chart of cracked-gasoline secondary hydrogenation process

Structure
explanation,
[After improvement]
Shape, and/or
System
diagram
Improved section
Fig. 2 Flow chart of steam generation by recovered flue gas heat of heating furnace (recycle heater)
Table 1 Energy saving effect by steam generation by heating-furnace flue gas

Improvement effect Total
Energy saving
Reduction in steam consumption 0.21 x 106 kcal/h 1,100 kL/y
effects (in fuel oil C equivalent)
Steam generation by recovered heat 1.51 t/h
[Economics]
Equipment Improvement effect: 23.2million yen/year
Remarks
“Collection of Energy Conservation Cases 1984,” Japan Chemical Industry Association /
p. 1181 ECCJ (JIEC)
178
Chemical : BTX Steam turbine power generation using waste heat of Electricity
[Technology Classification] distillation column top vapor in BTX production process [Practical Use]
At this plant, power is generated in-house using a bleeding-condensing turbine. Steam for production processes
is the bleed from the turbine. Power balance is maintained by adjusting the condensing power generation.
However, along with the progress in energy saving, steam consumption in the processes was significantly
Outline reduced, and the condensing power generation nearly reached the upper limit. On the other hand, energy of
distillation column top vapor of the xylene production process was not recovered. Therefore, a new condensing
turbine was installed to recover power from the process, thus the steam to be generated by the old in-house
power generator was reduced, and the operation of one of the boilers was stopped.
- Case study for utilizing top vapor waste heat of distillation column (Table 1)
Type Waste heat recovery method Economy Prior adoptions
1 Absorption refrigeration Top vapor - Cold water generation OK Many

Improvement
Top vapor - Low-pressure vapor generation - (Compression) -
Study 2 Low-pressure steam recompression
Medium-pressure steam generation
OK A few
Top vapor - Low-pressure steam generation - Turbine drive

3 Heat pump Some None
(power, electricity generation)
Top vapor - Low-pressure steam generation - Turbine drive
4 Low-pressure steam turbine OK Many
(power, electricity generation)
1) The top vapor (153˚C, 45 x 106 kcal/h) of the distillation column for separating ortho-xylene from mixed
xylene in the xylene production process was formerly cooled by an air-fin cooler (AFC).
2) The 4th case among those studied was adopted to recover waste heat. The system comprises an evaporator
generating low-pressure steam (1.72 kg/cm2G) in parallel with the existing AFC, a condensing turbine power
[Description] generator, and a feed-water heater.
3) Specification of the facility
Condensing turbine: 3-stage impulse-type turbine with adiabatic efficiency of 72%
Generator capacity: 6,600 kW
Structure 4) System flow (Refer to Fig. 1)
explanation,
Shape, and/or
System
diagram
Improved section
Fig. 1 System flow chart of steam-turbine power generation using top vapor of distillation column
Table 2 Energy saving effect

effects
Recovered energy in heavy oil equivalent 11,300 kL/y (Fuel oil C basis)
[Economics]
cost Investment payback: 1 year
Remarks
P. 43 ECCJ (JIEC)
179
Chemical : BTX Combustion air preheating using heating furnace Fuel
[Technology Classification] flue gas in BTX production process [Practical Use]
This plant has three heavy-oil/gas fired reboilers for the distillation column and one gas fired furnace for the
reaction-system charge heater. All of them are of a horizontal natural draft type. Accordingly, their flue gas
Outline temperatures were as high as 400 to 500˚C, and their thermal efficiencies were as low as 70 to 75%. This
improvement achieved the thermal efficiency of 88% by lowering the flue gas temperature through installing
preheaters for combustion air and employing mechanical draft.
Before
Improvement
Fig. 1 Combustion system of heating furnaces (before improvement)

1) The natural draft system was modified to
a system using forced draft fans (FDFs) Table 1 Energy saving and environmental improvement data
[Description and induced draft fans (IDFs). Rotary- Before After
Effect
type air preheaters are installed. improvement improvement
of 2) As a measures to suppress NOx emis- Reduction by
sions, conventional burners were changed Energy saving effect
Improvement] 0.94 kl/h
to low-NOx burners which assure stable Reduction by
combustion even under a low excess-air SOx emissions 2.29 m3N/h 1.19 m3N/h
48%
ratio.
Reduction by
Structure The low-NOx burner type: Voltmetric NOx emissions 10.4 m3N/h 7.1 m3N/h
32%
burner of sonic atomizing type
explanation, 3) The result of the improvement is shown
Shape, and/or in Table 1.
System
diagram
Improved section
Fig. 2 Flow chart of improvement by combustion air preheating using heating furnace flue gas
Table 2 Energy saving effect by combustion air preheating

Energy saving Recovered energy 6
8.5 x 10 kcal/h (0.94 kL/h) (in fuel oil C equivalent)
effects
Reduction in crude oil equivalent * 6,975 kL/y
Note*: Heating furnace operating hours: 7,000 h/y

[Economics]
cost Investment payback: 0.7 year
Remarks
180
CB-OM-1 Energy Conservation Directory
Chemical : BTX Change of washing system in amine desulfurization Fuel (steam), Water
[Technology Classification] process for BTX production [Practical Use]
At this plant, sulfur-bearing gas generated as a by-product of BTX production by reforming is desulfurized. A
survey of the current operation showed that the sulfur concentration in feed naphtha was in a range of 1/4 to 1/
Outline 14 of the designed value. However, the circulation rate of amine as the absorbent of hydrogen sulfide was
maintained at the excessive design level. This improvement is to reduce the circulation rate of amine, and
reduce the steam rate to the reboiler of the amine regeneration column, eliminating a significant amount of
unnecessary energy input.
[Operating condition]
Before - The design value of the sulfur concentration in feed naphtha : 1,400 ppm
Current operation data: 100 ~ 350 ppm
Improvement - The circulation rate of amine (monomethanolamine) used to absorb hydrogen sulfide was at the design level.
[Description of the process flow] (Refer to Fig. 1)

1) The circulation rates of amine at V301, V302, and V303 were adjusted to optimal values according to the
respective feed gas flow rate of each column.
2) The return water from V301, which was a cause of poor water quality, was re-routed so as to be directly fed
to V308. This change reduced the pure water feed rate.
3) As a result, steam for the reboilers of V304 and V108 was reduced.
[Description
of
Improvement]
Structure
explanation,
Shape, and/or
System
diagram
Improved section
Fig. 1 Flow chart of amine desulfurization process
Table 1 Energy saving effect by reducing amine circulation rate

Energy saving
Reduction in steam consumption 4,200 t/y
effects

cost
Remarks
181
Chemical : BTX Reboiler heating by waste heat of top vapor of Fuel (steam)
[Technology Classification] distillation column in BTX production process [Practical Use]
This BTX production plant produces benzene, toluene, and xylene from light oil generated as a by-product of
Outline coke production. This improvement is to utilize heat of condensation of top vapor of the distillation column,
heat held by condensate of steam used in the reboiler.
Before
Improvement
Fig. 1 Flow chart of BTX production around distillation columns (before improvement)
[Flow after improvement] (Refer to Fig. 2)
1) By increasing the heat transfer area of the heat exchanger for the top vapor of the crude benzene column by
three fold, the heat of condensation of the top vapor is utilized for preheating the feed crude light oil. In
[Description addition, the heat of condensation of the top vapor of the crude toluene column and the heat held by the
of condensate of reboiler steam are utilized as the heat source of the reboiler of the pure benzene column.
2) To do this, a circulation pump for the reboiler liquid of the pure benzene column and a drain heat exchanger
Improvement] are newly installed.
Structure
explanation,
Shape, and/or
System
diagram
Improved section
Fig. 2 Improved flow for reboiler heating by top-vapor waste heat of distillation columns
Table 1 Energy saving effect by waste heat recovery

Energy saving
effects Reduction in steam consumption 11,860 t/y
[Economics]
Remarks
182
Chemical : BTX Waste heat recovery from heating furnace flue gas Fuel (general) (steam)
in BTX production 1979
Operation & Management
Outline A unit to strip (separate) H2S dissolved in oil after hydrogenation of sulfur compounds (mainly thiophene) in a
benzene derivative production process.
1. The unit is a multi-stage deaerator to remove H2S by heating the oil with steam.
Principle 2. The operating pressure in a conventional system is 7.5 kgf/cm2G with heating steam
& of 10 kgf/cm2G.
3. This unit is operated at 3.0 kgf/cm2G with heating steam of 5.2 kgf/cm2G.
Mechanism 4. Thus, the unit enables to reduce steam consumption and steam pressure.
1. The safe operation range of the stripper is an area surrounded by the blowing (upperlimit), pulsating (lower
limit), and flooding.
2. The requirements for modification are the following two items.
•The cross-sectional area of the downcomer at each stage shall be sufficiently
large in relation to the amount of liquid flowing down in the column, that is, the treatment capacity.
•The gap between the bottom of the downcomer and the tray, and the gap betweenthe downcomer and the
inlet weir shall be adequate, and the pressure drop shall not be excessively high.
3. Improvements to be made on a conventional stripper are; To enlarge the cross-sectional area of the downcomer
and the gap between the downcomer and the inlet weir.
To enlarge the tray spacing (reduction of number of stages). To change the tray to a low pressure-loss type
[Description] (bubble cap tray to perforated tray).
4. Configurations of strippers before and after the modification are shown below.
(Before modification) (After modification)

Structure
explanation,
Shape, and/or
System
diagram
Improved section
Modifications
•The downcomer length was shortened by 17 mm.
•The inlet weir was distanced from the downcomer by 18 mm.
•The inlet weir was raised by 2 mm due to the fabrication convenience.
At a capacity of 300 t/d, the steam consumption, the steam pressure, and the stripping pressure are the
following.
Steam consumption Steam pressure Stripping pressure
Energy saving (kg/h) (kgf/cm2G) (kgf/cm2G)
Before modification 660 10 7.5
effects After modification 535 5.2 3.0
Effect 125
(accounting for ¥ 7,100,000 per year including the benefit of
lowered steam pressure)
cost
Remarks
“Collection of Energy Conservation Cases 1981,” Japan Chemical Industry Association /
Firs volume ECCJ (JIEC)
183
Chemical : BTX Control of reflux ratio of distillation column using Fuel (steam)
[Technology Classification] on-line analyzer [Practical Use]
Since the operation control of the benzene distillation column in this plant was done by analog instruments,
changes in feed rate and composition varied the toluene concentration in the product benzene, which raised
Outline problems in quality. The improvement is the introduction of decentralized control system (DCS) to the plant,
and the adoption of reflux ratio control of distillation column under the on-line control, thus attains the reduction
of steam consumption in reboiler.
The operation is under a condition of excess value of reflux ratio of distillation column aiming to prevent the
toluene content in benzene from largely fluctuate owing to the changes of benzene concentration resulted from
Before fluctuation of feed rate of crude benzene to the benzene distillation column caused by upstream influence (dis-
Improvement turbance) or from fluctuation of composition of feed.
Furthermore, the bottom temperature of the column is set to higher level than normally expected value to pre-
vent entering benzene into the residue.
[Flow after improvement] Refer to Fig. 1
(1)The GC analysis values of feed are entered to the decentralized control system via an advanced control
system (ACS), and the control loop is changed to Fig. 1.
[Description 1)The quantity of benzene (FC-7) in the feed is determined using the feed analyzer (GC-1) and the flow meter
of (GC-1), thus controlling the quantity of crude benzene (FC-1).
2)Instead of the control of temperature inside of the distillation column, the internal reflux ratio control (RC-
Improvement] 1) is adopted, and AC-1 is employed in the superior loop to control the toluene concentration in benzene to
a constant level.
Structure 3)To the superior group of the temperature inside of the column TC-1, AC-2 is added to control the benzene
concentration in the bottom liquid at a constant level.
explanation,
Shape, and/or (2)The result is the stabilized dispersion of toluene concentration, the reduction in reflux ratio, and the reduc-
tion in steam consumption in the reboiler.
System
diagram
Improved section
Fig. 1 Control system of benzene distillation column after improvement
Table 1 Effect of control of reflux ratio of distillation column

Before improvement After improvement Effect
Energy saving Toluene content in benzene 130±50 ppm 180±10 ppm
effects Reduction of steam unit requirement 508 kg/t-Bz 470 kg/t-Bz Reduction by 101 kg/t-Bz; (20%)
Reduction of energy (crude oil basis)
[Economics]
cost Investment payback: 1 year
Remarks
184
CG-PE-1 Energy Conservation Directory
Chemical : General Gelatin drying system using heat pump in Electricity
[Technology Classification] pharmaceutical production line [Practical Use]
Gelatin which is widely used in photograph films, drugs, and foods is an extremely hygroscopic material, and
the drying of gelatin consumes large quantity of energy. The system is a case of energy saving as well as
Outline improving the product quality by switching the conventional steam heat source hot air drying method to the heat
pump method.
- Flow diagram of steam heating drying process - Flow diagram of heat pump drying process
Principle
&
Mechanism
Improved section
[Improved heat pump drying system] (Fig. 4)

- Closed system of heat energy employs recycle of heat
[Description] not to generate waste heat.
Structure
explanation,
Shape, and/or
System
diagram
Improved section
Energy saving - Energy cost is reduced by 50%.

An actual plant result: Conventional method: 52 million yen/year
effects Heat pump method: 26 million yen/year

cost
Remarks
Adopted at many sites. “Energy Saving Journal (Vol. 42, No. 4, 1990),” Japan Chemical Industry Association /
ECCJ Version ECCJ (JIEC)
185
CG-PE-2 Energy Conservation Directory
Chemical : General Electricity, Fuel
[Technology Classification] Powder detergent drier utilizing turbine flue gas [Practical Use]
This improvement significantly reduced fuel consumption by a heating furnace in a powder-detergent produc-
tion line. When planning in-house power generation for peak power demand in the plant, a power generation
Outline system in which all the gas discharged from the gas turbine is recovered for reuse was adopted. The recovered
heat is used as heat sources for driers and other facilities for producing powder detergents for clothing.
[Energy balance of gas turbine generator] (Refer to Fig. 1)
[Relation among fuel types, atomizing-air volume, and dust generation] (Refer to Fig. 2)
When planning to use flue gas directly, its effect on the product quality needs to be checked.
Principle
&
Mechanism
Fig. 1 Energy balance of gas turbine Fig. 2 Relation among fuel types, atomizing-air volume,
and dust generation
[Gas-turbine specification]
Gas-turbine generator: 750 kW, simple open cycle, single-axis type
[Description] Flue-gas temperature: 300-500˚C
Structure
explanation,
Detergent
Shape, and/or
System
diagram
Improved section
Fig. 3 Flow chart of direct utilization of gas turbine flue gas for drier
Energy saving Gas-turbine energy efficiency: power generation (about 20%), waste heat recovery (about 75%), total 95%
(Refer to Fig. 1)
effects

cost
Remarks
Some sites adopting similar “Collection of Energy Conservation Cases 1989,” Japan Chemical Industry Association /
technology. p.1273 ECCJ (JIEC)
186
CG-ME-1 Energy Conservation Directory
Chemical : General Ethanol recovery unit using steam recompression Electricity
[Technology Classification] heat pump at alcohol distillation column [Practical Use]
This improvement is to utilize a high-temperature heat pump for recovering waste heat of the alcohol distilla-
tion column. The heat of condensation of top vapor of the distillation column, which was formerly wasted into
Outline cooling water, is recompressed by a screw compressor (VRC, MRC), and utilized to heat the bottom liquid of
the column.
[Example of ethanol recovery from aqueous ethanol solution]

1) As shown in Fig. 1, the vapor having a composition near to that of azeotrope (ethanol: 95.6 wt.%, 78.15˚C,
760 mmHg) is taken out from the column top, and the steam (73˚C, 265.3 mmHg) is generated by the
condenser/evaporator. The steam is heated to 816 mmHg (saturation temperature of 102˚C) using a screw
compressor (compression ratio of 3.08).
2) Since the facility gives a nearly zero alcohol concentration at the bottom of the column, the discharged
steam can be directly injected, and no reboiler is necessary.
[Description]
Structure
explanation,
Shape, and/or
System
diagram
Improved section
Fig. 1 Heat recovery system by steam recompression using heat pump at alcohol distillation column
Table 1 Energy saving effect by heat pump VRC
Conventional system Heat pump VRC Reduction effect

Energy saving Steam consumption 1,600 kg/h
effects Power consumption 163 kWh
Annual energy consumption 11,200 t/y 1,141,000 kWh/y
Consumption in crude oil equivalent 913 kL/y 277 kL/y Reduction of 636 kL/y
(Operating hours: 7,000 h/y)

cost
Remarks
Buyo Gas Corporation Japan Chemical Industry Association /
“OHM (No. 6, 1988),” P. 49 ECCJ (JIEC)
187
Reduction of waste water to be incinerated using
Chemical : General Fuel
reverse osmosis membrane in phenol production [Practical Use]
Machinery & Equipment process 1986
Since the waste water generated in a phenol production plant contains phenol, acetone, and polymers of these,
the biological treatment is difficult, and all of the waste water is incinerated by incinerators. Fuel consumed to
Outline treat the waste water accounts for about one third of the total consumption of fuel in the plant. This improve-
ment is to reduce this fuel consumption.
Description
of
Process
Fig. 1 Incineration of waste water of phenol plant

[Flow of reverse osmosis membrane treatment] (Refer to Fig. 2)
1) Waste water to be treated is 228 t/d from the oxidizer system, 125 t/d from the distillation system, and 72 t/
d from other systems. As the property of waste water from each system differs, several kinds of membranes
were tested.
2) It was decided that only the waste water from the distillation system is to be processed by the reverse
osmosis membrane (RO membrane) after preliminary treatment. As a result, the volume of concentrated
liquid to be incinerated was reduced to about one fourth. The treated liquid can be reused as a process water
[Description as its phenol content was reduced,.
3) For reference, Table 1 shows the observed data of RO-membrane treatment of waste water from the distilla-
of tion system.
Improvement]
Table 1 Observed data of RO-membrane treatment of

waste water from distillation system
Structure
Concentrated
explanation, Item Feed liquid Treated liquid
liquid
Shape, and/or Water throughput
125 94 31
System (t/d)
diagram COD (ppm) 7,000 200 27,400
Phenol (ppm) 500 50 2,000
Color Brown Transparent Black-brown
Fig. 2 Flow chart of RO-membrane treatment of waste water Improved section

from distillation system
Table 2 Energy saving effect by RO membrane
effects Reduction of auxiliary-fuel consumption 1,307 kL/y (Fuel oil C)
[Economics]
Remarks
Some sites adopting similar tech- “Collection of Energy Conservation Cases 1987,”
nology p. 1685 Japan Chemical Industry Association /
ECCJ (JIEC)
188
Chemical : General Improvement of oxygen enrichment process for Electricity
bulk pharmaceutical production Around 1994
In a conventional process for producing pharmaceuticals, the oxygen enrichment process adopted a vacuum
Outline concentrator using a steam ejector. This improvement saved significant energy by switching the vacuum con-
centrator to a membrane (ultra-filtration membrane) concentrator.
Conventional vacuum concentration using steam for oxygen enrichment had following problems.
Before 1) Instantaneous power failures or equipment troubles increased the liquid temperature, and generated a large
Improvement amount of poor-quality products.
2) It required many types of equipment for the purposes such as heating, cooling, and evacuating, and they
consumed a large amount of energy. In addition, unmanned operation was not possible.
Evacuation-concentration system [Before improvement]
[Description
of
Improvement]
Structure
explanation,
Shape, and/or
System Ultra-filtration membrane system [After improvement]
diagram
Improved section
Table 1 Comparison of energy saving effect and environmental improvement

Before improvement After improvement Reduction of energy
Energy saving
Facility capacity 75 kW 15 kW 60 kW
effects
Reduction in power consumption 18,000 kWh/Y 3,000 kWh/Y 15,000 kWh/Y
Reduction in crude oil equivalent 3.6 kL/y
[Economics]
Remarks
Tokyo Tanabe’s Ashikaga Plant “Collection of Improvement Cases at Excellent Japan Chemical Industry Association /
Energy Management Plants (1995)” ECCJ (JIEC)
189
Chemical : General Power generation by turbo-expander in Electricity
telephthalic acid production process 1992
In the feed-oxidizing reaction process for telephthalic-acid production, a large amount of non-reactive nitrogen
contained in the air is emitted to the atmosphere. The temperature of the emitted flue gas varies with seasons:
Outline about 20˚C in winter and about 60˚C in summer. This improvement significantly saved energy by recovering
the energy of the flue gas, which had formerly been dissipated to the atmosphere, using a gas expander (expan-
sion turbine).
[Selection of energy recovery system]
Table 1 Selection of a system to recover energy from flue gas
Merit Investment Invesment effect

Energy recovery system Recoverable energy
Principle (million yen/year) (million yen) (Investment/Effect)
& (1) cGoam

s expander + Steam 5kg/cm2G steam 100 450 4.1
pressor 13.8t/h
Mechanism
(2) G as expander + Turbo Electricity: 1,740kW 136 290 2.1
compressor Steam: 3.7t/h
(3) Gas expander + Small power Electricity: 2,600kW 176 280 1.6
generator Steam: 4.0t/h
1) The flue gas has the energy of 36,000 m3/h and the pressure of 20 kg/cm2G.
2) Gas expander specification
Expansion turbine: three-stage impulse-type (with heaters at inlet and intermediate stage)
Generator : induction generator
Output : 2,600 kWh/h
[Description] 3) Power generation system (Refer to Fig. 2)
Structure
explanation,
Shape, and/or
System
diagram
Improved section
Fig. 2 Power generation system by gas expander (expansion turbine)
Table 1 Energy saving effect by gas expander

Energy saving
effects Power generation 20,800 Mcal/y (2,600 kW)
Increase of steam consumption 32,000 t/y (4 t/h)
[Economics]
Remarks - The turbine rotor shall be made of SUS materials.

P. 31 ECCJ (JIEC)
190
Chemical : General
Waste heat recovery from solvent separator vapor Fuel (steam)
[Technology Classification] using absorption heat pump [Practical Use]
Machinery & Equipment in butadiene production process 1981
In this process, steam is introduced to the separator to heat and separate the solvent from the feed. The tempera-
Outline ture of vapor leaving the separator was about 90˚C, and this heat of condensation was wasted into the cooling
water at the cooler. This improvement for energy saving is to recover the waste heat in a form of hot water using
a heat pump, vaporize it in a flash tank, and reuse the steam at the separator.
The absorption heat pumps are classified into Class 1 and Class 2 as shown in Table 1 by the application
method of waste heat.
Table 1 Classification and features of heat pumps
Principle
Low-temperature heat Generated heat
& Driving power
source
Usable heat
temperature range
Cooling water
Mechanism Class 1 Steam (5 to 10 kg/cm2G) or Waste heat, About 170% of the driving power
80 - 120˚ C Not necessary
(cycle) fuel environment in thermal equivalent
Class 2 Waste heat Less than 50% of the waste heat

Waste heat (60 or more) 160 or less Necessary
(cycle) (60 or more) used
1) A Class-2 absorption-type heat pump is installed in parallel with the existing cooler. Heat of condensation at
the cooler is 4.3 x 106 kcal/h.
2) The absorption heat pump recovers the waste heat of the cooler in a form of hot water (133˚C), from which
steam (127˚C) is generated in the flash tank. The generated steam is supplied to the solvent separator. The
vapor condensed in the heat pump is separated into solvent and water in the drain tank. The separated water
[Description] is reused as make-up hot water for the heat pump.
Structure
explanation,
Shape, and/or
System
diagram
Improved section
Fig. 1 Flow chart of Class-1 absorption-type Fig. 2 Flow chart of Class-2 absorption-type heat pump
heat pump applied to solvent separation process
Table 2 Energy saving effect by waste heat recovery using heat pump
effects Reduction in steam consumption 24,000 t/y Total (in heavy oil equivalent)
Increase in power consumption * 234 x 103 kWh/y 1,792 kL/y
[Economics]
Remarks
Many sites adopting similar “Energy Saving Journal (Vol. 36, No. 7, 1984),” Japan Chemical Industry Association /
technology P. 15 ECCJ (JIEC)
191
Chemical : General Fuel (general)
Low temperature catalyst combustor [Practical Use]
Machinery & Equipment 1970s
1) A catalyst to oxidize waste gas containing organic matters, tar generated in a furnace and hydrocarbons at a
low temperature of 350˚C or below.
Outline 2) Oxidization decomposition allows to apply the catalyst for deodorizing, effective use of oxidization heat,
and cleaning of waste gas, etc.
3) Low temperature combustion suppresses the thermal NOx generation
Principle 1) The supporting metals are Pt, Pd, or Rh.
& 2) The catalyst effect enhances oxidization at a low temperature level (150 to 350˚C depending on the type of
gas).
Mechanism 3) The operating condition is space velocity of 20,000 to 40,000 l/h, and catalyst bed height of 15 to 25 cm.
1) The catalyst is used in a shape of grain, honeycomb, foam, or fiber, depending on the operating condition.
2) Following is an example of a catalyst system.
[Description]
Structure
explanation,
Shape, and/or Operating Concentration Concentration
System Substance before treatment after treatment

temperature (˚C) (ppm) (ppm) Improved section
diagram
Energy saving
Compared with a direct heating (high temperature oxidization) waste gas treatment facility, the fuel cost is
effects decreased to a level of 30 to 35%.

cost
Deodorizing and removal of harmful substances from waste gas of a chemical plant, oxidization cleaning of un-
Remarks burnt gas and tar in an incinerator.
The Agency of Natural Resources and Energy, Japan Chemical Industry Association /
"Energy Conservation Setsubi Souran," P245, ECCJ (JIEC)
The Energy Conservation Center, Japan, 1986.
192

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Section 3

Item No. Technology Item/Title Item No. Technology Item/Title

Item No. Technology Item/Title

Caustic soda production process

Item No. Technology Item/Title Item No. Technology Item/Title

Naptha cracking production process

Item No. Technology Item/Title

Item No. Technology Item/Title

Energy saving Q = Qs/kn

[Economics] Investment amount: 130 million yen

Fig. 1. Heat-exchanger-type primary reformer

Fig. 2 Improved reforming process flow of ammonia plant

Energy saving Improvement effect Remark

effects Reduction in specific energy consumption 0.15 x 106 kcal/NG3-t

Reduction in crude oil equivalent 10,708 kL/y

[Economics] Investment amount: 200 million yen

Reduction in unit requirement after

Reduction of energy (crude oil basis) 5,708 kL/y

Table 2 Reduction in unit requirement in a pressure difference reactor

Heat recovered to steam 0.17 x 106 kcal/t-NH3

Reduction of energy (crude oil basis) 6,931 kL/y

[Economics] Investment amount: million yen

Fig. 1 Reactor used in the CO conversion process

Table 1 Effect of improvement of energy unit requirement during ammonia production

Heat recovered as steam 0.1 x 106 kcal/t-NH3

Reduction of energy (crude oil basis) 128,000 kL/y

Remarks The facility is also applicable to hydrogen plants.

Fig. 1 Flow diagram of CO conversion in ammonia production process

Remarks The facility is also applicable to hydrogen plants.

Table 1 Energy saving effect

Reduction in crude oil equivalent 1,454 kL/y

[Economics] Investment amount: 60 million yen

Fig. 1 Schematic cross section of separation membrane module

- Energy saving effect

Heat recovered as steam 0.14 x 106 kcal/t-NH3

Reduction in crude oil equivalent 5,708 kL/y

[Before the improvement]

Table 1 Energy saving effect by power recovery turbine

effects Reduction in specific energy consumption 6

Fig. 1 Flow chart of reforming process with pre-reformer Improved section

Table 1 Energy saving effect by pre-reformer

Energy saving Reduction in specific energy consumption 0.15 x 106 kcal/NH3-t

Reduction in crude oil equivalent 5,354 kL/y

Table 1 Energy saving effect by waste-heat recovery

Reduction in crude oil equivalent 13,564 kL/y 19,988 kL/y

(Remark*: Ammonia production 2,000t/D, operation days 330 days/year)

[Economics] Investment amount: 500 million yen

[Example sites] [References] [Inquiry]

(1)The low temperature waste heat at about 200˚C of

Table 1 Effect of energy saving by the humidification process

[Economics] Investment amount: 250 million yen

[Example sites] [References] [Inquiry]

[Before improvement] [After improvement]

Fig. 2 Flowchart of ammonia recovery Fig. 3 Flowchart of ammonia recovery

Table 1 Improved effect of energy saving in the ammonia recovery step

Energy saving Improved effect Remark

Reduction of energy (crude oil basis) 4,240 kL/y

[Economics] Investment amount: 7 million yen

Fig. 1 Flowchart of energy saving type carbonate removal process

Increased power consumption 10 kWh/t-NH3

Reduction of energy (crude oil basis) 23,733 kL/y

[Economics] Investment amount: 1,200 million yen

[Example sites] [References] [Inquiry]