1

FM_07/ 2000
Utility systems
How to satisfy the energy
requirements of a process
Dr Ir Franois Marchal
LENI - DGM - EPFL
francois.marechal@epfl.ch
Laboratoire dnergtique i ndustrielle LENI -ISE-STI-EPFL
Transformation de
l'nergie
Procds
Traitements des rejets
Supports de
production
Matires
Premires
Energie
Produits
Sous-produits
Energie
Eau
Rejets et dchets
Environnement
Air
Air
Eau
Sol
Traitement
Le systme nergtique industriel
2
Laboratoire dnergtique i ndustrielle LENI -ISE-STI-EPFL
Performances dun procd
En termes montaires : Le profit
Le profit dpend :
Performances des technologies
Performances de lintgration
Agencement des technologies
Environnement Socio-conomique
Management du systme de production
opration
Laboratoire dnergtique i ndustrielle LENI -ISE-STI-EPFL
Transformation de
l'nergie
Procds
Traitements des rejets
Supports de
production
Matires
Premires
Energie
Produits
Sous-produits
Energie
Eau
Rejets et dchets
Environnement
Air
Air
Eau
Sol
Traitement
Le systme nergtique industriel
3
Laboratoire dnergtique i ndustrielle LENI -ISE-STI-EPFL
Transformation de lnergie
Combustibles
Ptrole
Gaz naturel
Dchets
Biomasse
Chaleur
Soleil
Autre industrie
Electricit
Energie utile pour le procd
Turbines
Chaudires
Compresseurs
Echangeurs
Technologies nergtiques
Racteurs
Pertes
Emissions
Resources nergtiques
Diffrentes caractristiques
Cot (march)
Emissions (lgislation)
Disponibilit
MIse en oeuvre
Technologies
Performances
Matriaux
Emissions
Investissements
Technicit
FM_07/ 2000
Heat exchanger network Investments
Identify the energy saving
heat exchanges
Utilities
Cost of Energy
Satisfy the energy requirement
Improve the MER : onion structure
Chemical processes : the onion structure
Reaction
Separation
Energy
Minimum Energy Requirements
4
FM_07/ 2000
The process utilities
Waste
Utilities
Raw
Utilities
Intermediate
Utilities
Process
Hot : fuels
Cold : Cooling Water
Thermodynamic cycles
Rankine, refrigeration,
steam networks
Raw materials
Products
and
by-products
Energy
electricity
Export
FM_07/ 2000
Engineering work method
From Goals & Constraints to Solutions ...
Analyse
Generate
Evaluate
Problem definition
Results
New problems - New goals
Goals & Constraints
Solutions
5
FM_07/ 2000
20
40
60
80
100
120
140
160
180
0 10 20 30 40 50 60 70 80 90 Q(kW)
T (C)
60
2.5
-82.5
75
-15
DH=
Hot - Cold
(KW)
Cascade
(KW)
20
80
82.5
0
75
60
0
60
62.5
-20
55
40
Utility integration
DH= 60 kW
DH= 2,5 kW
DH= -82,5 kW
DH= 75 kW
DH= -15 kW
60 kW
62,5 kW
0 kW
60 kW
0 kW
0 kW
Hot utility : above the pinch point
20 kW
Hot utility at
low T !
?
?
15 kW
Cold utility below the pinch point
Cold utility at
higher T !
Pinch point
FM_07/ 2000
Utility definition
T
H
Type of utility (e.g. : Hot stream)
Outlet conditions (T,P)
(environment, operation)
3 characteristics :
- H-T diagram (from GCC analysis)
- Cost as a function of flowrate
- Flowrate : to be determined to satisfy the
requirements at Minimum Costs.
inlet conditions (T, P)
(fuel type, combustion , operation)
6
FM_07/ 2000
Utility integration
GCC = cold stream
GCC = hot stream
Heat sink
Heat source
Self sufficient zones
Exchange process -> process
T
H Q
T
H Q
P
T
H
Q
T
H
Q
P
Counter current analogy
Hot utility -cold process
Counter current analogy
Hot process -cold utility
220
200
180
160
140
120
100
80
60
40
0 200 600 H(kW)
T(C)
D
E
F
Ambient T
Z
o
n
e

1
Z
o
n
e

2
Z
o
n
e

3
FM_07/ 2000
Multiple utilities
PINCH
T
Qhmin
(C)
Q1
T1
Q2
T2
T3
H (kW)
Identify the temperature levels
7
FM_07/ 2000
Multiple utilities
T
H
HP
LP
T3
T2
T1
F
U
M
E
S
RAD
Use of multiple utilities for different levels
-> Cost of Energy instead of Energy
FM_07/ 2000
Multiple utilities
T
H
HP
LP
T3
T2
T1
F
U
M
E
S
RAD
Minimising exergy losses
-> multiple levels : max numbers
8
Combustion : stoechiometry
Fuel : C
x
H
y
O
z
S
s
N
n
xC + xO
2
+ = xCO
2
yH +
y
4
O
2
=
y
2
H
2
O
nN + nO
2
= nNO
2
sS + sO
2
= sSO
2
x +
y
4
+ n + s
z
2
0.21










* 1 +
a
( )* (0.79N
2
) +
x +
y
4
+ n + s
z
2
0.21










*
a
( )* (0.21O
2
) + xCO
2
+
y
2
H
2
O + nNO
2
+ sSO
2
x +
y
4
+ n + s
z
2
0.21










* 1 +
a
( )* (0.21O
2
+ 0.79N
2
)
O2 (air)
Flue gases
Heat
Lower Heating Value
Useful heating value
Combustion
T
Fuel
O2 (air)
Stack temperature Tc
Environnement
Q
air
= m
air
cp
air
25
ta

dT = m
air
cp
air
(ta 25)
Q
fuel
= LHV+ m
fuel
cp
fuel
25
tf

dT = LHV + m
fuel
cp
fuel
(tf 25)
Q
pertes
= m
fumes
cp
fumes
25
Tc

dT = m
fumes
cp
fumes
(tc 25)
T
0
=25C
Adiabatic temperature of combustion
9
Pouvoir calorifique
Pouvoir calorifique suprieur
PCS (kJ/kg) ou HHV
Quantit dnergie obtenue par le refroidissement
jusqu 25C dans des conditions standard (1atm) des
fumes obtenues par la combustion dune unit de
combustiible avec lair stoechiomtrique (excs dair =
0) pris 25C et 1 atm.
Pour le pouvoir calorifique suprieur, on tient compte
de la condensation de leau
Pouvoir calorifique infrieur
PCI (kJ/kg) ou LHV
PCS-nergie de condensation de leau 25C
Temprature adiabatique de combustion
Temprature rsultant de la combustion
adiabatique (sans change de chaleur) dun
combustible
Profils de temprature pour une combustion
0
500
1000
1500
2000
2500
-10000 0 10000 20000 30000 40000 50000 60000
T (C)
Q(kJ/kg)
o2=10%
Stoechiometrique
Prchauffe de lair
Chemine
Condensation
Combustion du mthane
10
FM_07/ 2000
Useful heating value of a fuel
LHV
u
= cp
f
* T
ad
0
T
stack [ ]
: Useful heating value
cp
f

LHV
(T
ad
0
T
0
)
in
kW
(kg
fuel
C)
,T
0
= 25C
cp
f
cp
gc
*
m
gc
m
fuel
Intrisic Losses =1
LHV
u
LHV
Real losses = m
fuel
* LHV
u


Q
mer
Elments spciaux
Conversion du soufre : contrle cintique
0.95 * sS + 0.95 * sO
2
= 0.95* sSO
2
0.05 * sS + 0.05 *
3
2




sO
2
= 0.05* s* SO
3
0.05 * s* SO
3
+ 0.05* s* H
2
O= 0.05* s* H
2
SO
4
Affinits avec leau => temperature de condensation + leve
(+70C)
Problmes de corrosion
NO
x
= NO, N
2
O, NO
2
diffrentes formes contrles par la
cintique (vitesse) donc par T et conditions de mlange
Imbrls = combustible non bruls => cendres et poussires,
perte de pouvoir calorifique.
11
FM_07/ 2000
Fuels containing S
SO
3
(ppm) =- 27,712 + 4,331 S(%) +
29.863
O
2
(%)
- 3,707
S(%)
O
2
(%)
+ 54,396 LOG(O
2
(%))
avec SO
3
(ppm) la teneur en ppm de SO
3
dans les fumes;
S(%) le pourcentage massique de soufre dans le combustible;
O
2
(%) le pourcentage molaire de O
2
dans les fumes;
limite de validit: 0,5 <S(%) <5
1 <O
2
(%) <4
T
ra
= T
ch2o
+ T
c
= 273.15+ 100
4
[H
2
O] P + 49,7041 (
SO
3
(ppm)
H
2
O (%)
)
0.1173

avec [H
2
O] la fraction molaire de H2O dans les fumes;
T
ch2o
le point de rose de la vapeur d'eau dans les fumes;
T
c
l'avance la condensation;
T
ra
la temprature de rose acide des fumes (K);
P la pression dans la chemine (bar).
Temperature de rose acide
FM_07/ 2000
Values for different fuels
LHV
(kJ/kg)
O2
s
(kg/kg)
T
ad
s0
(K)
Tch
(K)
LHV
u
(kJ/kg)
LHV
u
Gaz naturel 39680 13,879 2270 374 38163 -3,82%
Gaz de cokerie 2780 0,696 1688 346 2685 -3,43%
Distrigaz 44945 15,693 2290 374 43225 -3,83%
Mer du Nord 47900 16,735 2292 374 46047 -3,87%
Gaz de charbon 27270 8,557 2373 376 26246 -3,75%
Essence 47798 15,003 2431 438 44665 -6,55%
Vaporizing oil 46105 15 2389 438 43023 -6,69%
Diesel 45867 14,583 2426 439 42838 -6,60%
Krozne 46924 14,826 2429 438 43850 -6,55%
Fuel lger 45316 14,454 2425 440 42303 -6,65%
Fuel lourd 44500 14,264 2423 441 41507 -6,73%
Anthracite 33220 11,53 1819 434 30256 -8,92%
Bitume 31520 10,21 1954 435 28929 -8,22%
Lignite 25450 7,23 2111 438 23488 -7,71%
12
FM_07/ 2000
CO
2
Impact
DPCU CO
2
(LHV)
CO
2
(LHV
u
)
DCO
2
CO
2
(LHV)
CO
2
(LHV
u
)
Gaz naturel -3,82% 55 57 3,97% 0,00% 0,00%
Gaz de cokerie -3,43% 186 193 3,56% 239% 238%
Distrigaz -3,83% 57 59 3,98% 3,54% 3,55%
Mer du Nord -3,87% 55 58 4,03% 1,26% 1,31%
Gaz de charbon -3,75% 58 60 3,90% 5,19% 5,11%
Essence -6,55% 65 70 7,01% 19,53% 23,02%
Vaporizing oil -6,69% 69 74 7,16% 25,77% 29,63%
Diesel -6,60% 69 74 7,07% 25,71% 29,45%
Krozne -6,55% 67 72 7,01% 22,88% 26,47%
Fuel lger -6,65% 70 75 7,12% 27,08% 30,92%
Fuel lourd -6,73% 71 76 7,21% 29,29% 33,31%
Anthracite -8,92% 100 109 9,80% 81,53% 91,69%
Bitume -8,22% 86 94 8,96% 56,84% 64,35%
Lignite -7,71% 81 88 8,35% 48,39% 54,64%
FM_07/ 2000
Utilities definitions
0 20 40 60
T(K)
Q(kW)
-20
QMER
Utility cost : C(CHF/s) = cost(CHF/kg) * flow(kg/s)
Tad
Tstack
Increasing flow
Infeasible
13
FM_07/ 2000
Utilities definitions
For the same MER !!!
0 20 40 60
T(K)
Q(kW)
-20
Q2
Q1
Energy available or excess
Different utility heat
loads
Utility 1 : C1 = cost 1 * flow 1
Utility 2 : C2 = cost 2 * flow 2
Tad
2
Tad
1
FM_07/ 2000
For the example
T stack
m
fuel
k
*cp
f
* T
ad
max T
stack
min
, T
k
*
+ T
min
/2
f ( ) ( )



]
]
]
=

Q
mer
k
m
fuel
=
max
k

Q
mer
k
cp
f
* T
ad
max T
stack
min
, T
k
*
+ T
min
/2
f ( ) ( )



]
]
]





]
]
]
]
]
cp
f

LHV
(T
ad
T
0
)
en
kW
(kg
fuel
C)
,T
0
= 25C
cp
f
cp
gc
*
m
gc
m
fuel
m
fuel

max
k

Q
mer
k
*(T
ad
T
0
)
LHV * T
ad
max T
stack
min
, T
k
*
+ T
min
/2
f ( ) ( )



]
]
]
|


1

|
`

1

14
FM_07/ 2000
Intgration de la combustion
0
500
1000
1500
2000
2500
-10000 0 10000 20000 30000 40000 50000 60000
T (C)
Q(kJ/kg)
o2=10%
Stoechiometrique
Prchauffe de lair
Chemine
Condensation
Combustion du mthane
T pincement
Effet de la prchauffe
Pour un mme dbit de combustible :
plus dnergie au-dessus du pincement
Excs dair : moins dnergie disponible
FM_07/ 2000
Combustion
Prchauffe de l'air
T prchauffe : 450C
Dbit: 94,78%
0 10000 20000 30000 40000
Excs d'air 10%
Dbit = 100,67 %
Pertes
Quantit de chaleur utile fixe
Prchauffe de l'air
0
500
1000
1500
2000
2500
3000
0 10000 20000 30000 40000
Excs d'air 10%
Pertes air stoechiomtrique
Pertes avec
excs d'air
T(K)
Q(kJ/kg)
Dbit de combustible fix
Q(kJ)
PCU
PCI
Air stoechiomtrique Combustion
stoechiomtrique
Dbit = 100 %
15
FM_07/ 2000
Cogeneration : gas turbines
0 20 40 60
T(K)
Q(MW)
-20
Energy available or excess
ToT
Gaz
Air
P1
P2
H
S

E =
GT
e
* m
fuel
* LHV
fuel
m
fuel
=
max
k

Q
mer
k

GT
th
* LHV
fuel
(T
oT
T
stack
min
)
* T
oT
max T
stack
min
, T
k
*
+ T
min
/2
f ( ) ( )




















T
stack
min
FM_07/ 2000
Gas Turbine : fixed size
0 20 40 60
T(K)
Q(MW)
-20
Energy available or excess
Fuel
Air
P1
P2
H
S

E =
GT
e
* m
fuel
GT
* LHV
fuel
T
stack
min

Q
GT
= m
fuel
GT
* LHV
fuel
*
GT
th

Q = m
fuel
PC
*UHV
fuel
+ m
fuel
PC
* LHV
fuel
* (
GTth
)
T
oPC
= T
0
+
m
fuel
PC
+ m
fuel
GT
* (1
GT
e
)
m
fuelPC
(T
ad
T
0
)
+
m
fuelGT
*(1
GTe
)
(T
oT
T
0
)
T
oPC
T
oGT
16
FM_07/ 2000
Cogeneration engines
0 20 40 60
T(K)
Q(MW)
-20
Energy available or excess
Fuel
Air
V1
V2
H
S

E =
ENG
e
* m
fuel
ENG
*LHV
fuel
T
stack
min
120C
T
cg
500C
T
cg
T
c

Q
cg
=
ENG
tcg
* m
fuel
ENG
* LHV
fuel

Q
c
=
ENGt
c
* m
fuelENG
* LHV
fuel
T
c
80 90C
FM_07/ 2000
Combined heat and power
Example : Rankine cycle
Condensation
Heat source
Heat sink
Pompe
Vaporisation
Turbine
W
W Heat sink
Condens
Vapo
Heat source
T
H
17
FM_07/ 2000
Steam network and restricted matches
Process 1
Process 2
H
C
fuel
Cooling system
FM_07/ 2000
Combined heat and power
Q+W
T
W
Q
W
Q
Q+W

Q
MER
Hotu
+

W

Q
MER
Coldu

W
18
FM_07/ 2000
Combined heat and power
T
Q1
Q3-W
Q3

Q
3
W +

Q
4
=

Q
MER
Coldu

W
Q2
W

Q
1
+

W +

Q
2
=

Q
MER
Hotu
+

W
W
Q1+W
Q4
FM_07/ 2000
Combined heat and power
Q+W
T
Q

Q
MER
Hotu
+

W +

Q

Q
MER
Coldu
+

Q
W
19
FM_07/ 2000
How to integrate mechanical power production ?
Q+W
W
Q
0
Q
W
Q+W
Q+W
Q
W
T
F10+W
F9-Q
F8-Q
F7
F6
F5
F4
F3
F2
F1
F10
F9
F8
F7
F6
F5
F4-Q-W
F3-Q-W
F2-W
F1-W
F10+(Q+W)
F9
F8
F7
F6
F5+Q
F4+Q
F3+Q
F2+Q
F1+Q
Above the pinch point :
1 thermal kW
=
1mechanical kW
Below the pinch point :
1 cold utility kW
=
1 mechanical kW
Across the pinch point:
Energy penalty
0 !!!
0 !!!
FM_07/ 2000
Pincement
Recrues
Recrues On rentre du boulot
On y retourne
On rentre du boulot
Allez auTravail
Allez auTravail
Cognration
20
FM_07/ 2000
Max flowrate

Q
Choose the appropriate pressure levels
Exploit the self sufficient zones to maximise the
mechanical power production : insert rectangles
P =
T 273
100




4

E
Carnot
=

Q *(1
Tv
Tc
)
Max
Expansion
Ratio
Tc
Tv
0
5000 10000 15000 20000 25000 30000 35000
Q(kW)
300
350
400
450
500
550
600
T(K)
650
115 bar
58 bar
35 bar
7,7 bar
1,5 bar
1,0 bar
FM_07/ 2000
Estimate the mechanical power production
Above the pinch point: A is the area of the integrated
rectangles =

E = q
c
T
v
T
c
T
v

c
T
v
T
c
( )










=
A
T
v

c
T
v
T
c
( )

E = q
v

c
T
v
T
c
T
v






=
c
A
T
v
Below the pinch point A is the area of the integrated
rectangles =
21
FM_07/ 2000
Utilities : combined heat and power
0 2000 4000 6000 8000 10000
200
300
400
500
600
700
800
900
1000
1100
T(K)
Q(kW)
12000
Gas turbine ?
Fuels ?
Gas engines ?
Enriched air ?
Preheating ?
Steam ?
Organic Rankine Cycles ?
Liquid Fuel ?
Natural gas ?
PSA ?
VSA ?
Membrane ?
Cryogenic ?
Temperature ?
Pressure ?
Turbine ?
FM_08/2002 Laboratory of Industrial EnergySystems
LENI -ISE-STI-EPFL s.a.
BELSIM Together wit h
Heat pump and refrigeration
CONDENSATION
HIGH TEMPERATURE
EVAPORATION
LOW TEMPERATURE
COMPRESSOR
EXPANSION
VALVE
Cold utility (cooling water)
Process stream
T
Q

E
k

E
k
22
FM_07/ 2000
Heat pump
T
Q+W
Q

Q
MER
Hotu
(

Q +

W )

Q
MER
Coldu

Q
W
FM_07/ 2000
Heat pump
T

Q
MER
Hotu
(

W )

Q
MER
Coldu
+

W
W
Q+W
Q
Above pinch point
W
Q+W
Q
Below pinch point
23
FM_07/ 2000
Definition des niveaux de recompression
250
300
350
400
450
500
550
600
650
700
0 10000 20000 30000 40000 50000 60000
T(K)
Q(kW)
Grand composite curve
Emec
FM_07/ 2000
Integrating MVR
Q+W
W
Q
0
Q
W
Q+W
Q+W
Q
W
T
F10-W
F9+Q
F8+Q
F7
F6
F5
F4
F3
F2
F1
F10
F9
F8
F7
F6
F5
F4+Q+W
F3+Q+W
F2+W
F1+W
F10-(Q+W)
F9-(Q+W)
F7-(Q+W)
F6
F5-Q
F4-Q
F3-Q
F2-Q
F1-Q
Above the pinch point:
Wmec = hot utility
Below the pinch point :
Wmec = hot utility !!!
Accross the pinch point:
Wmec => energy savings: W+Q
0 !!!
0 !!!
24
FM_07/ 2000
Pincement
On rentre du boulot
! On y retourne ?
Au travail
On y retourne
Au travail
Ne me dit pas
quon y retourne ?
On rentre du boulot
Tout a pour a !
Ca valait
pas la peine !
Pompe chaleur
Au travail
FM_07/ 2000
Refrigeration
T

Q
c
+

Q
r
+

W =

Q
MER
Coldu
+

W
W
Q
c
Q
r
+W
Ambient T
Q
r
25
FM_07/ 2000
Refrigeration cycle integration
C/W
1
2
(a)
T
A
Tamb
B
D
E
C
F
1 2
Qr
H (b)
Single stage cooling
C/W
1
2
T
A
Tamb
B
D
E
C
F
1 2
Qr
H (d)
3 4
(c)
4
Two stages cooling
1
2
T
A
Tamb
B
D
E
C
F
1
2
H (f)
3 4
5 6
7 8
B'
D'
(e)
6
5
7
8
3
4
C/W
Three stages cooling
+ condensation
FM_07/ 2000
Combined heat and power : important rules
Producing mechanical power
Above : 1 thermal kW for 1 mechanical kW
Below : 1 kW cold utility becomes 1 mechanical kW
Use self sufficient zones
Appropriate placement : Never accross the pinch
Using mechanical power
Use if:
Hot utility at low temperature
Cold utility at high temperature
Small temperature difference
Take heat below the pinch and sent it back above
26
FM_07/ 2000
Utilities
0 2000 4000 6000 8000 10000
200
300
400
500
600
700
800
900
1000
1100
T(K)
Q(kW)
12000
Gas turbine ?
Fuels ?
Gas engines ?
Enriched air ?
Preheating ?
Steam ?
Heat pumps ?
Organic Rankine Cycles ?
Water ?
Air ?
refrigeration ?
Liquid Fuel ?
Natural gas ?
PSA ?
VSA ?
Membrane ?
Cryogenic ?
Compressor ?
Absorption ?
Refrigerant ?
Pressure ?
Compressor ?
Temperature ?
Pressure ?
Turbine ?
FM_07/ 2000
Energy balance of a temperature interval
Integrating heat producers and consumers
Sharing energy by counter current heat exchange
Excess of energy from the upper intervals
Energy for the hot streams in interval i
Energy for the cold streams in interval i
Energy to the lower intervals
T
i +1
T
i
*
*
For each utility stream
Unknown flowrate-> f
j
: Continuous variable
Use YES/NO ? -> y
j
:Interger variable 1/0
R
i+1
R
i
f
j
q
ji
f
j
q
ji
27
FM_07/ 2000
Optimalisation
Submit to :
f
min,j
y
j
f
j
f
max,j
y
j
0; R
1
=0; R
ni+1
=0
y
j

{0,1}
min
R
i
, f
j
, y
j
Cost =
n
u
j=1
C1
j
y
j
+C2
j
f
j
Minimum cost of energy requirement (MCER)
Mixed Integer Linear Programming (MILP)
Heat balance
Utility
2nd principle
ideal HEN model
Hot stream j in interval i
R
i+1
+
n
c

j=1
f
j
q
ji
=1
- R
i
=0
n
f

j
f
j -
q
ji
Cold stream j in interval i


R
i

(2)
(1)
FM_07/ 2000
Combined mechanical power production
- Export of electricity
Linear constraints
Mechanical power consumption
- Operating cost
Cost = (C1
w
y
w
+ C2
w
f
w
) + Cel Wel - Celv
Welv
w
w
f
w

w
+ Wel - Wp 0
w=1
w
w
f
w

w
+ Wel - Welv - Wp = 0
w=1
nu
w=1
nu
Process requirement
Production from the utilities(W
w
> 0 )
Electricity import
Electricity export
sell
buy
nu
Welv
(3.1)
(3.2)
(1)
28
FM_07/ 2000
Use of integer variables
1 integer variable for each flowrate
y
j
= 0 : the utility j is not used
y
j
= 1 : the utility j is used
f
min,j
y
j
f
j
f
max,j
y
j
Linear constraint
if y
j
=0 =>f
min,j
0 f
j
f
max,
j
0
=> 0 f
j
0 => f
j
=0
if y
j
=1=> f
min,j
f
j
f
max,j
j is not selected
j is selected
= y
Cost
j
C1
j
j
+C2
j
f
j
if y
j
=0=>Cost
j
= C1
j
0 +C2
j
0 =0
if y
j
=1=>Cost
j
= C1
j
+C2
j
f
j
Linear cost :




j is not selected
j is selected
FM_08/2002 Laboratory of Industrial EnergySystems
LENI -ISE-STI-EPFL s.a.
BELSIM Together wit h
MILP formulation
Subj ect to
Electricity consumption
Electricity production
Feasibility
Technology selection
Operating cost
Fixed maintenance
I nvestment
29
FM_08/2002 Laboratory of Industrial EnergySystems
LENI -ISE-STI-EPFL s.a.
BELSIM Together wit h
Targeting the optimal integration : model
MILP formulation
Gas turbine g : hot stream from T
oT
to T
stack
Fuel
Electricity
Operating cost
I nvestments
Part load efficiency
unknown
FM_08/2002 Laboratory of Industrial EnergySystems
LENI -ISE-STI-EPFL s.a.
BELSIM Together wit h
Combustion model
O2 balance
Post combustion
Post comb
Air Enriched ai r Fuels
Heat above Trad
Heat from Trad to stack
Fuels
Fuels
Enriched ai r
Enriched ai r
Preheating
Air
Air
30
FM_08/2002 Laboratory of Industrial EnergySystems
LENI -ISE-STI-EPFL s.a.
BELSIM Together wit h
Outlet temperature calculation
Stream
Add linear constraints
Compute the temperature a posteriori
FM_07/ 2000
Mechanical vapour recompression
Qb
W
Qi
Q
T
Qc+W
Qb
Qi
Qc
W
CW
Steam
An other way of changing the condenser temperature level
Combined heat and power !
31
FM_07/ 2000
MVR global solution
T
H
Q1
Q2
B
A
C
A
C
B
BB
T
H
Q1-QcA - W1
B
A
C
A
C
B
BB
T
B
A
C
A
C
B
B
B
Qb
W1
H
Qb
W2
B
A
Q2-QcA
Q1-QcA - W2
Q2-QcA
W1> W2
Integrating two distillation columns
MVR : 1 column MVR : 2 columns
FM_07/ 2000
Analyze the shape of the GCC
T
H
Q1
Q2
Qc
Qb
T
H
Q2
Qc
Qb
T
H
Hot utility at low temperature T
Cold utility at high temperature T
Small DT -> small DP
Pinch
32
FM_07/ 2000
200
300
400
500
600
700
800
900
0 2000 4000 6000 8000 10000 12000 14000
T(K)
Q(kW)
Condenser
Boiler 2
Compression 2
P = 16 bar
T= 470 K
Qmer= 6768.5 kW
6439 kW
MER
9481.33 kW
Boiler 1
Compression 1
P = 3 bar
T= 388 K
Qmer= 3422.4 kW
FM_07/ 2000
Comparing MVR and pressure changes
MVR pressure modification
Pressure increase increase or decrease
Mechanical power compressor compressor, pump
Temperature condenser boiler and condenser
Loads condenser boiler and condenser
Operation no change new set point by simulation
Integration can be self only with other
integrated columns
Technological new compressor new pressure
constraint
33
FM_07/ 2000
Evaluate the integration of a Rankine cycle
200
300
400
500
600
700
800
900
1000
1100
-1000 0 1000 2000 3000 4000 5000 6000
T(K)
Q(kW)
supplement of hot utility
HP superheating
Vaporisation
HP preheating
Rankine cycle
Other streams
MP condensation
mechanical power
production
Under cooling
FM_07/ 2000
200
300
400
500
600
700
800
900
1000
1100
0 5000 10000 15000 20000 25000 30000 35000
T(K)
Q(kW)
exothermal reactor
steam production
steam consumption
combustion
Air cooling
water cooling
Results : balanced hot and cold composite curves
Multiple pinch points
optimal use of the cheapest utility
34
FM_07/ 2000
200
300
400
500
600
700
800
900
1000
1100
0 1000 2000 3000 4000 5000 6000 7000 8000
T(K)
Q(kW)
Balanced Grand composite curve
Understand the results ?
FM_07/ 2000
RAk = Rref -
n
k

r=k
(
n
Aw

w=1
f
w
q
wr
+
n
A

i=1
Q
ir
) - Rn
k
+1
RB
kp
= 0 => R
ref
=-
n
k

r=kp
(
n
Bw

w=1
f
w
q
wr
+
n
B

i=1
Q
i r
)
Evaluate : the Integrated Composite Curves
RBk = Rref +
n
k

r=k
(
n
Bw

w=1
f wq
wr
+
n
B

i=1
Q
ir
)
Hot and cold streams
Sub-set A
Sub-set B : complement
T
Q
35
FM_07/ 2000
200
300
400
500
600
700
800
900
1000
1100
-2000 0 2000 4000 6000 8000 10000 12000 14000
T(K)
Q(kW)
Process
Utility system
ICC for utility system integration
Furnace
air cooling
water
fridge
FM_07/ 2000
200
300
400
500
600
700
800
900
1000
1100
-1000 0 1000 2000 3000 4000 5000 6000 7000
T(K)
Q(kW)
Other systems
Furnace
Excess of heat in the fumes
ICC for the integration of the fumes
36
FM_07/ 2000
200
300
400
500
600
700
800
900
1000
1100
-1000 0 1000 2000 3000 4000 5000 6000 7000 8000
T(K)
Q(kW)
"process"
"Fridge system"
ICC for refrigeration cycle integration
FM_07/ 2000
200
300
400
500
600
700
800
900
1000
1100
-1000 0 1000 2000 3000 4000 5000 6000 7000 8000
T(K)
Q(kW)
Other systems
Steam network
ICC of the steam network
Mechanical production
Energy supplement
Steam production
Steam cons.
37
FM_07/ 2000
Heat exchanger placement audit
250
300
350
400
450
500
550
600
650
700
-2000 0 2000 4000 6000 8000 10000 12000
T
(
K
)
Q(kW)
Existing Heat Exchanger
MER
Rest of the process
cf remaining problem
Penality
Systematic drawing of the ICC of the existing heat exchangers
Heat exchange through the pinch point
FM_07/ 2000
Heat exchanger placement audit
250
300
350
400
450
500
550
600
-1000 -500 0 500 1000 1500 2000 2500 3000
MER
Penalty of heat exchanger
Heat exchanger
Remaining
Overall process
T(K)
Q(kW)
Heat exchanger below the pinch point
38
FM_07/ 2000
Optimisation
T(K)
200
300
400
500
600
700
800
900
1000
1100
-1000 1000 2000 3000 4000 5000 6000 7000
Q(kW)
90b
30b
11b
6b
127 kW
0
436 kW
Courbes composes intgres du rseau dutilits
- Approche MER (thermique)
- Approche CMER (globale)
FM_07/ 2000
Conclusions
Analyse
using composite curves
Generate
using Mixed Integer Linear Programming
Evaluate
using a new graphical representation:
the Integrated Composite Curves
Better Understanding of the Integration of the
components of the system
processes - utilities - steam network - heat exchangers
Support to the engineers creativity
Method for targeting Minimum Cost of Energy Requirements
39
FM_07/ 2000
Restricted matches constraints
Why ?
Safety - product quality
Topology
Site scale and processes independence
Existing approaches
Cerda et al. (1983) - Papoulias and Grossmann (1983)
Energy target with constraints using large scale LP
Floudas - Grossmann and others
HEN superstructure together with energy target
Pinch technology
Restricted matches during the HEN synthesis
FM_07/ 2000
Restricted matches : our goals
Targeting the Minimum Cost Energy Requirement
taking into account the restricted matches
Energy penalty of the constraints ?
Cost of the energy penalty ?
Solve site scale problems
Find technological solutions to minimise the cost
penalty of the restricted matches
choice of the heat transfer fluids
Before the HEN synthesis task
Start HEN synthesis with the complete list of streams
40
FM_07/ 2000
The heat cascade a LP formulation
minimise R
n
k
+1
R
k
Heat balance of a temperature interval
R
k+1
+

i=1
n
h
f
i
q
ik
- R
k
-
j=1
n
c
f
j
q
jk
= 0 k=1,...n
k
R
k
0 k=1,...n
k
+1
(R
*
k,
T
k
) the MER heat cascade
(Grand composite curve)
FM_07/ 2000
The constraints
Heat balance of a temperature interval
Rk+1 +

i=1
nh
fi qik - Rk -
j=1
nc
fj qjk = 0 k=1,...nk (1)
Heat balance of a hot streami in a restricted match

j=1
ncai

Q
ijk + R
ik - f
i
q
ik - R
ik+1 = 0 k=1,...,k
i , i =1,...,n
h
(R1)
Heat cascade of the cold streamj

i=1
n
h
Q
ijk
f
j
q
jk
k=1,...,n
k
, j=1,...,n
c
(R2)
Overall heat cascade

i=1
n
h
R
ik Rk k=1,...,nk (R3)
Accepted Matches
Accepted Matches
R
ik
0 k=1,..., k
i
, i =1,...,n
h
;
R
ik+1
= 0 when k k
i
;
Q
ijk
0 k=1,..., n
k
, i =1,...,n
h
, j=1,...,n
c
New variables
41
FM_07/ 2000
Compute the energy penalty
Target the Minimum Cost Energy Requirement
without constraints
Optimal heat cascade : R
*
k
Fix the flowrates
Add the restricted matches constraints
Solve the problem (P1)
if penalty is acceptable goto HEN Synthesis
if not choose the heat transfer fluid
minimise R
n
k
+1
R
ik
, Q
ijk
, R
k
R
n
k
+1
- R
*
n
k
+1
is the energy penalty
FM_07/ 2000
Choose the heat transfer fluid
200
300
400
500
600
700
800
-6000 -4000 -2000 0 2000 4000 6000 8000 10000 12000
Rcold
1560 kJ
R hot
5250 kJ
Energy
penalty
6810 kJ
MER
4807 kJ
Heat sink
Heat source
Process pinch point
R
ik
= R
k
i=1
n
h
Grand composite curve
R
ik
i=1
n
h
Restricted matches cascade
Ro
k
=
42
FM_07/ 2000
Heat transfer fluid characteristics
Process : Hot streams
Process : Cold streams
- - - Heat transfer fluid hot stream
- - - Heat transfer fluid : cold stream
1) All the R
k
must be positive (definition of the MER);
2) R
n
k
+1
= R
*
n
k
+1
(no energy penalty is due to the use of the
intermediate stream);
3) Ro
k
= R
k
for all k =1,...,n
k
(the intermediate fluids solve the
restricted matches constraints)
Conditions to be satisfied by the heat transfer fluid
FM_07/ 2000
Choose the heat transfer fluid
200
300
400
500
600
700
800
900
0 8000
T( K)
Q( kJ )
MER
4807 kJ
Rhot
5250 kJ
4000 2000 4000 0 2000 4000 6000 0 2000
p
Col d s t r e a m
p
Hot s t r e a m
p
Add c ol d
s t r e a m
MER
10057 kJ
RMC Pr oc e s s GCC Ne w GCC
Rhot
5250 kJ
Above the pinch point
Heat to cold stream
Heat from hot stream
43
FM_07/ 2000
Choose the heat transfer fluid
360
380
400
420
440
460
480
500
520
540
- 2000 - 1000 0 1000 2000 3000 4000 5000 6000
T( K)
Q( kJ )
Col d s t r e a ms Hot s t r e a ms
Rc ol d
1560 kJ
Rhot
5250 kJ
27. 5 b
12 b
6 b
1. 5 b
Ene r gy pena l t y i f
1. 5 b s t e a m i s us e d
Place the heat transfer fluid between Red and Blue lines
FM_07/ 2000
Target the minimum cost of energy requirement
Add the heat transfer fluids
Hot and cold streams
Unknown flowrate
Use the MILP model
Heat cascade
Mechanical power balance
EMO models
Energy technologies
Heat transfer fluids or steam network
Restricted matches constraints
Objective function : Minimum Cost of Energy
Fuels - Electricity - CHP - Investments
SYNTHESIS
with complete list of streams