Frank Zhu

Energy and Process Optimization for the Process Industries

• Gebundenes Buch

Produktbeschreibung

Exploring methods and techniques to optimize processing energy efficiency in process plants, Energy and Process Optimization for the Process Industries provides a holistic approach that considers optimizing process conditions, changing process flowschemes, modifying equipment internals, and upgrading process technology that has already been used in a process plant with success. Field tested by numerous operating plants, the book describes technical solutions to reduce energy consumption leading to significant returns on capital and includes an 8-point Guidelines for Success. The book provides managers, chemical and mechanical engineers, and plant operators with methods and tools for continuous energy and process improvements.

Produktdetails

• Verlag: Wiley & Sons
• 1. Auflage
• Seitenzahl: 536
• Erscheinungstermin: 16. Dezember 2013
• Englisch
• Abmessung: 241mm x 167mm x 32mm
• Gewicht: 868g
• ISBN-13: 9781118101162
• ISBN-10: 1118101162
• Artikelnr.: 38537111

Autorenporträt

FRANK (Xin X.) ZHU is a Senior Fellow at UOP LLC, where he has led innovation efforts to optimize industrial process design and operation to achieve higher energy efficiency and lower capital cost. Before joining UOP, Dr. Zhu served as a research professor at the Centre for Process Integration at the University of Manchester in the UK. He is also a former editor-in-chief of CACS Communications, the magazine of the Chinese-American Chemical Society. He is the recipient of the 2014 AIChE Energy and Sustainability Award.

Inhaltsangabe

PREFACE xv PART 1 BASIC CONCEPTS AND THEORY 1 1 Overview of this Book 3 1.1 Introduction
3 1.2 Who is this Book Written for?
4 1.3 Five Ways to Improve Energy Efficiency
5 1.4 Four Key Elements for Continuous Improvement
7 1.5 Promoting Improvement Ideas in the Organization
8 2 Theory of Energy Intensity 9 2.1 Introduction
9 2.2 Definition of Process Energy Intensity
10 2.3 The Concept of Fuel Equivalent (FE)
11 2.4 Energy Intensity for a Total Site
13 2.5 Concluding Remarks
15 3 Benchmarking Energy Intensity 16 3.1 Introduction
16 3.2 Data Extraction from Historian
17 3.3 Convert All Energy Usage to Fuel Equivalent
17 3.4 Energy Balance
21 3.5 Fuel Equivalent for Steam and Power
23 3.6 Energy Performance Index (EPI) Method
29 3.7 Concluding Remarks
32 4 Key Indicators and Targets 35 4.1 Introduction
35 4.2 Key Indicators Represent Operation Opportunities
36 4.3 Define Key Indicators
39 4.4 Set up Targets for Key Indicators
45 4.5 Economic Evaluation for Key Indicators
49 4.6 Application 1: Implementing Key Indicators into an "Energy Dashboard
" 53 4.7 Application 2: Implementing Key Indicators to Controllers
56 4.8 It is Worth the Effort
57 PART 2 ENERGY SYSTEM ASSESSMENT METHODS 59 5 Fired Heater Assessment 61 5.1 Introduction
61 5.2 Fired Heater Design for High Reliability
62 5.3 Fired Heater Operation for High Reliability
68 5.4 Efficient Fired Heater Operation
73 5.5 Fired Heater Revamp
80 6 Heat Exchanger Performance Assessment 82 6.1 Introduction
82 6.2 Basic Concepts and Calculations
83 6.3 Understand Performance Criterion--U Values
89 6.4 Understanding Pressure Drop
94 6.5 Heat Exchanger Rating Assessment
96 6.6 Improving Heat Exchanger Performance
106 7 Heat Exchanger Fouling Assessment 112 7.1 Introduction
112 7.2 Fouling Mechanisms
113 7.3 Fouling Mitigation
114 7.4 Fouling Mitigation for Crude Preheat Train
117 7.5 Fouling Resistance Calculations
119 7.6 A Cost-Based Model for Clean Cycle Optimization
121 7.7 Revised Model for Clean Cycle Optimization
125 7.8 A Practical Method for Clean Cycle Optimization
128 7.9 Putting All Together--A Practical Example of Fouling Mitigation
130 8 Energy Loss Assessment 138 8.1 Introduction
138 8.2 Energy Loss Audit
139 8.3 Energy Loss Audit Results
147 8.4 Energy Loss Evaluation
149 8.5 Brainstorming
150 8.6 Energy Audit Report
152 9 Process Heat Recovery Targeting Assessment 154 9.1 Introduction
154 9.2 Data Extraction
155 9.3 Composite Curves
156 9.4 Basic Concepts
159 9.5 Energy Targeting
160 9.6 Pinch Golden Rules
160 9.7 Cost Targeting: Determine Optimal DTmin
162 9.8 Case Study
165 9.9 Avoid Suboptimal Solutions
169 9.10 Integrated Cost Targeting and Process Design
171 9.11 Challenges for Applying the Systematic Design Approach
172 10 Process Heat Recovery Modification Assessment 175 10.1 Introduction
175 10.2 Network Pinch--The Bottleneck of Existing Heat Recovery System
176 10.3 Identification of Modifications
179 10.4 Automated Network Pinch Retrofit Approach
181 10.5 Case Studies for Applying the Network Pinch Retrofit Approach
183 11 Process Integration Opportunity Assessment 195 11.1 Introduction
195 11.2 Definition of Process Integration
196 11.3 Plus and Minus (+/-) Principle
198 11.4 Grand Composite Curves
199 11.5 Appropriate Placement Principle for Process Changes
200 11.6 Examples of Process Changes
205 PART 3 PROCESS SYSTEM ASSESSMENT AND OPTIMIZATION 225 12 Distillation Operating Window 227 12.1 Introduction
227 12.2 What is Distillation?
228 12.3 Distillation Efficiency
229 12.4 Definition of Feasible Operating Window
232 12.5 Understanding Operating Window
232 12.6 Typical Capacity Limits
253 12.7 Effects of Design Parameters
255 12.8 Design Checklist
257 12.9 Example Calculations for Developing Operating Window
257 12.10 Concluding Remarks
276 13 Distillation System Assessment 281 13.1 Introduction
281 13.2 Define a Base Case
281 13.3 Calculations for Missing and Incomplete Data
284 13.4 Building Process Simulation
287 13.5 Heat and Material Balance Assessment
288 13.6 Tower Efficiency Assessment
292 13.7 Operating Profile Assessment
295 13.8 Tower Rating Assessment
298 13.9 Column Heat Integration Assessment
300 13.10 Guidelines for Reuse of an Existing Tower
302 14 Distillation System Optimization 305 14.1 Introduction
305 14.2 Tower Optimization Basics
306 14.3 Energy Optimization for Distillation System
312 14.4 Overall Process Optimization
318 14.5 Concluding Remarks
326 PART 4 UTILITY SYSTEM ASSESSMENT AND OPTIMIZATION 327 15 Modeling of Steam and Power System 329 15.1 Introduction
329 15.2 Boiler
330 15.3 Deaerator
333 15.4 Steam Turbine
334 15.5 Gas Turbine
338 15.6 Letdown Valve
339 15.7 Steam Desuperheater
341 15.8 Steam Flash Drum
342 15.9 Steam Trap
342 15.10 Steam Distribution Losses
344 16 Establishing Steam Balances 345 16.1 Introduction
345 16.2 Guidelines for Generating Steam Balance
346 16.3 AWorking Example for Generating Steam Balance
347 16.4 A Practical Example for Generating Steam Balance
357 16.5 Verify Steam Balance
362 16.6 Concluding Remarks
364 17 Determining True Steam Prices 366 17.1 Introduction
366 17.2 The Cost of Steam Generation from Boiler
367 17.3 Enthalpy-Based Steam Pricing
371 17.4 Work-Based Steam Pricing
372 17.5 Fuel Equivalent-Based Steam Pricing
373 17.6 Cost-Based Steam Pricing
376 17.7 Comparison of Different Steam Pricing Methods
377 17.8 Marginal Steam Pricing
379 17.9 Effects of Condensate Recovery on Steam Cost
384 17.10 Concluding Remarks
384 18 Benchmarking Steam System Performance 386 18.1 Introduction
386 18.2 Benchmark Steam Cost: Minimize Generation Cost
387 18.3 Benchmark Steam and Condensate Losses
389 18.4 Benchmark Process Steam Usage and Energy Cost Allocation
394 18.5 Benchmarking Steam System Operation
396 18.6 Benchmarking Steam System Efficiency
397 19 Steam and Power Optimization 403 19.1 Introduction
403 19.2 Optimizing Steam Header Pressure
404 19.3 Optimizing Steam Equipment Loadings
405 19.4 Optimizing On-Site Power Generation Versus Power Import
407 19.5 Minimizing Steam Letdowns and Venting
412 19.6 Optimizing Steam System Configuration
413 19.7 Developing Steam System Optimization Model
417 PART 5 RETROFIT PROJECT EVALUATION AND IMPLEMENTATION 423 20 Determine the True Benefit from the OSBL Context 425 20.1 Introduction
425 20.2 Energy Improvement Options Under Evaluation
426 20.3 A Method for Evaluating Energy Improvement Options
429 20.4 Feasibility Assessment and Make Decisions for Implementation
442 21 Determine the True Benefit from Process Variations 447 21.1 Introduction
447 21.2 Collect Online Data for the Whole Operation Cycle
448 21.3 Normal Distribution and Monte Carlo Simulation
449 21.4 Basic Statistics Summary for Normal Distribution
456 22 Revamp Feasibility Assessment 459 22.1 Introduction
459 22.2 Scope and Stages of Feasibility Assessment
460 22.3 Feasibility Assessment Methodology
462 22.4 Get the Project Basis and Data Right in the Very Beginning
465 22.5 Get Project Economics Right
466 22.6 Do Not Forget OSBL Costs
470 22.7 Squeeze Capacity Out of Design Margin
471 22.8 Identify and Relax Plant Constraints
472 22.9 Interactions Between Process Conditions
Yields
and Equipment
473 22.10 Do Not Get Misled by False Balances
474 22.11 Prepare for Fuel Gas Long
475 22.12 Two Retrofit Cases for Shifting Bottlenecks
477 22.13 Concluding Remarks
480 23 Create an Optimization Culture with Measurable Results 481 23.1 Introduction
481 23.2 Site-Wide Energy Optimization Strategy
482 23.3 Case Study of the Site-Wide Energy Optimization Strategy
487 23.4 Establishing Energy Management System
492 23.5 Energy Operation Management
496 23.6 Energy Project Management
499 23.7 An Overall Work Process from Idea Discovery to Implementation
500 References
502 INDEX 503