Energy and Process Optimization for the Process Industries
, by Zhu, Frank (Xin X.)
- ISBN: 9781118101162 | 1118101162
- Cover: Hardcover
- Copyright: 12/16/2013
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.
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.
Dedications
Preface
Part 1: Basic concepts and theoryChapter 1: Overview of this book
1.1 Introduction
1.2 Who is the book written for
1.3 Five ways to improve energy efficiency
1.4 Four key elements for continuous improvements
1.5 Promoting improvement ideas in the organization
Chapter 2: Theory of Energy Intensity
2.1 Introduction
2.2 Definition of energy intensity for a process
2.3 The concept of fuel equivalent for steam and power
2.4 Energy intensity for a total site
2.5 Concluding remarks
2.6 Nomenclature
2.7 References
Chapter 3: Energy benchmarking
3.1 Introduction
3.2 Data extraction from historian
3.3 Convert all energy usage to fuel equivalent
3.4 Energy balance
3.5 Fuel equivalent for steam and power
3.6 Energy performance index method for energy benchmarking
3.7 Concluding remarks
3.8 Nomenclature
3.9 References
Chapter 4: Key indicators and targets
4.1 Introduction
4.2 Key indicators represent operation opportunities
4.3 Define key indicators
4.4 Set up targets for key indicators
4.5 Economic evaluation for key indicators
4.6 Application 1: Implementing key indicators into an “Energy Dashboard”
4.7 Application 2: Implementing key indicators to controllers
4.8 It is worth the effort
4.9 Nomenclature
4.10 References
Part 2: Energy system assessment methods
Chapter 5: Fired heater assessment
5.1 Introduction
5.2 Fired heater design for high reliability
5.3 Fired heater operation for high reliability
5.4 Efficient fired heater operation
5.5 Fired heater revamp
5.6 Nomenclature
5.7 References
Chapter 6: Heat exchanger performance assessment
6.1 Introduction
6.2 Basic concepts and calculations
6.3 Understand Performance criterion – U values
6.4 Understand pressure drop
6.5 Heat exchanger rating assessment
6.6 Improving heat exchanger performance
6.7 Appendix: TEMA Types of Heat Exchangers
6.8 Nomenclature
6.9 References
Chapter 7: Heat exchanger fouling assessment
7.1 Introduction
7.2 Fouling mechanisms
7.3 Fouling mitigation
7.4 Fouling mitigation for crude preheat in oil refining
7.5 Fouling resistance calculations
7.6 A cost-based model for clean cycle optimization
7.7 Revised cost-based model for clean cycle optimization
7.8 A practical method for clean cycle optimization
7.9 Putting all together – A practical example of fouling mitigation
7.10 Nomenclature
7.11 References
Chapter 8: Energy loss assessment
8.1 Introduction
8.2 Energy loss audit
8.3 Energy loss audit results
8.4 Energy loss evaluation
8.5 Brainstorming
8.6 Energy audit report
8.7 Nomenclature
8.8 References
Chapter 9: Process heat recovery opportunity assessment
9.1 Introduction
9.2 Data extraction
9.3 Composite curves
9.4 Basic concepts
9.5 Energy targeting
9.6 Pinch golden rules
9.7 Cost targeting: determine optimal ΔTmin
9.8 Case study
9.9 Be aware of sub-optimal
9.10 Integrated cost targeting and process design
9.11 Challenges for applying the systematic design approach
9.12 Nomenclature
9.13 References
Chapter 10: Heat recovery modification assessment
10.1 Introduction
10.2 Network pinch – the bottleneck of existing heat recovery system
10.3 Identification of modifications
10.4 Automated network pinch retrofit approach
10.5 Case studies for applying the network pinch approach
10.6 References
Chapter 11: Process integration opportunity assessment
11.1 Introduction
11.2 Definition of process integration
11.3 Plus and minus (+/-) principle
11.4 Grand composite curves
11.5 Appropriate placement principle for process changes
11.6 Examples of process changes
11.7 References
Part 3: Process system assessment and optimization
Chapter 12: Distillation operating window
12.1 Introduction
12.2 What is distillation
12.3 Distillation efficiency
12.4 Definition of feasible operating window
12.5 Understanding operating window
12.6 Typical capacity limits
12.7 Effects of design parameters
12.8 Design check list
12.9 Example calculations for developing operating window
12.10 Concluding remarks
12.11 Nomenclature
12.12 References
Chapter 13: Distillation system assessment
13.1 Introduction
13.2 Define a base case
13.3 Calcu7lations for missing and incomplete data
13.4 Building process simulation
13.5 Heat and material balance assessment
13.6 Tower efficiency assessment
13.7 Operating profile assessment
13.8 Tower rating assessment
13.9 Heat integration assessment for column design
13.10 Guidelines for reuse of an existing tower
13.11 Nomenclature
13.12 References
Chapter 14: Distillation system optimization
14.1 Introduction
14.2 Tower optimization basics
14.3 Energy optimization for distillation system
14.4 Overall process optimization
14.5 Concluding remarks
14.6 References
Part 4: Utility system assessment and optimization
Chapter 15: Modeling of steam and power system
15.1 Introduction
15.2 Boiler
15.3 Deaerator
15.4 Steam turbine
15.5 Gas turbine
15.6 Letdown valve
15.7 Steam desuperheater
15.8 Steam flush drum
15.9 Steam trap
15.10 Steam distribution losses
15.11 Nomenclature
15.12 References
Chapter 16: Establishing steam balances
16.1 Introduction
16.2 Guidelines for generating steam balance
16.3 A working example for generating steam balance
16.4 A practical example for generating steam balance
16.5 Verify steam balance
16.6 Concluding remarks
16.7 Nomenclature
16.8 References
Chapter 17: Determining steam pricing
17.1 Introduction
17.2 The cost of steam generation from boiler
17.3 Enthalpy-based steam pricing
17.4 Work-based steam pricing
17.5 Fuel equivalent-based steam pricing
17.6 Cost-based steam pricing
17.7 Comparison of different steam pricing methods
17.8 Marginal steam pricing
17.9 Effects of condensate recovery on steam cost
17.10 Concluding remarks
17.11 Nomenclature
17.12 References
Chapter 18: Benchmarking steam and power system
18.1 Introduction
18.2 Benchmark steam cost – minimize generation cost
18.3 Benchmark steam and condensate losses
18.4 Benchmark process steam usage and energy cost allocation
18.5 Benchmark steam system operation
18.6 Benchmark steam system efficiency
18.7 Nomenclature
18.8 References
Chapter 19: Steam and power management and optimization
19.1 Introduction
19.2 Optimizing steam header pressure
19.3 Optimizing steam equipment loadings
19.4 Optimizing onsite power generation versus import
19.5 Minimizing steam letdowns and venting
19.6 Optimizing steam system configuration
19.7 Developing steam system optimization model
19.8 Nomenclature
19.9 References
Part 5: Retrofit project evaluation and implementation
Chapter 20: Determine true benefits from OSBL
20.1 Introduction
20.2 Energy improvement options under evaluation
20.3 A method for evaluating energy improvement options in OSBL
20.4 Feasibility assessment and make decision for implementation
Chapter 21: Determine true benefits from operation variations
21.1 Introduction
21.2 Collect online data for the whole operation cycle
21.3 Normal distribution and Monte Carlo simulation
21.4 Basic statistic summary for normal distribution
21.5 Nomenclature
21.6 References
Chapter 22: Feasibility Assessment
22.1 Introduction
22.2 Scope and stages of feasibility assessment
22.3 Feasibility assessment methodology
22.4 Get the project basis and data right in the very beginning
22.5 Get the project economics right
22.6 Don’t forget OSBL costs
22.7 Squeeze capacity out of design margin
22.8 Identify and relax plant constraints
22.9 Interactions of process conditions, yields ad equipment
22.10 Don’t get misled by false balances
22.11 Prepare for fuel gas long
22.12 Two revamp cases for shifting bottlenecks
22.13 Concluding remarks
22.14 Nomenclature
22.15 References
Chapter 23: Create optimization culture with measurable results
23.1 Introduction
23.2 Site wide energy optimization strategy
23.3 Case study of the site wide energy optimization strategy
23.4 Establishing energy management system
23.5 Energy operation management
23.6 Energy project management
23.7 An overall work process from idea discovery to implementation
23.8 References
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