Energy Saving and Carbon Reduction: Approaches for Energy and Chemical Industries

ISBN-13: 9789811952944 / Angielski / Twarda / 2022 / 682 str.

Tony A. Chen

Opis

The book provides an integrated energy/exergy analysis method to identify the energy utilization issues and systematically propose the cost-effective energy-saving and CO₂ mitigation/capture solution. There is a strong market needs on energy-saving and greenhouse gas (GHG) reduction. CO₂ mitigation/capture will achieve economic benefit of fuel, power, and carbon tax saving as well as environmental GHG reduction.The book is a professional book for energy-saving and GHG gas mitigation technology in oil & gas, oil refining, and chemical industry. It is an integrated technical book that combines energy utilization theory and practical method, including: thermodynamic analysis for unit operation and process units; energy and exergy calculation for various process streams and utilities; three-link energy/exergy analysis model; energy/exergy balance of equipment, process units, and entire plant; approach and technology of energy saving; optimization of pipeline and equipment; pinch energy-saving technology and its application; CO₂ capture and utilization with 8 case studies incorporated for all different scenarios; key energy-saving technologies such gas turbine, FCCU regeneration CO combustion and energy recovery, flue gas turbine system optimization, low-grade heat recovery and utilization.  The book is intended for engineers and professional personnel who are working in process engineering, EPC companies, chemical and petrochemical plants, refineries, oil & gas production facilities, power generation plant. It can also be a professional reference or textbook for undergraduate or graduate-level university students and teaching personnel of chemical, energy, and process engineering faculties of universities. 

Spis treści

1 Thermodynamics Fundamentals 1

1.1 Basic Terms 1

1.2 Energy Form and Reference State 5

1.3 The First Law of Thermodynamics 9

1.4 The Second Law of Thermodynamics 15

1.5 Energy saving and GHG gas mitigation 23

2 Calculation of Thermophysical Energy and Exergy 25

2.1 Calculation of energy and exergy of process thermal effect 25

2.2 Calculation of Energy and Exergy of Petroleum and Its Fractions 39

2.3 Calculation of Energy and Exergy of Light Hydrocarbon and Its Mixture 46

2.4 Calculation of water vapor, water and air energy and exergy 51

2.5 Calculation of heat dissipation energy and exergy 52

3 Calculation of Mechanical Energy and Chemical Exergy 58

3.1 Calculation of real gas energy and exergy 58

3.2 Calculation of Energy in the Process of Fluid Flow 66

3.3 Chemical Exergy and Calculation of Fuel Exergy 70

4 Thermodynamic Analysis of Energy Consumption in Process 79

4.1 Thermodynamic analysis of heat transfer process 79

4.2 Thermodynamic analysis of fluid flow process [2] 84

4.3 Thermodynamic Analysis of Mass Transfer Process 87

4.4 Thermodynamic Analysis of Chemical Reaction Process 92

4.5 Thermodynamic analysis of the combustion process [5，6] 96

5 Energy utilization three-link analysis method 100

5.1 Energy consumption characteristics of petrochemical industry 100

5.2 Improvement of the three-link model of energy consumption analysis[3] 101

5.3 The consideration of using energy utilization Three-link model 103

5.4 The detail items of the improved three-Link model 105

5.5 Balance relationship and evaluation index of the three-link model 108

6 Equipment Energy Balance and Exergy Balance 116

6.1 The content and requirements of the device energy analysis test 116

6.2 Pump and Compressor Equipment 118

6.3 Industrial Furnace Equipment 127

6.4 Catalytic cracking regenerator 142

6.5 Process energy utilization equipment 152

6.6 Energy recovery and utilization equipment 164

7 Energy balance and exergy balance of petrochemical plants 174

7.1 Balance verification of system energy consumption data in the plant 174

7.2 Plant heat loss verification and summary 183

7.3 Balance of supply and consumption of steam, electricity and water 186

7.4 Plant energy balance and exergy balance calculation and summary 190

8 Utility/Auxiliary system and energy balance of the whole plant 206

8.1 Energy balance of utility system 207

8.2 Energy balance of auxiliary system 218

8.3 Summary of plant-wide energy balance 223

9 Energy consumption analysis and energy-saving improvement methods 235

9.1 The influence of plant size and ambient temperature on energy consumption 235

9.2 Analysis and estimation of the impact of loading on plant energy consumption [3] 239

9.3 Assessment of energy use level and energy saving potential 253

9.4 Approaches for energy-saving improvement of production plant 262

9.5 Large-scale system optimization method and improvement approach 274

10 Approach on CO2 mitigation and capture 284

10.1 Fuel efficiency Improvement, using lower carbon fuel and renewable energy 284

10.2 CO2 distribution and its properties 286

10.3 CO2 Capture-solvent absorption 288

10.4 CO2 capture case studies using Amine solvent 296

10.5 CO2 capture case studies using DEPG physical solvent 302

10.6 Flue gas CO2 capture using oxygen instead of combustion air 307

10.7 CO2 capture using Cryogenic / Turbo Expander

10.8 Flue gas CO2 capture using Membrane Technology

10.9 CO2 compression and dehydration 309

10.10 CO2 chemical utilization and storage 313

11 Technical and economic evaluation of energy-saving measures 322

11.1 Time value of Capital 322

11.2 Static evaluation method 327

11.3 Dynamic evaluation method 331

11.4 Estimation of economic benefits of energy-saving measures 339

12 Optimization on pipeline and equipment 347

12.1 Process rate and exergy loss 347

12.2 Economical insulation thickness of hot fluid pipeline 352

12.3 Economical pipe diameter and insulation thickness for fluid transportation [11] 356

12.4 Optimization of heat exchange equipment 〔6, 17〕 364

12.5 Economical thermal efficiency of heating furnace 370

13 Pinch energy-saving technology and its application 374

13.1 The concept of pinch point and its determination 374

13.2 Pre-estimate the heat exchange network area and the optimal  ∆Tmin 381

13.3 Energy target determination 389

13.4 Pinch design method of heat exchange network 392

13.5 Reasonable placement of the heat engine (pump) of the total energy system [5, 14] 400

13.6 The effect of cross heat transfer on heat exchange network area and energy 403

13.7 Energy saving principle of pinch technology 414

13.8 Pinch analysis examples using Aspen Energy Analyzer 421

14 Key Energy-saving technologies in petrochemical process 433

14.1 Pump speed control technology 433

14.2 Energy saving with Gas turbine combined heat and power supply 437

14.3 FCCU regenerating gas CO combustion outside of regenerator 441

14.4 FCCU flue gas turbine energy-saving process optimization

14.5 Low temperature heat recovery and utilization technology

O autorze

Tony A. Chen is a registered professional engineer in Canada with over 40 years of experience in the petrochemical and oil & gas industries. He is an expert in energy integration, GHG mitigation, process engineering, process simulation and optimization. He received his Master’s Degree in petroleum engineering from Beijing Petroleum University. Most recently, he served as a senior process advisor for Chevron Corporation worked on Chevron LNG plant, gas processing, TCO oil & gas facilities and received Chevron TCO Management Recognition Award in 2020 for initiating and implementing an ethane gas flaring reduction project that achieved significant cost savings. While at Chevron, Tony also led the energy integration and GHG reduction program for an LNG project with significant cost saving and made a presentation for Chevron FE 2014 World Conference in Houston on Energy Integration and GHG Mitigation for the LNG Project. 

He is also the author of Methods and Technology of Energy Conservation on Petrochemical Process, written two textbooks used in the continuing engineering training for SINOPEC. He delivered an integrated simulation model on H&M balance and BFD development using HYSYS and presented it on 2009 Aspen Worldwide User Conference in Houston. He received four Science and Technology Awards from SINOPEC. Granted 1 invention patent by Patent Bureau of China. 

Prior to Chevon, as a principal process engineer, he also worked for Jacobs and other EPC companies in Canada, experienced whole range of process engineering, including FEED and detail engineering, and completed 50+ projects with cost-effective solutions. He was the manager of environmental engineering department of LPEC/SINOPEC before 2000. In this role, he completed multiple oil refinery energy integration and GHG mitigation projects and process design and energy integration for multiple process units.