Energy saving measures from their cradle to full adoption with verified, monitored, and targeted performance: a look back at energy audit at Catalytic Naphtha Reforming Unit (CCR)

Variny, Miroslav; Blahušiak, Marek; Mierka, Otto; Godó, Š.; Margetíny, Tibor

doi:10.1007/s12053-019-09808-9

Cited by 9 publications

(11 citation statements)

References 53 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Direct fuel consumption and associated emissions, which contribute a major part of the total energy consumption in a refinery, are attributed to process heaters and steam boilers [17,18]. Heavy fuel oils and refinery fuel gas represented the majority of fuels used in both cases [19,20]. The scheduling of a fuel gas network represents a challenge for a refinery due to both its multiple sources and its variable composition [21,22], as well as its variable production and demand [23,24].…”

Section: Introductionmentioning

confidence: 99%

An Investigation of the Techno-Economic and Environmental Aspects of Process Heat Source Change in a Refinery

et al. 2019

Self Cite

View full text Add to dashboard Cite

This study of process heat source change in industrial conditions has been developed to aid engineers and energy managers with working towards sustainable production. It allows for an objective assessment from energetic, environmental, and economic points of view, thereby filling the gap in the systematic approach to this problem. This novel site-wide approach substantially broadens the traditional approach, which is based mostly on “cheaper” and “cleaner” process heat sources’ application and only takes into account local changes, while neglecting the synergic effect on the whole facility’s operations. The mathematical model employed assesses the performance change of all the affected refinery parts. The four proposed aromatic splitting process layouts, serving as a case study, indicate feasible heat and condensate conservation possibilities. Although the estimated investment needed for the most viable layout is over €4.5 million, its implementation could generate benefits of €0.5–1.5 million/year, depending on the fuel and energy prices as well as on the carbon dioxide emissions cost. Its economics is most sensitive to the steam to refinery fuel gas cost ratio, as a 10% change alters the resulting benefit by more than €0.5 million. The pollutant emissions generated in the external power production process contribute significantly to the total emissions balance.

show abstract

Section: Introductionmentioning

confidence: 99%

An Investigation of the Techno-Economic and Environmental Aspects of Process Heat Source Change in a Refinery

et al. 2019

Self Cite

View full text Add to dashboard Cite

show abstract

“…Adjustment of combustion parameters is also possible using mathematical models and simulations. Combined computationalexperimental studies confirmed the possibility for thermal efficiency to increase in cases of industrial biomass boiler [7] in regeneration boiler for black liquor combustion [8] as well as in refinery furnaces [9].…”

Section: Introductionmentioning

confidence: 88%

Numerical Modelling of Gaseous Fuel Combustion Process with the Stepwise Redistribution of Enriched Combustion Air

2020

View full text Add to dashboard Cite

The authors of this paper present the results of simulations for burner system design changes in the smelting aggregate. Based on the analysis of the existing burner system in the experimental aluminium smelting equipment, changes in the burner design were proposed. The obtained results are presented in tables and figures. The properties of the proposed changes were investigated using the simulation software ANSYS. The simulations confirmed the suitability of the proposed system for shortening the flame length and intensification of the mixing of gaseous media.

show abstract

“…Cogeneration units, serving as energy suppliers for production processes, are operated in different regimes throughout the year [31], which results in a whole range of possible impacts of a process retrofit on the resulting energy and economic balance. Saving of low or middle pressure steam targeted by such measures is accompanied by cogenerated electric energy production decrease in the combined heat and power (CHP) unit [32]; thus, a "better" retrofit is to be compared with an already existing "efficient" energy production and consumption scheme. Available papers on the alkylation process optimization usually take into account fixed utilities' prices, which may not fully represent the real impact of the optimization process on the energy and cost balance of the whole plant.…”

Section: Introductionmentioning

confidence: 99%

Novel Concept of Cogeneration-Integrated Heat Pump-Assisted Fractionation of Alkylation Reactor Effluent for Increased Power Production and Overall CO2 Emissions Decrease

et al. 2020

Self Cite

View full text Add to dashboard Cite

Alkylate produced by catalyzed reaction of isobutane and olefin-rich streams is a desired component for gasoline blending. Fractionation of the alkylation reactor effluent is energy demanding due to the presence of close boiling point components and solutions cutting its energy intensity; expenses associated with this process are investigated intensely nowadays. This paper presents a novel conceptual design and techno-economic analysis of alkylation reaction effluent fractionation revamp to reach a cut in energy costs of the fractionation process without the need to revamp the rectification columns themselves, providing thus an alternative approach to a more sustainable alkylation process. Two cases are considered—A. additional steam turbine installation or B. combustion engine-driven heat pump-assisted rectification. Mathematical modeling of the considered system and its revamp is applied using the “frozen technology” approach. Real system operation features and seasonal variations are included considering the refinery’s combined heat and power (CHP) unit operation and CO2 emissions balance both internal and external to the refinery. Case A yields an expectable yearly benefit (saved energy minus additionally consumed energy minus CO2 emissions increase; expressed in financial terms) of €110–140 thousand, net present value (NPV) of −€18 to €272 thousand and produces 3.3 GWh/year of electric energy. Case B delivers a benefit of €900–1200 thousand, NPV of −€293 to €2823 thousand while producing 33 GWh/year of electricity. Both cases exhibit analogous simple payback periods (8–10 years). Marginal electric efficiency of Case B (78.3%) documents the energy integration level in this case, exploiting the system and CHP unit operation synergies. CHP unit summer operation mode and steam network restrictions significantly affect the seasonal benefit of Case B. CO2 emissions increase in both cases, Case A and Case B, considering the refinery level. However, including external CO2 emissions leads to emissions decrease in both cases of up to 26 kton/year (Case B.) The presented results document the viability of the proposed concepts comparable to the traditional (reference) solution of a high performance (COP = 8) heat pump while their performance sensitivity stresses the need for complex techno-economic assessment.

show abstract

Energy saving measures from their cradle to full adoption with verified, monitored, and targeted performance: a look back at energy audit at Catalytic Naphtha Reforming Unit (CCR)

Cited by 9 publications

References 53 publications

An Investigation of the Techno-Economic and Environmental Aspects of Process Heat Source Change in a Refinery

An Investigation of the Techno-Economic and Environmental Aspects of Process Heat Source Change in a Refinery

Numerical Modelling of Gaseous Fuel Combustion Process with the Stepwise Redistribution of Enriched Combustion Air

Novel Concept of Cogeneration-Integrated Heat Pump-Assisted Fractionation of Alkylation Reactor Effluent for Increased Power Production and Overall CO2 Emissions Decrease

Contact Info

Product

Resources

About