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In this paper minimisation of total cost for retrofit of Total Site heat recovery system is proposed. It based
on analysis of balanced Total Site Profiles and includes procedure for calculation of heat transfer area.
Heat transfer area is calculated for different regions with use of intermediate utility and direct heating and
cooling. Minimal tempe...
Context in source publication
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... A binding EU target of at least 40 % less greenhouse gas emissions by 2030, compared to 1990; A binding target of at least 27 % of renewable energy used at EU level; An energy efficiency increase of at least 27 %; The completion of the internal energy market by reaching an electricity interconnection target of 15 % between member states and pushing forward important infrastructure projects. The energy efficiency improvement is one of the key goals for future sustainable development. As reported by IEA in 2012 the industrial energy consumption is 28 % in overall world energy balance (see Figure 1). Energy saving potential in industry is still huge despite last time there are a lot of researches and applications which allowed reducing energy consumption considerably. They are mostly based on Pinch analysis, Mathematical Programming and Life Cycle Assessment as well as combinations and modifications of these methods as reported by Klemeš et al. (2014). For example Čuček et al. (2014) proposed the multi-period synthesis of an optimally integrated regional biomass and bioenergy supply network through a mixed-integer linear programing (MILP) approach. They obtained solutions with optimal selection of raw materials, technologies, intermediate and final product flows, and reduced greenhouse- gas emissions. Čuček et al. (2011) presented combination of mathematical programming and life cycle assessment for biomass and bioenergy supply chain. delivered the application of Pinch Analysis for bromine chemical plant and shown the reduction of energy consumption on 45 %. Last time big progress was reached in energy efficiency improvement of individual industrial process and more attention should be paid to industrial sites. Firstly, it allows reducing energy consumption of industrial regions and decreasing pollution reduction considerably, secondly, it provides the possibility to utilise the industrial heat for residential and commercial sectors which are still big energy consumers. From the other hand it makes appropriate background to implement alternative energy sources including renewables that leads additional reduction of energy cost and improves environmental impact. These measures need well developed approaches which solve this type of system objectives. To utilise the waste industrial heat for different needs on site level the Total Site Analysis (TSA) should be used as was reported by Klemes et al. (1997). More recent developments shown that it could be based on different approaches. Karimkashi and Amidpour (2012) proposed a method for analysis an industrial energy system. It is based on the development and modifications of the R-curve concept which was previously developed by Kimura and Zhu (2000) and later updated by Varbanov et al. (2004). It was also used by Boldyryev et al. (2012) to estimate the investment for Total Site power cogeneration. and provided a methodology for minimisation of heat transfer area of Total Site heat recovery systems. Last time the authors were concentrated on development of methodology which allow minimise the heat transfer area of heat recovery on Total Site level. So, it was the significant step in estimation of retrofit targets of industrial site. This paper proposes the methodology to estimate minimum total cost for retrofit of Total Site heat recovery systems including energy and ...
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Citations
... The method is based on the decomposition of TPSs into enthalpy blocks, wherein TPSs are built with real temperatures. Real temperatures allow to use of specific IM in enthalpy blocks and maximise the heat recovery between TSPs [35]. Besides, the cogeneration of heat and power (CHP) is considered within enthalpy blocks maximizing the electricity output. ...
Maximizing heat recovery in the process industry is important to cut primary energy targets. It is always the trade-off between saved energy and spent capital investment. This issue became more important in the transition to a low-carbon economy. Inter-plant integration can be a source of clean energy, which does not need to be produced but proper targeting gives its economic feasibility and attraction to investments. This paper provides a new extension of the Total Site method accounting optimal amount of energy that can be saved on the inter-plant level. The approach utilises the construction of the Total Site Profiles with real temperature considers heat transfer with intermediate utility and finds cogeneration potential within enthalpy blocks of Total Site heat recovery. Merging of intermediate utilities and optimisation of its temperature were considered together with CHP optimisation. Targeting of the total annual cost was performed based on Total Site Pinch concept finding the optimum temperature approach between site temperature profiles. The case study for monomer production of polymer plant was investigated and 6 different options of Total Site heat recovery were assessed. The minimum total annualised cost of 45.3 mils. EUR was accounted for option with maximum cogeneration potential and the minimum number of heat exchangers. The heat recovered is 160.7 MW, CHP potential is 32.9 MW, and the number of heat exchangers is 144 for a total site minimum temperature approach of 20 °C. The results were compared with the traditional Total Site approach and the advantages were highlighted. The sensitivity analysis of the results was performed by applying energy price changes of ± 50% of the base level. The results can be used for the detailed design of the site energy system and further development of Total Site methods.
... Minimum heat transfer area of Total Site heat recovery is calculated by (Eq. 4) that was previously modified in [41]: ...
The present work is focused on finding a cost-effective solution to the synthesis of Heat Exchanger Networks (HEN) for Total Site Integration (TSI). The possible solutions for minimum-investment retrofit of the Total Site HEN are also discussed. The feasibility of intermediate heat carriers number is also analysed for better plants interconnection considering the optimal amount of the recovered heat.
The presented case studies illustrate the pathway selection of site recovery system synthesis with a certain number of heat exchangers, heat transfer area, intermediate utilities, and interconnection between production processes, heat consumers, heat generation facilities and other members of an integrated regional network. Case studies demonstrate that the use of two proposed approaches allows minimising unit numbers and heat transfer area. The first one provides 18% less heat transfer area and the second one suggest network with 41 % less unit. The economic results are compared and discussed. The results of this work can be used for site recovery network development as well as a decision-making tool during interplant heat integration and improvement of side-wide heat recovery. The results of this paper are potentially interesting for both research and engineering staff. The current work provides the methodological improvement when designing the Total Site Heat Recovery and better estimation of the HEN capital cost.
... A hybrid power system (HPS), using the integration of the process heat supplies and demands, was proposed in [75]. The heat recovery through a Total Site network was investigated to reduce the capital cost [76] upon design and retrofit of Total Site HEN [77]. The method of both isothermal network synthesis and nonisothermal network synthesis was proposed in [78]. ...
Due to the rapid growth in the world population, there has been an increase in energy consumption globally. The problem of efficient energy use becomes more relevant and stimulates research and development of new energy and resource-saving technologies. This task is becoming more complicated when the other factors are accounted for, resulting in multiple-factor trade-offs, such as the water-energy-food nexus. This paper highlights the main points for the development of Process Integration in the Commonwealth of Independent States (CIS) countries. It shows the main achievements in the field to date and demonstrates the scientific schools that are working on these problems. A comprehensive review of modern approaches and methods, which are now being developed or have been recently developed, was done. It shows a research gap in Process Integration in CIS and other leading countries. It demonstrates the significant research potential as well as practical applications. The main challenges in process systems engineering and for the sustainable development of industrial energy systems are also discussed. Industry digital transformation, energy transition, circular economy, and stronger energy and water integration are pointed out as priorities in analysis, design, and retrofit of society in the future. A state-of-the-art review in the area of integration of continuous and batch processes, mass integration technologies, and process intensification is presented to show the variety of existing approaches. The necessity of Process Integration development in the CIS is shown to be a necessary condition for building a more sustainable society and a resource-efficient economy.
... Integration approaches could be applied also to reduce the fuel consumption and emission as reported by Klemeš and Kravanja (2013). These methods is grounded on the thermodynamic approach and has very wide applications in reprocessing industries, see for example recent one, which was published by Boldyryev and Varbanov (2015). To utilise the waste industrial heat and optimise site utility system of some energy consumers and producers the TSA (Total Site Analysis) should be used as was reported first by Klemes et al (1997). ...
... Composite Curves show the energy targets, the source and sink temperature of ORC as well as process streams available as source. The methodology for estimating of side wide demands is based on construction of site profiles, selection of number of intermediate utilities available, calculation of heat transfer area (Boldyryev et al, 2015). ...
The cement industry sector as an energy intensive industrial sector, where energy cost represents approximately 40% of the total production cost per one ton of cement, and one of the highest greenhouse gases - GHG emitting industrial sectors, accounts for around 5% of global anthropogenic GHG emissions as reported (Mikulčić et al, 2015). Considering that, the cement is the most widely used material for construction needs, this paper analyses the potential of energy efficiency improvement of the cement production for a particular cement plant in Croatia. The heat recovery potential was determined and an amount of waste heat available for utilisation accounting site wide demands are identified with use of Process Integration technique. The results show huge potential for energy saving of cement production. Different scenarios for utilization of low potential heat are proposed accounting different site demands and energy prices. Implementation of paper results helps to the cement plant’s profitability and reduces environmental impact of the cement industry.
... In this paper proposed the methodology to estimate minimum cost for retrofit of Total Site heat recovery systems including energy and investments. The methodology was previously described by Boldyryev et al. (2015). The case study is presented in this paper and show the results and applicability of the offered method. ...
This paper deals with selection of optimum amount heat to be recovered during Total Site integration and
utility targets for external heating, cooling, refrigerating etc. The methodology provides the calculation of
minimum capital investment during heat integration of industrial site. It uses heat transfer area targets, utility
distribution with overall cost of retrofit. Heat transfer area is calculated for different regions with use of
intermediate utility and direct heating and cooling. Minimal temperature difference between Total Site profiles
is analysed. Minimum of total heat transfer area for Total Site recovery is calculated for array of minimal
temperature differences. The utility consumption, numbers of units and material of equipment are analysed too
and minimum total cost for retrofit project of site recovery system is calculated. The case study shows heat
recovery improvement on 1.94 MW. Site heating demands is reduced on 37.3 % and cooling capacity
reduction is 39.6 %. The implementation of retrofit EUR 777,474 and payback time is 11.96 months.
... The researchers using the targeting technique of Pinch Analysis are developing different extension of Total Site Profile analysis e.g. renewable energy (Varbanov and Klemeš, 2011), incorporating district cooling system (Liew et al., 2015), investment cost minimization via appropriate selection of intermediate utility temperature (Boldyryev et al., 2015), pressure drops (Chew et al., 2015). The other group is usually using mathematical programming approaches. ...
Although Heat Exchanger Network (HEN) synthesis methods have been in existence for forty years, several issues still need to be resolved in order to obtain more realistic networks. Moreover, the complexity of the problem further increases when Heat Integration is performed at the Total Site level rather than at the process level. The usual approach is first to perform Heat Integration within the processes, and later to consider the non-integrated parts for Total Site Heat Integration. This sequential approach can omit some promising solutions and thus generally leads to worse results compared to the approach where the entire Total Site is synthesized simultaneously (Nemet et al., 2014). In order to obtain more realistic results, several practical constraints should be accounted for, such as transport between processes, optimal intermediate utility temperature level(s), pipeline design, heat losses and pressure drop (Nemet et al., 2015). In this work a synthesis of the Total Site is performed, which simultaneously considers integration within and between plants (at the plant and at the Total Site levels). For this purpose, the superstructure optimization approach is used. The superstructure contains all the possible matches for heat exchange within and between processes. Heat exchange between processes can be performed in the following ways: i) directly, by exchanging heat between the hot stream of one process and the cold stream of another process, or ii) indirectly, by utilizing an intermediate utility at optimal temperature levels (these are optimization variables). In both cases the transport of the heat carrier, either the process stream or the intermediate utility stream, is considered. Because there are severe nonlinearities and numerous options for heat recovery, the model is difficult to implement even for small-scale problems. However, when evaluating potential matches, it usually happens that most matches are either infeasible given heat transfer limitations, or unviable for economic reasons. A two-step approach is therefore proposed, where in the first step match alternatives are pre-screened with respect to infeasibility and unviability, and in the second step, a more detailed design is synthesized, taking into consideration the reduced superstructure obtained in the first step. The proposed two-step procedure yields results simultaneously at both the process and the Total Site levels, while also accounting for important properties such as heat losses, pipeline design and cost, temperature/pressure drop during transport between processes, and different types of heat exchangers.
... In general, the method prioritises intra-process heat integration before searching for inter-process heat integration opportunities via the utility system (Klemeš et al. 1997) and/or dedicated indirect heat recovery systems (Walmsley et al. 2014). Recent advances in TSHI methodology include methods for minimising cost for Total Site recovery (Boldyryev et al. 2015), incorporation of district cooling into Total Sites (Liew et al. 2015), and consideration of safety aspect when proposing TS solutions (Liu et al. 2015). The Total Site (TS) method has five main steps: (1) process and stream data specification, (2) process level Pinch Analysis, (3) extraction of excess heating and cooling loads from process Grand Composite Curves (GCC), (4) Total Site Profile (TSP) composition, and (5) TS utility consumptions targeting. ...
Total Site Heat Integration (TSHI) provides a valuable framework for practical integration of multiple energy users. Previous studies have introduced the idea of utilising process heat recovery pockets to assist TSHI. However, these methods are shown to be effective for only some Total Site (TS) problems. As a result, this paper presents a new method for calculating assisted heat transfer and shaft work targets for an example TS problem. Analysis results show that assisted heat transfer increases TSHI only when a process heat recovery pocket spans the TS Pinch Region. The maximum assisted TSHI can be targeted by comparing each heat recovery pocket to the Site Utility Grand Composite Curve (SUGCC) using background/foreground analysis. Where heat recovery pockets span two steam pressure levels away from the TS Pinch Region (usually above), the example shows the potential for assisted shaft work production. In this case, the source segment of the heat recovery pocket generates steam (e.g. MPS), which replaces steam that would otherwise have been extracted from a steam turbine. The sink segment of the heat recovery pocket consumes lower pressure steam (e.g. LPS), which is extracted from the turbine. If a heat recovery pocket falls outside these two situations (assuming direct inter-process integration is disallowed), the entire pocket should be recovered internal to a process.
... Integration approaches could be applied also to reduce the fuel consumption and emission as reported by Klemeš and Kravanja (2013). These methods is grounded on the thermodynamic approach and has very wide applications in reprocessing industries, see for example recent one, which was published by Boldyryev and Varbanov (2015). To utilise the waste industrial heat and optimise site utility system of some energy consumers and producers the TSA (Total Site Analysis) should be used as was reported first by Klemes et al (1997). ...
The cement industry sector as an energy intensive industrial sector, where energy costs represent
approximately 40% of the total production costs per ton of cement, and one of the highest greenhouse
gases - GHG emitting industrial sectors, accounts for around 5% of global anthropogenic GHG
emissions. In 2011, the world cement production, according to the IEA, was 3635 Mt with predicted
increase to 4556 Mt in 2020, 4991 Mt in 2030 and 5549 Mt in 2050 for the high demand scenario.
Also according to the same scenario, by 2050 the cement producers are required to reduce CO2
emissions for 15%, representing a direct reduction of up to 913 MtCO2. Therefore, cement industry
needs to adopt more energy efficient technologies to reduce its environmental impact. However due
to the large amount of CO2 coming from the process itself, it will also be necessary to identify bigger
potential for application of renewables in the cement manufacturing process, or even change the
conventional production to a new less CO2 intensive production process.
Bearing in mind that cement is the most widely used material for housing and modern infrastructure
needs, the present paper analyses the energy efficiency of the cement manufacturing processes for a
particular cement plant. Investigation of heat supply and process cooling systems of cement
production plant aimed to increase heat integration and to reduce power consumption is performed.
Plant observation the stream data and thermo-physical properties of process streams and operation
modes of equipment were obtained. Energy audit and energy consumption of the cement plant were
made. Using the pinch-analysis technique, energy saving potential of existing process was
determined. It includes of data analysis, heat recovery possibility, utility analysis, power system
analysis and overall possible way of energy efficient retrofit. Energy targets for retrofit project were
outlined and compared with existing process. It consists of heating system and levels of heat energy
use, cooling demands, heat recovery, power targets and scheduling and possibility of renewable
energy sources integration.
The results show that the energy consumption is reduced by improved heat recovery, energy usage
and shares the renewable energy sources. Implementation of this retrofit project helps to the plant’s
profitability and the environmental impact of the cement manufacturing process.
Retrofit of the heat exchanger network is one of the vehicles of energy efficiency and emission reduction in the process industry. For further implementation, several alternative retrofit options exist, and better economic indicators provide the selection of the best one. Usually, the analysis is made using a forecasting model of energy prices, but the last pandemic and political crises demonstrate unpredictable changes. This paper proposed an approach for the economic and environmental assessment of retrofit options based on the experience of society from 1861 to 2021 and the corresponding energy price trends. Essential financial, e.g. NPV, IRR, DPP, and environmental criteria of retrofit options of heat exchanger network, are analysed considering different trends of energy prices. The most effective project is selected, providing the decision-makers with all data on overdetermined or lost benefits in all possible conditions. The case study analyses three alternative retrofit options for crude oil distillation. Two scenarios presume implementation after 1 and 3 years after project acceptance. The analysis shows IRR is on average 28, 99 and 61% for retrofit options 1, 2 and 3 when a preparatory period is 3 years and low energy prices. NPV is on average 21, 15 and 9 million USD, respectively. The DPPs are 3.8, 2.3, and 2.6 years and the reduction of carbon footprint is by 152, 71 and 45 ktCO2/year. It was also found that the retrofit option with the most extensive energy and emission saving is the most effective for periods with high energy prices regardless of a project implementation period. The retrofit option with the minor network changes is better for low and average energy prices regardless of a project implementation period. The method allows decision-makers to assess the alternative retrofit project in different economic conditions and could be applied in other process industries.
