Potential för energieffektivisering i industriella klustrar analys och scenarier

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1 Potential för energieffektivisering i industriella klustrar analys och scenarier Simon Harvey Professor i industriella energisystem Värmeteknik och maskinlära, Chalmers Ingår i projektet Bærkraftig bruk av energibærerne i KASK regionen

2 Kort om projektet Bærkraftig bruk av energibærerne i KASK regionen

3

4 Olika energislag inom de olika industrisektorerna i EU Energy usage industrial sector. EU 27, Kemiklustret i Stenungsund Renew Heat Electrical Energy Gas Oil Solid Fuels PJ Järn och stål Kemi Raffinaderi Mineral utom metaller Övrig tillverkning Papper och tryckeri Mat och tobak Verkstadsindustri Metaller utom järn Textil, läder och kläder Källa: Eurostat

5 Energy efficiency in the Stenungsund Rising energy prices chemical cluster Threat of global warming Policy instruments for CO 2 - emissions reduction Strong incentives to improve energy efficiency Energy intensive industrial process clusters can significantly increase energy efficiency by inter-process heat exchanging Total Site Analysis (TSA) is a useful tool to investigate opportunities for inter-process heat recovery in industrial process clusters This presentation: Tools for Single process and total site analyses Highlights from a case study (Chemical cluster, Stenungsund)

6 The potential of inter-process heat integration: Opportunities for improving energy efficiency in Stenungsund Sweden s largest chemical cluster Ethylene Air Naphtha Ethane Propane Butane Import terminal Cracker plant Ethylene Oxygen Nitrogen Hydrogen gas Fuel gas Electricity Water Fuel gas Fuel gas Fuel gas Ethylene Hydrogen gas Propylene Polyethylene plant Hydro Polymers Perstorp Oxo AB Polyethylene Polyvinyl chloride Amines Tensides Chemical intermediates Inter-process material flows are well-established. What about utility flows? Natural gas Key figures for total site: Total CO 2 emissions: ~900 kton/yr Total heating demand: 442 MW 320 MW are covered by internal heat recovery Current utility usage fr fired boilers: 122 MW Can theoretically be reduced to 0 MW through inter-process heat integration! How this can be accomplished: New circulating hot water systems C Harmonization of utility pressure levels to enable heat exchange between process plant utility systems Rebuild steam heaters for 2 bar(g) operation Fire process off-gases in different boilers

7 Pinch Analysis for Heat Integration studies Process integration (PI) refers to the analysis and optimization of large and complex industrial processes Pinch analysis is a widely-used PI tool in many industry sectors, including Chemical sector Pinch analysis enables investigation of energy flows within a process, and identification of the most economical way to maximize heat recovery and minimize the demand for external utilities (e.g. steam and cooling water)

8 Basics of Pinch Analysis Raw material P r o c e s s Heat supply Products El Heat balance T Heat supply G ra fic a lly Process Pinch Determined by ΔT min T ( C) Hot streams M inim um ho t utility Cold stream s Cooling 0 M inim um co ld utility Q Cooling Maximal Internal Heat recovery Process streams Energy analysis

9 Can the same approach be used for investigating interprocess heat exchange in multi-plant industrial clusters? 100 AGA Sum of individual process minimum heating requirements = 77 MW Can this target be decreased further? Akzo 100 Borealis PE Borealis Cracker Perstorp Ineos Sum of individual process current hot utility requirements = 122 MW Use Total Site Analysis (TSA)

10 Temperature [ C] Heat and Power Technology Step 1: Establish the temperature profiles in the heaters and coolers for each process plant Process streams in utility coolers (Sources) Utility streams in process heaters Utility streams in process coolers Process streams in utility heaters (Sinks) Heat load [kw] Sink Profile Source Profile Hot Utility Cold Utility 0

11 Temperature [ C] Heat and Power Technology Step 2: Combine the curves for all process plants in the cluster Q CW and Air =560 MW 1600 Q rec =324 MW Q heating, total =442 MW Q -200 cooling, total =953 MW Heat load [MW] Sink Profile Source Profile Hot Utility Cold Utility

12 Step 3: investigate the potential to reuse heat from coolers as hot utility elsewhere. Total Site Approach (TSA) Temperature [ C] Sink Profile Hot Utility Site Pinch Q cooling =633 MW Heat load [MW] Q rec =320 MW Q heating =122 MW Source Profile Cold Utility TSA results: Hot utility load is Q heating = 122 MW from fired boilers, i.e. no improvement over analysis of separate processes Site pinch at 120 C Cooling provided by CW, air and refrigerant In order to improve energy efficiency we must make changes to utility systems (in order to shift site pinch)

13 Temperature [ C] Heat and Power Technology Step 4: Investigate ways to improve the site utility system so as to reduce the total site heat demand Q cooling =506 MW Sink Profile Hot Utility Heat lead [MW] Q rec = 449 MW Q surplus =7 MW Source Profile Cold Utility Technical measures: Hot water system C Increased recovery of 2 bar(g) steam Harmonize utility levels (only 3 levels) Results: New heating demand: Q heating = 0 MW Potential savings: 122 MW Steam surplus: Q surplus = 7 MW Compare with sum of individual process minimum heating demands (77 MW)

14 Design options Availability of different heat sources and sinks at different companies provides many degrees of freedom in the design of the heat recovery system Delivering heat from one plant to another requires new HXs and piping construction Recovered excess heat mainly replaces LP steam, which can cause excess of LP steam at certain sites Excess LP steam has to be redistributed to sites with LP steam demand Combustible by-products (off-gases) that can t be used otherwise have to be redistributed to sites with demand

15 Hot water circuit max heat recovery (4 plants involved) Heat and Power Technology Plant E Current LP steam demand: 25.7 MW 30.6 MW 1 4 Plant C1 Heat sources Heat sinks Total investment: 335 MSEK 1 Potential demand: 40.3 MW 27 MW MW Potential heat sink for excess utility Total hot utility savings: 30.6 MW Payback period: App. 3.7 years New HX: MW 3.4 MW 0.4 MW 26.9 MW Fuel Steam Hot water Plant B Plant C2

16 Can we reduce complexity without severe energy savings penalty? Plant E Plant C1 Heat sources Current LP steam demand: 25.7 MW 26.1 MW 1 4 Heat sinks 1 Potential demand: 40.3 MW 26.1 MW MW Potential heat sink for excess utility Total investment: 306 MSEK (335) Total hot utility savings: 26.1 MW (30.6) Pay back period: App. 3.9 years (3.7) MW 26.1 MW Fuel Steam Hot water New HX: 7 (14) Plant B Plant C2

17 Summary Pinch analysis tools can be extended and used for Total Site studies of industrial process clusters TSA applied to the chemical cluster in Stenungsund indicates major opportunities for increased energy efficiency through inter-process heat exchange BUT this is not Business-as-usual New business models are required to realize the potential (or part thereof)

18 Combining Energy Efficiency in Industrial Clusters with integrated biorefinery options Overview of ongoing activities within the SKOGSKEMI project Simon Harvey and Matteo Morandin

19 OBJECTIVE, Partners, time-frame Heat and Power Technology To support strategic, renewable, competitive productions from two of the basic Swedish industrial sectors: forest and chemical (co-)financed by Systems Budget: 20 MSEK for 2 years project (sep 2012 sep 2014) : Swedish Governmental Agency for Innovation 10 MSEK from VINNOVA, 10 MSEK in-kind from research partners

20 Scope Feedstock is any forest product (mainly lignocellulosic biomass) 3 final products ( pathways ):. Methanol. Olefins (Ethylene, Propylene). Butanol 2 technology platforms. Gasification (syngas). Fermentation (sugar) 2 analysis platforms : system analysis, discussion

21 Possible Pathways Heat and Power Technology Cluster heat integration Current situation - little or no green Feedstock; MW heat from fired boilers Improved heat efficiency - Little or no green Feedstock; - Reduced heat from fired boilers (25 50% of current demand) Feedstock Sustainability Green Feedstock - large part of the feedstock is green MeOH or EtOH; MW heat from fired boilers Green Feedstock and Increased heat integration - large part of the feedstock is green MeOH or EtOH; - Reduced heat from fired boilers (25 50% of current demand)

22 Tack! Frågor? Bærkraftig bruk av energibærerne i KASK regionen

Dr Jonas Joelsson jonas.joelsson@processum.se www.processum.se

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