Process design process integration and energy system optimization

  • Slides: 18
Download presentation
Process design, process integration and energy system optimization Timo Laukkanen, Dr. Sc. (Tech. )

Process design, process integration and energy system optimization Timo Laukkanen, Dr. Sc. (Tech. ) Staff Scientist Timo Laukkanen

The main objectives of this course • To obtain a ”holistic” view for process

The main objectives of this course • To obtain a ”holistic” view for process design and energy systems • To learn how to use optimization in designing and improving energy systems • To learn how to use pinch technology in improving and integrating industrial energy systems Timo Laukkanen

Process Engineering, Process Systems Engineering and Process Integration • Process engineering focuses on the

Process Engineering, Process Systems Engineering and Process Integration • Process engineering focuses on the design, operation, control, and optimization of chemical, physical, and biological processes. • Process systems engineering = systematic computerbased methods to process engineering. • Process Integration = a holistic approach to process design and optimization, integrated process design or process synthesis Timo Laukkanen

Evolution of process design • Synthesis is the creation of a process Feed streams

Evolution of process design • Synthesis is the creation of a process Feed streams Product streams • Simulation predicts how the process would behave if built Feed streams Product streams Timo Laukkanen

Hierarchy of process design: The ”onion” diagram Reactor Separation and Recycle System Separation System

Hierarchy of process design: The ”onion” diagram Reactor Separation and Recycle System Separation System Heat Recovery System Heating and Cooling System Utilities Water and Effluent Treatment Timo Laukkanen

Continuous vs. Batch process BATCH processes – – – Small volumes Flexible in changing

Continuous vs. Batch process BATCH processes – – – Small volumes Flexible in changing product formulation Flexible in production rate Allows the use of multipurpose equipment Best if regular cleaning necessary Products from each batch can be identified CONTINUOUS processes – Economical for large volumes Timo Laukkanen

New design (greenfield) vs. Retrofit process design • Retrofit design – Old and new

New design (greenfield) vs. Retrofit process design • Retrofit design – Old and new equipment can be used – The wearing of old equipment needs to considered • Greenfield design – Only new equipment can be used Separation System Utility System Timo Laukkanen

Irreducible structure vs. Reducible stucture (super structure) approach to process design • Irreducible structure

Irreducible structure vs. Reducible stucture (super structure) approach to process design • Irreducible structure (for example the pinch approach) – – Follows the onion logic Series of local decisions Many designs need to be made due to sequential approach No quarantee that best possible solution is found due to fixed designs in different levels – Designer in control of the design process • Superstructure approach (mathematical programming) – – All design options included in a mathematical model Huge problem that can be hard to solve Needs simplifications in unit operations If the best design is not one that is embeded in the superstructure , optimal solution is not found – Teoretically possible to find the global optimum Utility System Timo Laukkanen

Trade-offs in process design (multi-objective optimization) Energy Raw materials Process topology Capital Separation Operation

Trade-offs in process design (multi-objective optimization) Energy Raw materials Process topology Capital Separation Operation System Utility System Timo Laukkanen

Process Integration Methods Pinch Analysis Exergy Analysis Mathematical Programming Knowledge Based Expert Systems •

Process Integration Methods Pinch Analysis Exergy Analysis Mathematical Programming Knowledge Based Expert Systems • Systematic visual thermodynamic analysis • Targets before design • “Second law”-thermodynamic analysis • Quantitative measure of process efficiency • Suitable multicomponent plant criteria of performance • Constrained single- or multiobjective optimisation • Models for systematic design and analysis Separation • (Artificial intelligence) System • Case-based reasoning, rule-based reasoning Utility System Timo Laukkanen

Process Integration Application Heat recovery targets • Initial trade-off between operating and investment costs

Process Integration Application Heat recovery targets • Initial trade-off between operating and investment costs Heat exchanger networks synthesis • Number of units, total heat exchanger surface area • External energy supply vs. recycling Separation systems design Utility systems design Plant operability design • Thermally driven • Distillation, evaporation and drying • Boilers, turbine and heat pump integration • Utility system synthesis Separation System • Flexibility, controllability, startup- and shutdown Timo Laukkanen

Energy systems optimization Separation System Timo Laukkanen

Energy systems optimization Separation System Timo Laukkanen

Energy systems optimization Optimization is everywhere • Engineering design is optimization: choosing design parameters

Energy systems optimization Optimization is everywhere • Engineering design is optimization: choosing design parameters to improve some objective • Much of data analysis is also optimization: extracting some model parameters from data while minimizing some error measure (e. g. fitting) • Most business decisions = optimization: varying some decision parameters to maximize profit (e. g. investment portfolios, supply chains, etc. ) Separation System Timo Laukkanen

Energy systems optimization In process integration and heat exchanger networks Separation System Timo Laukkanen

Energy systems optimization In process integration and heat exchanger networks Separation System Timo Laukkanen

Energy systems optimization In HVAC technology Separation System Timo Laukkanen

Energy systems optimization In HVAC technology Separation System Timo Laukkanen

Energy systems optimization In national and global energy system models and energy policy Separation

Energy systems optimization In national and global energy system models and energy policy Separation System Timo Laukkanen

Energy systems optimization In power plants Separation System Timo Laukkanen

Energy systems optimization In power plants Separation System Timo Laukkanen

IEA BLUE MAP Separation System Timo Laukkanen

IEA BLUE MAP Separation System Timo Laukkanen