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Reducing energy consumption and heat exchanger network

  1. May 2, 2015 #1

    Maylis

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    1. The problem statement, all variables and given/known data
    If you are allowed to make changes of column pressure and temperature, stream preheating or cooling temperature, please propose a process change that can significantly reduce the energy consumption at DTmin of 10°C. The modified process should maintain the product quality and production rate unchanged.
    upload_2015-5-2_23-12-56.png


    Utility Information

    Low pressure steam (LP, 140°C) = 0.03 $/kWh = 240 $/kW-Yr

    Medium pressure steam (MP, 170°C) = 0.05 $/kWh = 400 $/kW-Yr

    High pressure steam (HP, 200°C) = 0.07 $/kWh = 560 $/kW-Yr

    Hot Oil (HO, supply 450°C – return ≥ 300°C) = 0.15 $/kWh= 1200 $/kW-Yr

    Electricity = 0.1 $/kWh = 800 $/kW-Yr

    Cooling water (CW, 30°C) = 0.005 $/kWh = 40 $/kW-Yr

    Chilled Water (ChW, 5°C) = 0.05 $/kWh = 400 $/kW-Yr

    Refrigeration

    (R-10, -10°C) = 0.1 $/kWh = 800 $/kW-Yr

    (R-50, -50°C) = 0.3 $/kWh = 2400 $/kW-Yr

    (R-100, -100°C) = 1 $/kWh = 8000 $/kW-Yr

    (R-200, -200°C) = 5 $/kWh = 40000 $/kW-Yr

    2. Relevant equations


    3. The attempt at a solution
    This is my converged aspen simulation of a process to produce acetone (AC) from isopropyl alcohol (IP). I used a heat exchanger simulation software and here are my streams
    upload_2015-5-2_23-11-57.png
    Basically just inputting the heat duties of all the units. I just do a heat curve analysis and when the heat capacity changes I add a separate cooler, which is why there are blank rows in "Name", because the specific heat capacity is assumed to be constant only in one phase.

    This is my composite curve
    upload_2015-5-2_23-15-22.png

    This is my heat exchanger network
    upload_2015-5-2_23-15-49.png

    I'm wondering what I could do to improve the efficiency of this process? Or at least places I could start looking and what I should look for.
     
    Last edited: May 2, 2015
  2. jcsd
  3. May 4, 2015 #2

    Maylis

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    Some new idea, I decided to add a heater before the reactor in order to preheat the IP, since I can use low pressure steam which is cheaper than hot oil for the reactor. However, for some reason the Aspen file will not converge when I add this heater. The amount of IP being fed is changed, even though I specify the amount. In the OP the mass flow rate is 19483 kg/hr, now its 21123 kg/hr. It is quite strange.

    upload_2015-5-4_16-16-19.png
    The Energy report from SPRINT
    upload_2015-5-4_16-20-35.png

    This is my original energy report from the previous iteration
    upload_2015-5-4_16-22-11.png
     
  4. May 4, 2015 #3

    BvU

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    Wouldn't trust any answer at all from a non-converged A+ simulation.
    I have preciously little to go by, but my advice is to check the pressure drop in the feed preheater. T1 has trouble now (offgas flow disproportional) and then T2 crashes.
    Good luck !
     
  5. May 4, 2015 #4

    Maylis

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    If you wish, I can send you the Aspen file, but in the mean time I will try your suggestion
     
  6. May 4, 2015 #5

    BvU

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    Either that or increase the feed pressure.
    Something else that came to mind: does the reactor do the same thing with a feed of 25 degrees as it does with a feed of 140 degrees ?
     
  7. May 4, 2015 #6

    Maylis

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    As far as I know there is no difference
     
  8. May 4, 2015 #7

    BvU

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    If there are no temperature dependencies in the reactor, then it must be the pressure ...
     
  9. May 4, 2015 #8

    Maylis

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    Ah yes, I forgot that the pressure in the preheater should be 2 atm.
     
  10. May 6, 2015 #9

    Maylis

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    Okay, so I added a preheater before the reactor to IP, and a cooler for the AC.

    upload_2015-5-6_20-57-55.png

    This is my grand composite curve, and I should somehow use it to improve my energy efficiency. I know the flat blue lines are the utilities that I need, but I am unsure how to translate this curve into my process so that I know where I should put heaters/coolers.

    upload_2015-5-6_20-59-24.png

    And here is my utilities cost (this one is higher because DTmin is 20 C), but I have improved it with what I have done so far

    upload_2015-5-6_21-8-12.png
     
    Last edited: May 6, 2015
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