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Energy Integration of IRCC
1. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
E NERGY I NTEGRATION OF C OMBINED
H YDROGEN & E LECTRICITY P RODUCTION -
M ETHODOLOGY & T OOLS I NTEGRATION
Rahul Anantharaman, Olav Bolland & Truls Gundersen
Department of Energy & Process Engineering
Norwegian University of Science and Technology
PRES 08
Prague, 27.08.2008
2. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
O UTLINE
1 I NTRODUCTION
Motivation
The Process
2 M ETHODS AND T OOLS
Methods
Tools
3 I NTEGRATION C ASE S TUDY
Utilities and cost information
ELCC
Heat Exchanger Network Synthesis
4 S UMMARY
3. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
O UTLINE
1 I NTRODUCTION
Motivation
The Process
2 M ETHODS AND T OOLS
Methods
Tools
3 I NTEGRATION C ASE S TUDY
Utilities and cost information
ELCC
Heat Exchanger Network Synthesis
4 S UMMARY
4. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
BACKGROUND
5. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
BACKGROUND
6. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
BACKGROUND
7. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
CO2 CAPTURE PROCESSES AND SYSTEMS
8. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
H YDROGEN AS AN ENERGY VECTOR
H2 is predicted to be key player in future energy scenarios.
Significant steps are being taken, specifically within
Norway and the EU, to develop H2 infrastructure.
H2 is increasingly needed in oil refineries to make more
environmentally friendly fuels.
Power generation with pre-combustion process provides H2 as
a product that can be supplied to a H2 network.
9. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
M OTIVATION
T HE PLANT
400 MW power plant with 50 MW (LHV) of H2 with 90% CO2
capture using Natural Gas as the fuel.
Most capture plants are associated with large energy
penalty (~10%) - decreasing their economic viability.
Efficiency is the most important factor when selecting and
designing plants with CO2 capture.
A IM
Develop an engineer-driven procedure for improving the
efficiency of CO2 capture plants using an integration of tools
and methodologies.
10. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
O UTLINE
1 I NTRODUCTION
Motivation
The Process
2 M ETHODS AND T OOLS
Methods
Tools
3 I NTEGRATION C ASE S TUDY
Utilities and cost information
ELCC
Heat Exchanger Network Synthesis
4 S UMMARY
11. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
C OMBINED H2 AND E LECTRICITY PRODUCTION
12. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
C OMBINED H2 AND E LECTRICITY PRODUCTION
13. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
K EY PROCESS PARAMETERS
R EFORMING S ECTION
Reforming system pressure: 30 bar
S/C Ratio: 1.4
Pre-reformer/Reformer feed temperature: 500 °C
Reformer temperature: 950 °C
HTS/LTS inlet temperature: 325/250 °C
H2 P RODUCT S ECTION
H2 pressure: 70 bar
H2 purity: 99.9 %
14. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
K EY PROCESS PARAMETERS
CO2 C APTURE S ECTION
Type: aMDEA (with piperazine)
CO2 capture rate: 95 %
Reboiler temperature: 120 °C(max)
Specific reboiler duty: 0.9 MJ/kg CO2
Total energy consumption: 1.02 MJ/kg CO2
CO2 pressure: 110 bar
P OWER I SLAND
Turbine: GE 9FA
Derating: 30 °C
Steam system: 3 pressure levels - no reheat
15. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
O UTLINE
1 I NTRODUCTION
Motivation
The Process
2 M ETHODS AND T OOLS
Methods
Tools
3 I NTEGRATION C ASE S TUDY
Utilities and cost information
ELCC
Heat Exchanger Network Synthesis
4 S UMMARY
16. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
E NERGY L EVEL C OMPOSITE C URVES (ELCC)
I NTRODUCING E NERGY L EVEL
E NERGY L EVEL
Energy levels at target & supply conditions are evaluated as:
(H−H0 )−T0 (S−S0 )
Ω= H−H0
Streams with increasing energy levels are energy sinks
Streams with decreasing energy levels are energy sources
Energy sources at higher energy levels can be potentially
integrated with energy sinks at lower energy levels
N OTE
It may not be possible to transfer energy from a stream at a higher
energy level to that at a lower energy level as Ω is not an explicit
driving force.
17. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
E NERGY L EVEL C OMPOSITE C URVES
ELCC are energy level –enthalpy curves constructed by plotting
energy level intervals of process streams against cumulative values
of enthalpy differences.
ELCC merges Pinch Analysis and Exergy Analysis into a
methodology utilizing the graphical approach of Pinch Analysis.
It functions as a screening tool or idea generator, giving physical
insight for energy integration between streams on energy source
curve and energy sink curve
18. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
E NERGY L EVEL C OMPOSITE C URVES
E XAMPLE - M ETHANOL PLANT
19. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
E NERGY L EVEL C OMPOSITE C URVES
E NERGY TARGETING
Energy targeting is performed by identifying optimal path
for each stream from supply to target conditions.
Optimal path implies maximizing shaft work produced and
minimizing shaft work consumed.
Optimal path heuristics were developed for 4 possible
temperature and pressure combinations above
atmospheric conditions.
20. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
S EQUENTIAL F RAMEWORK FOR HENS
M OTIVATION
Pinch based methods for Network Design
Improper trade-off handling
Cannot handle constrained matches
Time consuming
Several topological traps
MINLP Methods for Network Design
Severe numerical problems
Difficult user interaction
Fail to solve large scale problems
Stochastic Optimization Methods for Network Design
Non-rigorous algorithms
Quality of solution depends on time spent on search
21. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
S EQUENTIAL F RAMEWORK FOR HENS
M OTIVATION
HENS TECHNIQUES DECOMPOSE THE MAIN PROBLEM
Pinch Design Method is sequential and evolutionary
Simultaneous MINLP methods let math considerations
define the decomposition
The Sequential Framework decomposes the problem into
subproblems based on knowledge of the HENS problem
Engineer acts as optimizer at the top level
Quantitative and qualitative considerations included
22. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
S EQUENTIAL F RAMEWORK FOR HENS
U LTIMATE G OAL
Solve Industrial Size Problems
Defined to involve 30 or more streams
Include Industrial Realism
Multiple and ``Complex´´Utilities
Constraints in Heat Utilization (Forbidden matches)
Heat exchanger models beyond pure countercurrent
Avoid Heuristics and Simplifications
No global or fixed ∆ Tmin
No Pinch Decomposition
Develop a Semi-Automatic Design Tool
EXCEL/VBA (preprocessing and front end)
MATLAB (mathematical processing)
GAMS (core optimization engine)
Allow significant user interaction and control
Identify near optimal and practical networks
23. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
S EQUENTIAL F RAMEWORK FOR HENS
T HE E NGINE
C OMPROMISE BETWEEN P INCH D ESIGN AND MINLP METHODS
24. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
O UTLINE
1 I NTRODUCTION
Motivation
The Process
2 M ETHODS AND T OOLS
Methods
Tools
3 I NTEGRATION C ASE S TUDY
Utilities and cost information
ELCC
Heat Exchanger Network Synthesis
4 S UMMARY
25. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
M ODELING T OOLS
HYSYS
The steady-state simulation tool ASPEN HYSYS is used to
model the reforming section, the CO2 capture section and the
H2 purification section.
GTP RO
GTPro from Thermoflow Inc. is used to model the power island.
GTPro is particularly effective for creating new designs and
finding their optimal configurations. To this end, it has a library
of gas turbine models that replicates real performance.
Initial HRSG design and marginal costs for HP, IP & LP steam
are derived from GTPro.
26. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
T OOLS I NTEGRATION
HYSYS-GTP RO XL A DD - IN
27. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
O UTLINE
1 I NTRODUCTION
Motivation
The Process
2 M ETHODS AND T OOLS
Methods
Tools
3 I NTEGRATION C ASE S TUDY
Utilities and cost information
ELCC
Heat Exchanger Network Synthesis
4 S UMMARY
28. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
U TILITIES
S TEAM L EVELS
HP/IP/LP steam: 118/32/3.5 bar
U TILITIES COST
Electricty: 63 ¤/MWh
HP steam: 0.79 MW for 1 kg/s of sat steam raised
IP Steam: 0.68 MW for 1 kg/s of sat steam raised
LP Steam: 0.42 MW for 1 kg/s of sat steam raised
H EAT E XCHANGER C OST L AW
10,000 ¤+ (800 ¤)*(Area)0.8
29. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
O UTLINE
1 I NTRODUCTION
Motivation
The Process
2 M ETHODS AND T OOLS
Methods
Tools
3 I NTEGRATION C ASE S TUDY
Utilities and cost information
ELCC
Heat Exchanger Network Synthesis
4 S UMMARY
30. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
E NERGY L EVEL C OMPOSITE C URVES
P RELIMINARY E NERGY TARGETS
Shaft work required: 28 MW
Hot utility requirement: 0 MW
Cooling Water requirement: 34 MW
31. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
O UTLINE
1 I NTRODUCTION
Motivation
The Process
2 M ETHODS AND T OOLS
Methods
Tools
3 I NTEGRATION C ASE S TUDY
Utilities and cost information
ELCC
Heat Exchanger Network Synthesis
4 S UMMARY
32. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
H EAT E XCHANGER N ETWORK S YNTHESIS
I NTEGRATION O PTIONS
1 Integrate Amine reboiler directly to the process
2 Extract LP steam from utility system to feed the reboiler
3 Generate required LP steam for reboiler from LTS exit
33. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
H EAT E XCHANGER N ETWORK S YNTHESIS
I NTEGRATION R ESULTS
O PTION HP STEAM IP STEAM LP STEAM E FFICIENCY U NITS C AP. C OST
KG / S KG / S KG / S % ¤
1 126.3 81 36 44.2 21 12107600
2 128.9 81.31 51 44.45 23 12434000
3 122.2 79 42 43.7 24 12420100
34. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY
S UMMARY
Combined hydrogen and power generation with carbon
capture is expected to play a significant role in the near
future energy portfolio.
An integration of methodologies and tools for the energy
integration of a combined hydrogen and electricity is
presented.
The methodologies presented lead to designs with slightly
higher efficiency than those presented in literature.
The methodology provides multiple designs with same
efficiency and similar costs but with varying degrees of
complexity to enable the engineer to select an integration
scheme based on qualitative parameters such as operability
etc.