Energy Integration of IRCC

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Energy Integration of IRCC

  1. 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. 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. 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. 4. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY BACKGROUND
  5. 5. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY BACKGROUND
  6. 6. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY BACKGROUND
  7. 7. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY CO2 CAPTURE PROCESSES AND SYSTEMS
  8. 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. 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. 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. 11. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY C OMBINED H2 AND E LECTRICITY PRODUCTION
  12. 12. I NTRODUCTION M ETHODS AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY C OMBINED H2 AND E LECTRICITY PRODUCTION
  13. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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.

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