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Overall Plant Energy-saving by Mathematical Optimization
through HERO Service &
Energy-saving Distillation SystemSUPERHIDIC ®
Overall Plant Energy-saving by Mathematical Optimization
through HERO Service &
Energy-saving Distillation SystemSUPERHIDIC ®
India‐Japan Business Forum for
Energy Efficiency , Conoservation and Renewable EnergyNovember 7th
TOYO ENGINEERING CORPORATION
Energy-saving Distillation SystemSUPERHIDIC ®
Energy-saving Distillation SystemSUPERHIDIC ®
November 2019
TOYO ENGINEERING CORPORATION
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Heat Integrated Distillation Column - Fundamental-
Ideal Reality
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Feed distillate
bottomsReboiler
CondenserFindings through intensive thermodynamics studyIdeal heat duty is dependent on the composition (stage).Some composition may require heat while some others may not.Thus, discrete side H/Ex allocation. Seldom to have ideal heat duties at the same elevation.Stage having similar heat duty demand should be combined.
Discrete & a few side H/Ex Different heat duty at each side H/Ex
Appropriate stage to be exchanged not at same level
Inappropriate side H/Ex manner = Increase in column loading in vain= Increase in compressor
Evolved HIDiC - SUPERHIDIC ® -Example of Ideal Heat Duty Allocation
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【 Features 】 Side exchangersNormal stabbed-in type H/Ex
(Normal S/T H/Ex can be used) Installed at the desired composition Freedom in pairing of stagesHeat transfer area is variable Limited number (around 4) only
Column Strip. sect. elevated above rect. sect. No pump is required for circulationNormal tray or packing
Patent registered by Toyo/AIST
Evolved HIDiC - SUPERHIDIC ® -
Maintenance possibleApplicable to any process scheme, e.g.side-cut product draw-off, multi-feedOptimal side heat duty allocation close to reversible distillation achievable
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Awarded for world-1st HIDiC commercial application with SUPERHIDIC® in 2014 3QContract Summary
Client : Maruzen PetrochemicalSite: Chiba, JapanProcess Unit : MEKScope : License & EPC TKLSS/U : FY 2016 Aug.Replacement of conventional distillation column
ResultsEnergy Conservation : 57 % reduction to conventional distillationStable Operation w/ 0 kW Reboiler Duty More than 3 years commercial operation
Actual Performance in Commercial Plant
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Feed
Dist.Bottoms
STM
NOTE
1.013
1.023
0.952
0.566
0 3.511
: Heat Duty [MW]: Power [kW]
915
STM0.301
0
25 3427
SW
109.3 kPa354.7 K
229.3 kPa380.9 K
239.8 kPa392.9 K
17631 Nm3/h106.6 kPa
360.3 K
194.4 kPa352.7 K
15933 kg/h366.6 K
4591 kg/h376.9 K
381.3 K
16090 kg/h
SHx #1
SHx #2
SHx #3
SHx #4
11342 kg/h
STM : steamSW : sea water
Low Press.(Rect.)
Low Press.(Strip.)
High Press.(Rect.)
Reboiler Duty“0” kWin stale operation!!
(6135 kW@conv. dist)
Bypass linew/ block valve
Comprinlet/oblock
Comprinlet/oblock
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SUPERHIDIC Conv.Distillation
Feed rate [S kL/h] 19.5 19.5Operating pressure
Low pressure column @OVHD [kPa] 109 109High pressure column @OVHD [kPa] 229 -
Separation specificationsMEK @distillate [wt%] 99.94 99.94MEK @bottoms [wtppm] 200 200
Energy consumptionReboiler duty [kW] 0 6135Compressor power [kW] 915 0Reflux/dist. Pump [kW] 25 55Bottoms pump [kW] 27 10Recycle pump [kW] 34 -
Energy Saving 56.7%
to Conv. Distillation
Energy Saving [%] = ×100
Qr-SH : Reboiler duty in SUPERHIDIC [MW]Qr-conv : Reboiler duty in conv. Distillation [MW] WSH : Compressor & pumps power in SUPERHIDIC [MW]Wconv : Compressor & pumps power in conv. distillation [MW]
366.0/366.0/1
convconvr
SHSHr
WQWQ
Actual Performance in Commercial Plant
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Awards2014 Nikkei Green Innovation Prize2017 ENAA Engineering Excellence Award 2018 Energy Conservation Grand Award
(METI Prize) 2018 SCEJ Award for Outstanding Technical
Development2018 JPI Award for Technological Progress2019 SSEJ Award for Outstanding Technical
Development
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How to achieve energy-saving and reduction of GHGs emission even without such super-technology
Next
How to apply such nice technology to your plant
Energy Conservation &Reduction of GHGs Emission
for Overall Process/Utility Plant by Mathematical Optimization
― Hybrid Energy system Re‐Op miza on ―
November 2019
Energy Conservation &Reduction of GHGs Emission
for Overall Process/Utility Plant by Mathematical Optimization
― Hybrid Energy system Re‐Op miza on ―
November 2019
TOYO ENGINEERING CORPORATION
Confidential
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Simultaneous Optimization onboth Process and Utility Systems
Utility Sys.Process Sys.
Power
Heat
Requestedheat duty
RequestedPower
Power Supply /
of consumed STMPressureFlowrate
of consumedsupplied
PressureFlowrate STM
Comprehensive mathematical optimization model
Comprehensive model optimizes both systems simultaneously for direct minimization of external utility resource usage.
Objective Minimization ofexternal utility usage
Sell/BuyElectricity
Fuel
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Superior Process System Optimization
Sell/BuyElectricity
Utility Sys.Process Sys.
Power
Heat
Requestedheat duty
RequestedPower
Power Supply /
of consumed STMPressureFlowrate
Comprehensive mathematical optimization model
Fuelof consumed
suppliedPressureFlowrate STM
Objective
Implementationof new HEXs
Multi‐effect dist.intensification
Implementationof heat‐pumpdistillationetc…
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Optimization on Heat Exchanges
Cooling: Condenser, heat recoveries at outlets Heating︓Reboiler, feed preheaters
All options which might be effective are covered.
From the all combinations, effective configuration is selected.
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Optimization on Operating Pressure
Operating pressures of distillation columns are also optimized
Linearized models for several ranges of operation pressure are embedded.
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Examination of Heat-Pump Distillation
As for each distillation column,Implementation of heat‐pump distillation ― especially SUPERHIDIC®, is also examined.
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Process Sys.
Superior Utility System Optimization
Sell/BuyElectricity
Utility Sys.
Power
Heat
Requestedheat duty
RequestedPower
Power Supply /
of consumed STMPressureFlowrate
Comprehensive mathematical optimization model
Fuelof consumed
suppliedPressureFlowrate STM
Objective
Turbine refit Header press.
change Letdown
adjustmentetc…
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Alternation of turbine‐inlet steam is examined.P1
HP
P3HP
P2HP
P1LP
P3LP
P2LP
P1MP
P3MP
P2MP
BFW
Header press.is optimized.
Optimization on Steam System
Header press.is optimized.
Header press.is optimized.
Power toprocess system
Steam usage/generation@ process sys.
P1IP
P3IP
P2IP Header press.
is optimized.
Implementation ofadditional header level is examined.
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Scale of Optimization
In the case ofx 6 columns& 4 levels of STM headers
2(2x6)x(3x6) x (42 x 2)6 x 34 1075 conditions
Heat‐exchange Dist. col. STM headercomb. ope. range ope press.
Corresponds to: 2(# of possible comb.)
Even this alone results in 1063 conditions
Solve1case w/ 1 sec ⇒ 1057 years
HERO’s efficient search using Mixed Integer Linear Prog.can find out the solution within moderate calc. time.
# of ope. press. ranges: 4 # of feed state ranges: 4
SUPERHIDIC® option: included # of candidate press. of each STM
header: 3
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Current Proposal Energy Saving
HP Steam [MW] 31.3 18.9 12.4 (39.7% Saving)
Current Proposal Energy Saving
HP Steam [MW] 9.24 9.24 0
MP Steam [MW] ‐2.7 ‐15.48 12.78 (473% for Sell)
Case 1
Case 2
Case 3Current Prop. 1
Prop. 2Energy Saving
Hot Oil [MW] 12.32 9.85 MW9.51 MW
Prop. 1: 2.47(20% Saving)Prop. 2: 2.81(23% Saving)
Achievements (through a National Project)
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Client TOYO
Optimal operation targetModification plan
Performance‐based reward
Concept Purchase
ΔOPEX‐basedcharge
Development of tailor‐made model for specific process & utility configuration
Min. initial charge
Energy
saving
score
Investment(or Equip. modification degree)
Proposal A
Proposal B
Proposal C
Configuration:Process & utility systems
Operation/Design Data Operation Philosophy
Business Scheme
Proposal of “Overall” Optimum
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Thank you for your kind attention!
For more details…TOYO Engineering Corporation
Business Development DivisionEnvironment and Energy ManagementDevelopment Department
Toshihiro WAKABAYASHITel: 047 454 1571 / 090 6724 1074E‐mail: toshihiro.wakabayashi@toyo‐eng.com