sebastian brechtel product & strategy...
TRANSCRIPT
Heat recovery – efficiency at any price? Sebastian Brechtel
Product & Strategy Manager
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Agenda
• Efficiency – General terms • Automotive fuel consumption – „Clean diesel“ • Thermal efficiency in acid plants • Financial efficiency - ROI • Facing real life • Take care of your cash cows • HEROS heat recovery system design • Getting digital support
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Efficiency – General terms
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Removal or conversion efficiency
Operational efficiency
Energy efficiency
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Efficiency – Automotive fuel consumption
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Standard operation
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Standard operation
Efficiency – Automotive fuel consumption
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29/10/15 6
loss
Best operation
Standard operation
Efficiency – Automotive fuel consumption
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loss
Standard operation
Best operation
Efficiency – Automotive fuel consumption
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29/10/15 8
loss
Standard operation
Best operation
Too small particle filter
Efficiency – Automotive fuel consumption
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Thermal efficiency – Waste heat recovery in sulfuric acid plants (sulfur burner)
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Sulphur Melting 1% 34%
10% Intermediate Heat Exchanger
Evaporator Economizer
Final Absorber
Acid Coolers
Tail Gas 3%
11% 3%
Sulphur 98%
Electric Energy 2%
Blower
Drying Tower
Air
Acid Coolers
6%
23% 9% 1%
Steam 57.5%
Acid Cooling 39%
Intermediate Absorber
Waste Heat Boiler
Converter Tray No.1
Converter Tray No.2
Converter Tray No.3
Converter Tray No.4
Sulphur Combustion Furnace
Production Acid 0.5%
Steam Superheater
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Thermal efficiency – Waste heat recovery in sulfuric acid plants (sulfur burner)
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Sulphur Melting 1% 34%
10% Intermediate Heat Exchanger
Evaporator Economizer
Final Absorber
Acid Coolers
Tail Gas 3%
11% 3%
Sulphur 98%
Electric Energy 2%
Blower
Drying Tower
Air
Acid Coolers
6%
23% 9% 1%
Steam 57.5%
Acid Cooling 39%
Intermediate Absorber
Waste Heat Boiler
Converter Tray No.1
Converter Tray No.2
Converter Tray No.3
Converter Tray No.4
Sulphur Combustion Furnace
Production Acid 0.5%
Steam Superheater
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Financial efficiency – Return on Investment (ROI)
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?
Financial efficiency – Return on Investment (ROI)
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Financial efficiency – Return on Investment (ROI)
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Design basis for a financial efficiency calculation
Plant capacity 4500 mtpd H2SO4 (as 100wt%) Plant location Europe Plant type Sulphur burning, 3+1
Utility concept “Over the fence” – purchase of electricity, cooling water, demin water and LP steam. Sale of HP and LP steam.
Financial concept Plant cost fully financed by a commercial loan: interest rate 6%, depreciation based on a 20 year period.
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ROI – HEROS heat recovery system
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0
0,2
0,4
0,6
0,8
1
1,2
1,4
0 1 2 3 4
Cum
uala
tive
RO
I
Operational years
HEROS
$$
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ROI - SAP and HEROS™
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0 0,2 0,4 0,6 0,8
1 1,2 1,4
0 2 4 6 8 10 12 14
Cum
uala
tive
RO
I
Operational years
SAP HEROS
$$
$$
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Facing real live – Failure scenarios
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Heat recovery (HR) failure scenarios
Short term failure Long term failure
Failure mode Acid pump failure Boiler leakage with weak acid scenario
HR shutdown duration 3 days 3 months Additional cost [% of initial investment]
3% 20%
$$
$$
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Interdependency of Acid plant & Heat recovery system
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loss loss
One way option
Two way option
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loss loss
Plant down time & production
loss
Fall back to standard operation
One way option
Two way option
Interdependency of Acid plant & Heat recovery system
Shut down of heat recovery system
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ROI - Heat recovery system (failure)
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0 0,2 0,4 0,6 0,8
1 1,2 1,4
0 1 2 3 4
Cum
uala
tive
RO
I
Operational years
HR short term failure
HR long term failure
$$
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ROI - Heat recovery system (failure)
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0 0,2 0,4 0,6 0,8
1 1,2 1,4
0 1 2 3 4
Cum
uala
tive
RO
I
Operational years
HR short term failure
HR long term failure
$$ ??
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ROI - Sulphuric acid plant (failure)
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0 0,2 0,4 0,6 0,8
1 1,2 1,4
0 2 4 6 8 10 12 14
Cum
uala
tive
RO
I
Operational years
HR short term failure
HR long term failure
$$
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ROI - Sulphuric acid plant (failure)
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0 0,2 0,4 0,6 0,8
1 1,2 1,4
0 2 4 6 8 10 12 14
Cum
uala
tive
RO
I
Operational years
HR short term failure
HR long term failure
?
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HEROS design aspect: Plant Availability
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Advantage Acid and HP steam production guaranteed even if
HEROS ís not in operation.
Features Separation of hot acid
circuit from system possible
IAT design for 100 % capacity
Target Failure of hot circuit must not lead to plant
shutdown
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HEROS design aspect: Safety precaution 1
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Advantage Wide operational window & minimized
corrosion under off-set conditions
Feature Material selection: stainless steel & acid
resistant bricklining (indicated in red)
Target
Limit hazard potential
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HEROS design aspect: Safety precaution 2
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Advantage Minimized corrosion in case of
heat exchanger failure and emergency stop
Features Heat exchanger
outside of acid tank Fast isolation of acid
and water circuit
Target
Limit hazard potential
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Getting digital support
• The PORS (Plant Operability Reliability and Safety) system is a virtual process expert - it is our online know-how at plant site
• Analysis of plant operation for potentially hazardous situations
• Guidance and support for plant operators
Plant Operability Reliability and Safety System
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PORS
Operational Data
Process know-how
Awareness of key
operational trend / upset
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PORS system – virtual process expert
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Benefits
Value proposition
Improved process safety and plant availability
Features
Operator support and guidance
Process know-how delivered to site in black box “traffic light” system
Permanent systemic process monitoring and analysis of plant status
Risk mitigation - early detection of developing hazards and reduction of response time to upset conditions
Improved awareness of operators for plant mal-operation
Improved plant availability
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Risk mitigations for heat recovery systems
HEROS™ feature
Availability Flow Sheet Fundamental principle is that HR plant failure will not lead to SAP plant shutdown. The hot acid circuit is completely separated from rest of the acid plant. Intermediate absorption tower is designed for complete SO3 absorption at 100% plant load.
✔
Availability
Material of Construction
All vessels are acid-brick lined to minimize corrosion. Use of Alloy 3033, which allows for wide operational window where no brick lining is possible
✔
Safety Flow Sheet Material of Construction Automation
In fail-safe mode, automatic draining of hot acid by gravity into brick lined equipment, reducing corrosion to minimum levels. ✔
Operability Support tools PORS system for additional high level trending/critical process information requiring operator action to safeguard operating plant integrity. Operator training simulator as optional training measure.
✔
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