EVALUATION

OF

ENERGY

RECOVERY

IN

AN

EQUIPMENT

PLANT SUPPORT SERVICE

Flrez Cristian, Molina Mitchel, Muoz Johan, Nez Diana, Ramrez Daniel, Sanjuan Shirley Cartagena University, Faculty of Engineering, Chemical Engineering Program Thermodynamics II Cartagena, Colombia

Abstract This article presents the evaluation of energy use in a plant auxiliary services, using the exergy method by which it can be shown that it is misusing it. It was estimated that the plant exergetic efficiency is 44.27% and 97.65% of the exergy destruction is concentrated in seven teams, which are three steam generators, two turbine generators, a deaereador and a hydraulic pump

Keywords: Energy, Exergy, Plant Auxiliary Services

Introduction Most petrochemical plants are currently in operation were designed and built in 1970, when there was no concern about the proper use of energy. This situation currently makes most of these plants are considered technologically obsolete, are energy intensive and contribute significantly to environmental degradation, so it is necessary to evaluate their use of energy and the potential recovery of it. In this study, is evaluating the potential for energy recovery in the various plant equipment and ancillary services of a petrochemical plant, whose function, providing desmineralized water, steam, cooling water, air service and instruments and electrical energy, which are necessary inputs for the operation of different processes at work in the plant. The operations are carried on the soles of Assistive use large amounts of energy as heat and / or work, so it is of interest to evaluate energy

consumption and use of it, to have technical features that allow proposals aimed at optimizing energy consumption in these services. This assessment can be made using exergy analysis based on the simultaneous application of the first and second laws of thermodynamics. The exergy method has the feature of using the same parameter for evaluating the energy from the definition given by Bejan exergy (Bejan, 1997): "The Exergy is the maximum work that can develop when a system is in thermal imbalance , kinetic, and chemical potential with respect to the terms of reference state. " Against this background, modern analysis of energy use should be based on exergy analysis, and in this work has been applied to a plant auxiliary service in order to evaluate the potential for energy recovery in the same, and so have the information needed to subsequently propose actions for the efficient use of energy.

Nomenclature

Process description This section describes the plant and ancillary services from its component areas and sections that make up each area, it also describes the processes at work in each area and lists the teams the same. In the Figure 1 shows the diagram of the areas and sections that make up the plant and ancillary services. The areas are two: the power and electricity generation. The force area is composed of sections of steam generation, water demineralization, water cooling and air service and tools. The area of power generation is made up of the turbine section.

Greek letters

Force area This area comprises four sections: 1. Water demineralization section 2. Steam generation section 3. Cooling water section and 4. Air Section Service and instruments. The description of these sections is below.

Subndices

Figure 1. Areas and sections that make up the plant and ancillary services

1. Water demineralization section

steam generators, CB-1, CB-2, CB-3 and stew the ethylene plant.

This section is shown in Figure 2 and consists of 3 stages of demineralization with water treatment capacity of 31.5 l / s each, through 3 anions (WIA-1, 2 and 3) and 3 cations (WIC-1, 2 and 3) to give a total capacity of water demineralization of 94.5 l / s. Both cations (WIC-1, 2 and 3) and anions (WIA-1, 2 and 3) contain selective resin inside. In that case the flow of circulating water flows first through the cation and then the anion. This section is characterized by the formation of chemically pure water and ideal for use in steam generation equipment. Demineralised water is placed in two storage tanks and called TV-101 TV103 to 1589.8 m3 capacity each. Condensate returns from plants is stored in the tank TV-102 and mixed with demineralized water to feed the Deaerators ED-100 and supplied to the

2. Steam generation section

The steam required for the petrochemical plant is generated by three steam generators, two high pressure to 4.23 MPa with a generation capacity of 125 ton / h each and one medium pressure to 1.99 MPa, with a generation capacity of 125 t / h. the outline of this section as shown in Figure 3. The high pressure superheated steam to 4.23 MPa and 4000C is produced in the steam generators or CB-2 CB-3 and is supplied directly to the ethylene plant (high density, low density HDPE and LDPE) for use in the turbines. In addition, the ED100 requires deaereador vapor of 0.13 MPa, which is supplied by the steam generator CB-1, after pressure reduction from 1.99 to 0.13 MPa.

Figure 2. Outline of water demineralization section

Figure 3. Schematic of the steam generation section

3. Cooling water section This consists of two cooling towers (DE1 and CT-8). The cooling tower-1 with a capacity of 757 l / s, provides cooling water to the PEBD plant and cooling

tower CT-8, with a capacity of 5047 l/s, provides cooling water to the ethylene plant the PEAD plant and ancillary services. Figure 4 shows a schematic of this section.

Figure 4. Scheme of the cooling water section

4. Area of power generation In this section, the fuel gas is received in the gas metering station EMG-2, the ground pressure of 4.31 MPa. This section reduces the pressure to 2.25 MPa, which subsequently passed through two gas separators to remove condensate. Upon exiting the separator, the gas passes through a pressure control valve to reduce pressure up to 1.66 MPa, which is the pressure that is supplied to the two turbine generators. Fuel gas consumption is 220 m3/s are generated 19 MW of electrical power per turbine group, to 13.80 kV and 60 Hz, and subsequently raise its electrical potential to 23 kV and under these conditions the plants distributed the

process. This section is shown in Figure 5.

Evaluation methodology In this section the mathematical model used for exergetic assessment of plant equipment and ancillary services, according to as proposed by Moran (Moran, 2004). The teams are discussed in the open systems model (volume control), operating in steady state. The teams analyzed in this study are those that make up the plant and ancillary services described in Tables 1 to 4.

Figure 5. Outline the area of power generation.

The mathematical model used in this work is composed of the equations of the first and second law of thermodynamics, the equation of

balance of the exergy and exergetic efficiency equation, which indicated as equations (1) to (4):

Equation of the first law of thermodynamics

Equation of the second law of thermodynamics (entropy balance)

Balance equation of exergy

Equation of exergetic efficiency (second law efficiency)

Table 1. Components of the plant equipment and ancillary services Service Water demineralization unit Nomenclature Bike pump BA-10_A BA-10_B BA-10_C BA-100_A BA-100_B BA-101_A BA-102_A BA-102_B BA-103_A BA-103_C BA-106_A BA-106_B BA-107_A BA-107_B Turbo pump BA-100_C BA-100_D BA-101_A Heat exchangers ED-100 Moto Compresors BC-100_A BC-100_B BC-100_C Process
Water tank transfer to anions Water tank transfer to anions Water transfer UDA 100 Boiler feed water CB-2 and CB-3 Boiler feed water CB-2 and CB-3 Boiler feedwater CB-1 Deaereada water to ethylene plant Deaereada water to ethylene plant Deaereador water to ED-100 Deaereador water to ED-100 Demineralized water or pre-treated plant (PEAD) Water service PEAD and PEBD plants Condensed section 07 PEAD plant Water pre-treated PEAD plant Bolier feed water CB-2 and CB-3 Bolier feed water CB-2 and CB-3 Bolier feed water to CB-1 Deaereador Instrument air Air plant Air service

Table 2. Components of the plant equipment and ancillary services Service Nomenclature Process

Steam generating Steam generators steam generation unit Steam generation CB-1 unit Steam generation CB-2 Steam generation CB-3 Steam-stations of the steam generation section A steam or conditioning temperature 4,23 to EAVapor (AP) EAVapor (AMP) EAVapor (MBP) EAVapor (MBP)
4,23 Mpa sat (600 to 600 psi) Pressure reduction and / or upgrading 4,23 to 1,99 MPa (600 to 275 psi) Pressure reduction and / or upgrading 1,99 to 1,79 MPa (275 to 245 psi) Pressure reduction and / or upgrading 1,99 to 0,13 MPa (275 to 20 psi)

Table 3. Components of the plant equipment and ancillary services Service Cooling water section Nomenclature Byke pump DE-P1 DE-P1-A DE-P2 DE-P2-A BA-1-A BA-1-B BA-1-C BA-1-D BA-1-F Turbo pump BA-1-E Process
Cooling water DE-1 Cooling water DE-1 Cooling water DE-1 Cooling water DE-1 Cooling water C1-8 Cooling water C1-8 Cooling water C1-8 Recirculating water cooling CT-8 Recirculating water cooling CT-8 Cooling water C1-8

Table 4. components of the plant equipment and ancillary services Service Section of turbo generators Nomenclature Turbo generators TG-1 TG-2 Process
Electric power generation (19 MW) Electric power generation (19 MW)

The exergy analysis was applied to each of the teams considered in the Auxiliary Services Plant shown in previous tables, for each case simplifying the

mathematical model equations according to the situation analyzed. In Figures 6 to 12 show diagrams of the computers as well as in the Table 5

equations applicable to each of these teams.

Figure 6. Diagram of a jet pump

Figura 9. Diagram of a heat exchanger separate streams

Figure 7. Diagram of a turbo pump Figura 10. Diagram of a compressor motor

Figura 8. Diagram of a steam-station

Figura 11. Diagrama de un generador de vapor

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Results From the equations in Table 5 for each of the computers was raised exergy balance and calculated the energy supplied, the recovered exergy, the exergy destroyed and exergetic efficiency. For the first stage of Figure 2 (demineralization of water), calculations and results were: Conditions of water entering the system after pretreatment Therefore:

P = 1 atm T = 25C Velocity = 3m/s Velocity of water leaving the pump: 6,3 m/s Flow: 95,5 l/s

Now, according to the F1 table of text introduction to the thermodynamics of Vann Ness, the enthalpy at 25 C is:

To determine the balance exegetical pumps A, B and C, we have: As is equal to:

Where W = exergy supplied = exergy recovered I = irreversibility To calculate which is the exergy supplied to the pump, proceed to calculate each of the terms of the proposed equation:

The entropy at T = 25 C according to the F1 table Vann Ness text is

We calculate the density at T = 25 C. According to the density tables in the text of Fluid Mechanics by Potter and interpolation:

You know the value of , we can estmate , if we perform an interpolation to the values of enthalpy gives us Table F1:

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Therefore, the exergy supplied for each pump (BA-10 A/B/C) system is:

The efficiency of each of the pumps (BA-10 A/B/C) is given by: In consequence:

Now we calculate the irreversibility described as:

Following a similar approach for the rest of the plant equipment, we obtained the following results shown in Table 6:

Table 6. Components of the plant equipment and ancillary services Equipment Exergy supplied KW 30 30 30 447 447 261 112 112 56 56 Exergy recovered KW
10 10 10 174 174 158 53 53 27 27

Exergy destroyed KW
20 20 20 273 273 103 59 59 29 29

Exergetyc efficiency %
33,33 33,33 33,33 38,92 38,92 60,53 47,32 48,21 48,21 50,00

BA-10_A BA-10_B BA-10_C BA-100_A BA-100_B BA-101_A BA-102_A BA-102_B BA-103_A BA-103_C

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BA-106_A BA-106_B BA-107_A BA-107_B BA-1-A BA-1-B BA-1-C BA-1-D BA-1-F DE-P1A DE-P1 DE-P2 BA-1-E BA-100-C BA-100-D BA-101-B BA-103-B EAC-1 EAC-2 ED-100 BC-100-A BC-100-B BC-100-C C-752 CB-1 CB-2 CB-3 TG-1 TG-2

30 30 19 19 746 746 746 746 746 447 447 186 1714 625 625 625 174 2954 8914 4203 597 447 447 521 100899 109011 109011 74747 74747

15 15 15 13 511

15 15 4 6 235

50,00 78,95 68,42 68,50 68,50

511 511
511 511 296 296 97 521 296 296 158 25 2826 8729 2084 250 201 201 128 36917 62652 62652 19000 19000

235 235
235 235 151 151 89 1193 329 329 467 149 128 185 2119 347 246 246 393 63982 46359 46359 55747 55747

68,50 68,50
68,50 68,50 66,21 66,21 52,15 30,39 47,36 47,36 25,28 14,37 95,66 97,92 48,58 41,88 44,97 44,97 24,57 36,59 57,47 57,47 25,42 25,42

If we add the values in each column, we get: Total exergy supplied: 496750 KW Total exergy recovered: 219934 KW Total exergy destroyed: 276816 KW Consequently, efficiency is: the total exergetic For a better analysis, we classified the irreversibility rates in four categories according to their magnitudes, as shown in Table 7.

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High

Table 7. Classification irreversibility Regular Lower middle

low

Equipment CB-1 TG-1 TG-2 CB-2 CB-3 ED-100

KW 63982 55747 55747 46359 46359 2119

% 23,45 19,77 19,77 16,75 16,75 00,75

Equipment BA-101-B C-752 BC-100-A BA-100-C BA-100-D BA-100-A BA-100-B BA-1-A BA-1-B BA-1-C BA-1-D BA-1-F

KW
467 393 347 329 329 273 273 235 235 235 235 235

Equipment

KW 185 246 246 151 151 128 103

Equipment

KW 89 59 59 20 20 20 15 15 6 4 4 4 4 4

% 0,032 0,021 0,021 0,007 0,007 0,007 0,005 0,005 0,002 0,001 0,001 0,001 0,001 0,001

0,17 E-AC-2 0,14 BC-100-B 0,13 BC-100-C 0,12 DE-P1-A 0,12 DE-P1 0,10 E-AC-1 0,10 BA-101-A 0,08 0,08 0,08 0,08 0,08

0,07 DE-P2 0,09 BA-102-B 0,09 BA-102-A 0,05 BA-10-C 0,05 BA-10-B 0,05 BA-10-A 0,04 BA-106-B BA-106-A BA-107-B BA-103-C BA-103-A BA-107-A BA-1-E BA-103-B

In this table we see that the teams ranked in the category of irreversibility high (> 1000), seven and correspond to the steam generators, the turbine, the Deaerators and a hydraulic pump. Together, these teams produce 97.65% of the exergy destruction, but if we remove from this group Deaerators and hydraulic pump, the steam generators and turbine generators produce 96.88% of the irreversibility generated in the plant and ancillary services. The teams ranked in the category of regular irreversibility produce 1.3% of them, the computer group considered as irreversibility medium-low, contributing 0.44% and the last group, under teams irreversibility low, contributing only 0.12% of the total.

information shows that the use of energy in the plant is deficient, because in form global exergetic efficiency is 44.27%, indicating that only this fraction of the available energy is being used and the rest is destroyed. An important aspect of exergy analysis is to identify computers that have higher exergy destruction, which in this case were the steam generators, turbine generators, the deaereador and a hydraulic pump (97.65%). This information is necessary to make technical proposals aimed at improving energy use, paying special attention to these teams and significantly optimize the use of energy in the entire plant. A proposal to optimize the operation of this plant is to use the exergy flow of content in the flue gas of turbogenerators to power a heat recovery boiler. This will decrease the fuel they consume one of steam generators, saving fuel and reducing pollutant emissions to the atmosphere, thus contributing to environmental protection. Proposals such as these highlight the importance of evaluation

Conclusion This paper raised the foundations of exergy analysis and applied to a plant of Assistive of a petrochemical plant. This made it possible to assess the irreversibility delivered, retrieved and destroyed in each of the teams that make up the plant and its exergetic efficiencies associated with this

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of energy losses through the application of exergy method. The Continuous application of exergy analysis to Plant Auxiliary Services will identify the equipment or processes in which there is a greater destruction of exergy while proposing actions and programs to achieve more efficient use of energy in the plant.

References

Bejan, A, Advances Engineering Thermodynamics, 2nd edition, Jhon Wiley and Sons, 1997.

Moran, M.J., and Shapiro, H.N., Fundamentals of Engineering Thermodynamics", 5a. edicin, John Wiley and Sons, 2004.

Merle Potter, David Wiggert. Fluid Mechanics, 3rd edition, Thomson, 2002.

Pedro Quinto. Evaluation of energy recovery in a petrochemical plant assistant, Mechanical Engineering and Development Review, 2008.

Smith, Vann Ness., Introduction to Chemical Engineering Thermodynamics, 5th Edition, McGraw-Hill, 1996

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