Heat integration of reactors—II. Total flowsheet integration

Abstract

A consideration of second-law analysis has been extended from the heat exchanger network to an overall energy balance of a chemical process. This enables the simultaneous integration of all kinds of energy-active apparatus (e.g. reactors, compressors, turbines, boilers, refrigerators, coolers, heaters) and hot feeds or effluents into a process flowsheet. The apparatus and the feeds or effluents together represent a utility exchanger network (UEN), process streams are utilized by several types of energy (utilities) that are of a chemical, mechanical, electrical, transmissible, radiative, or heat flow origin. Inherent and avoidable utilities are distinguished. An action of each utility on the enthalpy change of the process stream is represented in a temperature—enthalpy diagram by the corresponding utility stream. Hot utility streams are composed into a hot composite curve (UCC). It sums up the energy inflows and energy production of the system, called energy donors. On the other hand, cold utility streams are composed into a cold UCC that comprises energy outflows and energy consumption (energy acceptors). Process streams are excluded in this step. By matching both UCCs the method enables the direct targeting of an economical overall utility system through is structural and parametric modifications. Targeting is facilitated by using general rules for appropriate integration of energy donors and energy acceptors relative to the utility pinch temperature. At the same time, the improved energy system changes the dynamical performances; the control configuration must be adopted to the new structure of the total system. The method is based on a detailed thermodynamic analysis of process units and is followed by an optimal thermodynamic synthesis of the total system. The final detailed parametrical optimization is similar to the classic pinch analysis. It deals with process streams and brings additional savings. The whole procedure has been tested on an existing chemical process and its effectiveness has been proved.