Model-Based Identification and Analysis of the Energy Saving Potential in Batch Chemical Processes

Abstract

Optimization of energy consumption for reducing the relevant costs and environmental impacts is constantly gaining attention in chemical batch production. Existing methodologies focus on heat integration considering scheduling constraints and typically result in trade-offs between capital investment and operational costs. However, in multipurpose batch plants, even the allocation of energy flows and the consistent operation according to production recipes pose a great challenge due to batch-to-batch variability and lack of energy utility consumption meters. This paper utilizes a bottom-up modeling approach for energy utility consumption and proposes a method for model-based identification of the energy saving potential in chemical batch plants. The bottom-up models can accurately track the energy utility consumption at various production levels and are used as soft sensors for energy efficiency analysis studies. In this context, a set of energy key performance indicators (EKPIs) is proposed for quantifying efficiency in energy use, and an energy saving potential index (ESPI) based on historical plant performance serves as a shortcut method in the case of missing or inaccurate production recipes. The methodology is applied to an industrial multipurpose batch plant for specialty chemicals, exemplifying the obtained efficiency results and targeting energy saving potential for steam consumption.