overview of heat recovery projects related to the chemical … · 2018. 4. 11. · preem lysekil...

Heat and Power Technology Dept of Energy and Environment

IEA IETS Excess Heat Workshop, Lisbon, 26-27 May 2014

Overview of Heat Recovery projects related to the Chemical

Cluster in Stenungsund

Professor Simon Harvey

Chalmers University of Technology

Appendix 3: Presentations from the workshops

Page 153 of 367



105 kton

390 kton

1230 kton

590 kton

11 kton

115 kton

110 kton

531 kton

43,6 GWh

206 kton

113 kton

84 kton (??)

636 kton

111 kton

47,4 GWh

Chemical Cluster Stenungsund: Production and emissions 2011 CO2 41 kton

CO2 54 kton

CO2 56 kton

CO2 101 kton

CO2 650 kton

TOTAL Emissions of CO2 approx. 900 kton/yr


Page 154 of 367



The potential of inter-process heat integration: Opportunities for

improving energy efficiency in Stenungsund – Sweden’s largest

chemical cluster

Key figures for total site:

• Total CO2 emissions: ~900 kton/yr

• Total heating demand: 442 MW 320 MW

are covered by internal heat recovery

• Current utility usage fr fired boilers: 122 MW

• Can theoretically be reduced to 0 MW

through inter-process heat integration!

How this can be accomplished:

• New circulating hot water systems 50-100°C

• Harmonization of utility pressure levels to

enable heat exchange between process

plant utility systems

• Rebuild steam heaters for 2 bar(g) operation

• Fire process off-gases in different boilers

Substantial opportunities for energy efficiency through Inter-process heat recovery


Page 155 of 367



0

100

200

300

400

500

600

700

800

2

3

4

5

6

7

8

0 10 20 30 40 50 60

To

tal fixe

d c

ap

ita

l [M

SE

K]

Estim

ate

d P

BP

[yr

]

Amount of heat recovery [MW]

By-product fuelredistribution fromPerstorp to Cracker

Steam demandat Pertorp is met

Steam demandat Pertorp andINEOS is met

System 20

System 30System 40 System 50

System 54

Consequences of increased heat recovery with the HW systems on the

overall PBP; red squares: Total fixed capital, blue diamonds: PBP.

Detailed design of specific heat recovery systems has

been accomplished in a recent study at Chalmers


Page 156 of 367



Perstorp Borealis PE

Borealis Cracker

Heat sources

Heat sinks

E-443357

Hot water pipe

Steam pipe

Hot water pump

E-443201

E-1608 E-1845

HW1(79/55 °C)

E-442161

20.7 MW

22.8 MW

20.7 MW

Losses:

2.1 MW

Current LP steam demand: 25.7 MW

System 20

Total investment:

199 MSEK

Total hot utility savings:

20.7 MW

Payback period:

App. 3.2 years

New HXs: 5

System 20 can be pre-fitted for

extension to System 50 (extra cost 19

MSEK)


Page 157 of 367



Total investment:

598 MSEK (199)

Total hot utility savings:

50,8 MW (20.7)

Pay back period:

App. 3.9 years (3.2)

New HX: 32 (5)

Current LP steam demand: 25.7 MW Borealis PE

Borealis CrackerINEOS

Heat sources

Heat sinks

Potential heat sink

for excess utility

E-443357

E-1701

81,77,57,15,

72,50,31,2,13

Reboiler HTC, Air to spray dryer,

Air to two dryers

Perstorp

Potential

demand:

40.3 MW

Current LP steam demand: 2.5 MW

Hot water pipe

Steam pipe

Fuel pipe

Hot water pump

Potential

demand:

10.5 MW

E-443201

E-1608 E-1845

E-1890

56

Condensor

49

Condensor

47 flash steam

Condensor

65 Rx1

Cooler16

Cooler

24

Reb

E-1606Y

E-1802CT1701

cond

Preheat

demin

E-1609

E-442161

Rx2

Cooler

10.5 MW

40.3 MW

24 MW

5.5 MW

26.8 MW

Losses:

2.7 MW

27.7 MW

23 MW

2.2 MWLosses:

2.5 MWFuel:

21 MW

System 50HW1

(79/55 °C)

HW2(97/75 °C)

9x

4x


Page 158 of 367

Studying competition between internal heat recovery

and excess heat export

Lina Eriksson

SP – Energiteknik

Examinator and main supervisor: Simon Harvey

Co-supervisor: Matteo Morandin

Timeframe: September 2013 – December 2015


Page 159 of 367

Part of collaborative project package investigating

different aspects of regional district heating

• Other sub-projects:

– “How district heating market models influence industrial excess

heat usage” – SP, Magnus Brolin

– “Assessment of Sustainability of industrial waste heat - the

Stenungsund case” – Chalmers and IVL, Erik Ahlgren and Thomas

Ekervall

– “Analysis of need and demand for sustainable district heating from

the large customers”– Business Region Gothenburg, Lars Bern

• Scientific co-ordination of the projects lead by Thore Berntsson

– Exchange results

– Use common assumptions


Page 160 of 367

Aim: Promote rational use of industrial excess heat, and

provide conditions for creating a sustainable energy system.

The primary goal is to understand:

• Technical feasibility, profitability and environmental impact of

the use of excess heat for district heating

• The competition between the production of district heating

and opportunities within industry for heat recovery

Aim and goal Appendix 3: Presentations from the workshops

Page 161 of 367

Two case studies:

PREEM Lysekil

Chemical cluster in Stenungsund

1. Identify some different levels of use of excess heat internally for:

a. Heat recovery within each industry / sub-process

b. Exchange between industries / / sub-processes

c. Investigate the possibilities for using heat pumps

2. Identify for each level and area of use above:

a. Quantity and temperature of the remaining excess heat for district heating delivery

b. Opportunities to increase the delivery of district heat by using heat pumps

3. Evaluate costs and CO2 emissions for the different cases based on some different scenarios

for:

a. Marginal production for district heating (what is replaced)

b. Marginal production of electricity (what is replaced)

c. Policy instruments (such as future costs of emitting CO2)

Project outline

District Heating

Heat recovery

Marginal production


Page 162 of 367

Project outline

District

heating

Heat recovery

1. S

2. S

3. h

4. Identify and include some other technologies:

a. Biorefinery concepts

b. Electricity generation with ORC

c. Drying of biomass

d. CCS, etc.

Evaluate these in the manner described in step 2 and 3, in terms of economy, CO2

emissions and impact on the possibilities to produce district heating.

5. Find some optimal solutions for utilisation of excess heat with regards to costs and climate

impact (CO2) for the different scenarios that were created in step 3.

Marginal production

Biorefinery

ORC

CCS


Page 163 of 367

Potentials estimated using ACLC - Actual Cooling

Load Curves


Page 164 of 367

Industrial Excess Heat for District Heating

Comparison of potentials from top-down and bottom-up

studies for energy-intensive process industries

Based on the MSc Thesis project conducted

by Moa Swing Gustafsson

2013

Professor Simon Harvey

Heat and Power Technology Group

Department of Energy and Environment

Chalmers University of Technology


Page 165 of 367

Background

• In response to EU’s Energy Efficiency Directive: Ongoing

legislation changes in Sweden aim to facilitate third party

access to DH networks (in particular industrial processes)

• 4.1 TWh/yr of industrial excess heat was delivered to DH

networks in Sweden in 2012 (total DH heat delivered

2012: 50 TWh)

• A number of studies indicate that there is a potential for

increasing excess process heat recovery for DH delivery


Page 166 of 367

Major study commissioned by the Swedish

DH Association (SDHA) in 2009

Statistical data was compiled for excess heat deliveries from industrial plants.

This data was related to the corresponding fuel usage for these plants.

Sector Excess heat delivered per unit of fuel

usage [%]

Pulp industry 2.8

Paper industry 3.2

Chemicals and chemical products 24.3

Ferrous and non-ferrous metals 2.5

Based on this data it was estimated that the potential for excess recovery

for DH purposes is 6.3 TWh/yr compared to 4.1 TWh/yr currently delivered


Page 167 of 367

Objective of the MSc thesis project

Compare the potentials estimated in the SDHA report with

results generated using pinch analysis for case studies in key

industrial sectors

5 industrial plant case studies were studied

• Chemical pulp and paperboard mill

• Chemical pulp mill

• Mechanical pulp and paper mill

• Steel mill

• PVC plant


Page 168 of 367

Brief presentation of Pinch analysis

• Well established tool for analysing heat flows in industrial

processes with liquid and gas flows.

• Allows heat recovery targets to be established: Determines

minimum cooling and heating demand of a process for a

given value of minimum temperature difference allowed in

the heat exchangers (∆Tmin)

• Requires the following data for process streams that must

be heated or cooled

• Start temperature

• Target temperature

• Mass Flowrate

• Specific heat capacity


Page 169 of 367

Process streams Energy analysis

Basics of Pinch Analysis

P

r

o

c

e

s

s

Cooling

Heat

Feedstock Products

El

Heat

Kylning

T

Heat

balances

0

20

40

60

80

100

120

140

160

0 10000 20000 30000 40000 50000 Q

T (

°C)

Hot streams

Cold streams

Theoretical minimum heating demand

Teoretical cooling demand

Graphically

Process

Pinch Depends on choice of ΔTmin

Maximal internal

Heat recovery


Page 170 of 367

Grand composite curves

The grand composite curve (GCC) illustrates the net energy flow in each temperature interval


Page 171 of 367

Estimating the potential for export of excess process

heat to a DH network using the GCC

QC

Excess heat is discharged to

CW if no other options are

available

DH

Tshift QH


Page 172 of 367

Quantification of maximal excess heat recovery

DH

Temperature profile

for DH water

TDH,Supply

(Target

Temperature)

Tshift

Slope of line is

related to flowrate

QH,Min

Process GCC

)( Return,,, DHSupplyDHWpWDH TTCFQ

TDH,Return

(Start

Temperature)

Case 1: DH supply Ttarget can be reached.

All process excess heat can be

used for WW production.


Page 173 of 367

DH

Tshift QH,Min Case 2: All process excess heat

cannot be delivered to DH network.

(DH supply Ttarget too high)

Utility pinch activated.

DH flow is limited

by DTmin

Cold utility for

remaining cooling load

TDH,Supply

TDH,Return


Page 174 of 367

• DH export potentials estimated from GCCs for 4 different values of

∆Tmin

0 K 5 K 10 K 15 K

• In practice, few processes achieve the energy target. It is also of

interest to estimate potentials based on the composite curve of

process streams that are cooled in process coolers (ACLC Actual

Cooling Load Curve)

• These numbers are compared with the estimates obtained using the

SDHA procedure

Results presented in the thesis

theoretical maximum for

reference


Page 175 of 367

Limitations and assumptions

• All work based on case studies (pinch analysis studies

conducted within our group)

• District heating water temperatures

- Return temperature: 55°C

- Supply temperature: 85-105°C

• Required minimum ∆T between the district heating water

and process streams

- 7 K


Page 176 of 367

Chemical pulp and paperboard mill


Page 177 of 367

0

50

100

150

200

250

0 50000 100000 150000 200000 250000

Tsh

ift

(°C

)

Q (kW)

Grand Composite Curve ΔT=10

GCC DH at 85°C DH at 95°C DH at 100°C DH at 105°C


Page 178 of 367

0

50

100

150

200

250

0 50000 100000 150000 200000 250000

T (

°C)

Q (kW)

Grand Composite Curve ΔT=15

GCC


Page 179 of 367

Results

∆Tmin

DH export potentials [MW] for

varying DH water supply

temperature levels [°C] Pinch

temperature

[°C] 85 95 100 105

0 K 28.0 25.6 24.9 - 111.0

5 K 24.2 22.6 21.9 - 108.5

10 K 12.6 12.1 12.0 11,9 110.4

15 K - - - - (60)

ACLC Estimate 14.3 12.5 12.0 11.5

SDHA estimate

Pulp: 10.0 MW

Paper: 11.4 MW


Page 180 of 367

PVC plant


Page 181 of 367

-50

0

50

100

150

200

250

0 5000 10000 15000 20000 25000 30000 35000

Tsh

ift (°

C)

Q (kW)

Grand Composite Curve

GCC DH at 85°C DH at 95°C DH at 100°C DH at 105°C


Page 182 of 367

Estimated potentials for DH delivery

from PVC plant

∆Tmin

DH water supply temperature [°C]

85 95 100 105

0 K 17.6 MW 5.0 MW 4.0 MW -

5 K 21.5 MW 6.5 MW 5.3 MW 4.6 MW

10 K 22.2 MW 7.8 MW 6.3 MW 5.4 MW

15 K 23.0 MW 10.1 MW 8.2 MW 7.1 MW

ACLC 25.6 MW 20.4 MW 18.3 MW 16.9 MW

SDHA Estimate

13.1 MW


Page 183 of 367


Page 184 of 367

Case study 1

Chem. P&P

mill

Case study 2

Chem. Pulp

mill

Case study 3

Mech. P&P

mill

Case study 4

Steel works

Coking plant

Case study 4

Steel works

rest of plant

Case study 5

PVC Plant

DH [°C] 85 105 85 105 85 105 85 105 85 105 85 105

ΔTmin=0 28.0 - 38.2 - - - 4.4 1.5 14.6 14.6 17.6 -

ΔTmin=5 24.2 - 42.2 - 2.3 - 4.4 1.6 15.0 15.0 21.5 4.6

ΔTmin=10 12.6 11.9 45.5 - - - 4.5 1.7 15.4 15.4 22.2 5.4

ΔTmin=15 - - 48,9 - - - 4.5 1.8 16.2 16.2 23.0 7.1

ACLC 14.3 11.5 - - - - 11.0 7.2 17.2 17.2 25.6 16.9

SDHA

estimate

10.0-11.4 9.8 1.6-1.8 6.6 6.7 (13.1)

Estimated potentials for DH export [MW]


Page 185 of 367

Conclusions • The SDHA approach usually underestimates the

potential for DH export compared to estimates using

pinch analysis

• The potentials based the actual cooling (ACLC) are usually higher since they (often) reflect inefficient use of

heat within the process

• ”Beauty is in the eye of the beholder”. There is no clearcut definition of excess heat

• Even if the ”excess heat” at the plant isn’t at a high enough temperature to produce DH it may be beneficial

to recover the excess heat available and provide final

heating to the required delivery temperature with steam

(or other hot utility)


Page 186 of 367

Regional Energy System


Page 187 of 367

2 2

Idea: Benefits from an integrated system Appendix 3: Presentations from the workshops

Page 188 of 367

3 3

RESO, Studied region

Distance approx 50 km Heating demand approx 7 TWh/year

Sandviken Gävle

Skutskär

StoraEnso

KorsnäsSandvik

40 km

Sweden

Sandviken Gävle

Skutskär

StoraEnso

KorsnäsSandvik

40 km

Sweden


Page 189 of 367

4 4

When the systems are integrated

§  The profit for integrating the system is up to 240 MSEK* per year compared to the present system §  Average: 140 MSEK/year* §  Payback time: 2-11 years*

§  District heating market: 150 – 620 GWh/year* §  Average: 430 GWh/year*

§  Electricity production: 850 – 1360 GWh/year* §  Average: 1080 GWh/year*

*based on 30 scenarios with different investment possibilities


Page 190 of 367

5 5

Lowest cost solution, [GWh]

352 7 53 40 28 0

0 515

Sandviken Energy

Gävle Energy

Älvkarleby Fjärrvärme

Korsnäs Sandvik

168 0

StoraEnso Skutskär

0 39

Heat market

Karskär Energy


Page 191 of 367

6 6

Reasons for the profits when integrating the systems to one system

§  The boilers are used in a better way §  It is possible to produce more electricity §  Investments


Page 192 of 367

7 7

Influence on each operator, compared to separate systems*

-150

-100

-50

0

50

100

150

200

GEAB SEAB Sandvik KEAB Skutskär

MSEK/year

Scenario 5Scenario 10Scenario 14Scenario 18Scenario 21Scenario 24Scenario 25Scenario 26Scenario 28

*9 scenarios are analyzed in-depth


Page 193 of 367

8 8

The boundaries for CO2-emission accounting

§  Swedish average electricity mix §  European average electricity

mix §  Present marginal production


Page 194 of 367

9 9

Reduction of CO2 emissions, compared to reference scenario

0100200300400500600700800

Marginal Coal Marginal NGCC Average Swedish

Scenario

kton

CO

2/år Scenario 5

Scenario 21Scenario 25Scenario 28


Page 195 of 367

10 10

Idea: Benefits from an integrated system Appendix 3: Presentations from the workshops

Page 196 of 367

11 11

Development of a sustainable, competitive society with high security of supply

§  Develop a common infrastructure for energy and other resources §  Regional cooperation on infrastructure - Skutskär, Gävle, Sandviken och

Hofors, Falun and Borlänge!


Page 197 of 367

Projects at Linköping university

Excess heat

Mats Söderström, Energy Systems, Linköping university


Page 198 of 367

Contents

§  Harvesting

§  Quantification

§  Systems analysis §  Realization


Page 199 of 367

IR images from cooling bed 1 (CB1) and cooling bed 2 (CB2). The tubes move over the bed in the direction of the arrow. The diagrams to the right of the images show the temperature profile of the cooling bed along the arrow. Source: Johansson MT, Wren J, Söderström M. Submitted to Applied Energy

0

200

400

600

800

1000

Tempe

rature (°C)

Length profile of cooling bed 1

CB 1

0

200

400

600

800

1000

Tempe

rature (°C)

Length profile of cooling bed 2

CB 2

In this case: •  Measurements using IR

camera and thermocouples

•  Possible to transfer 0,3 GWh annually to water and air

Cooling beds in the steel industry Appendix 3: Presentations from the workshops

Page 200 of 367

Electricity generation from low-temperature industrial excess heat

Excess heat with a temperature below 230 C Technology alternatives

Thermo Electric Generator – F2F200W TEG Power Organic Rankine Cycle – 750 kWel Opcon Powerbox PCM-motor – 100-200 kWel Exencotech

Excess heat

Cooling water from EAF – ORC Cooling water from ingot casting – PCM electricity generation 3,5 GWh

Economy TEG – not suitable ORC for temperatures over 80 C PCM for temperatures below 80 C

Källa: Johansson MT, Söderström M, Electricity generation from low-temperature industrial excess heat – an opportunity for the steel industry. Energy Efficiency 6 (2013) 1-13.


Page 201 of 367

Excess heat today = ca 35 GWh Potential excess heat = ca 90 GWh !!

DH to Ovako 45 GWh Electricity and Fuels

700 GWh

DH

50 GWh

Wood

chips

100 GWh

El /oil

15 GWh

Excess heat

35 GWh

Supply to HEAB

El production

4 GWh

HEAB

Steam to Ovako 33 GWh

Ovako


Page 202 of 367

Survey of industry in Örebro och Östergötland counties

0

20

40

60

80

100

120

0

100

200

300

400

500

600

700

800

900

25 30 35 45 55 70 90 160

200

350

Not specified

GWh/year (A

ir/Flue

gases)

GWh/year (W

ater)

Temperature (°C)

Water

Flue gases

Air

•  Cooperation with county boards •  Energy intensive industries •  Responses from industries representing 10,5 of 12,5 TWh •  Today 107 GWh of excess heat is used in district heating •  Fig shows unused excess heat 1480 GWh •  146 GWh in flue gases over 160C •  Uppscaling to national level - 2TWh

Källa: Broberg S, Backlund S, Karlsson M, Thollander P, Industrial excess heat deliveries to Swedish district heating networks: drop it like it´s hot. Energy Policy 51 (2012) 332-339


Page 203 of 367

Survey of industry in Gävleborg county

0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0

20

40

60

80

100

120

140

160

180

200

GWh/year (H

eat in material)

GWh/year (W

ater/Flue gases/Air)

Temperature (°C)

Water

Fluegases

Air

•  Cooperation with the county board •  Survey to the energy manager in 58 industries •  Responses from industries representing 9,5 of 11,2 TWh •  Today 220 GWh is used in district heating •  Fig shows unused excess heat 800 GWh •  Over 100 C: ca 300 GWh (water and gases)

Källa: Broberg Viklund S, Johansson MT, Technologies for utilization of industrial excess heat: Potentials för energy recovery and CO2 emission reduction. Energy Conversion and Management 77 (2014) 369-379


Page 204 of 367

Technologies for utilization of excess heat based on the survey of Gävleborg county

Case 1: to district heating water over 95 C Gases over 100 C Hot material ca 90 GWh to district heating

Case 2: to electricity generation

Hot material 1000 C TPV Gases and water over 80 C ORC Water under 80 C PCM –motor ca 25 GWh electricity

Källa: Broberg Viklund S, Johansson MT, Technologies for utilization of industrial excess heat: Potentials för energy recovery and CO2 emission reduction. Energy Conversion and Management 77 (2014) 369-379.


Page 205 of 367

Systems analysis

•  Based on input data from the Gävleborg survey

•  System optimization reMIND

•  Energimarket scenarios ENPAC

Results: •  All available excess heat is

used

•  ORC is not used

•  CO2-emissions decrease in all scenarios, decrease depends on what is replaced by the excess heat

Broberg S, Karlsson M, Systems analysis and CO2 reductions using industrial excess heat. Int Conf on Applied Energy 2013, Pretoria


Page 206 of 367

Idea: Benefits from an integrated system Gävleborg county


Page 207 of 367

Thanks!


Page 208 of 367

We also do:

•  Biogas applications in industry – excess heat •  Excess heat and policies


Page 209 of 367

overview of heat recovery projects related to the chemical … · 2018. 4. 11. · preem lysekil...

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