Heat Integration retrofit analysis—an oil refinery case study by Retrofit Tracing Grid Diagram

doi:10.1007/s11705-015-1520-8

Front. Chem. Sci. Eng.

2015, Vol. 9

Issue (2) : 163-182 https://doi.org/10.1007/s11705-015-1520-8

RESEARCH ARTICLE

Heat Integration retrofit analysis—an oil refinery case study by Retrofit Tracing Grid Diagram

Andreja NEMET¹,Jiří Jaromír KLEMEŠ^1,^*(

),Petar Sabev VARBANOV¹,Valter MANTELLI²

1. Centre for Process Integration and Intensification CPI², Faculty of Information Technology, Egyetem utca 10, 8200 Veszprém, Hungary
2. IPLOM SpA, Via C. Navone 3B, 16012 Busalla, Genoa, Italy

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Abstract

Heat Integration has been established over the last decades as a proven chemical engineering methodology. Two design implementations are often used in the industry: grassroots and retrofit. Although various methods have been developed for retrofit, it still needs more development to ensure simultaneously thermodynamic feasibility and economic viability. In this paper, a novel graphical approach has been developed to facilitate the understanding of the current situation and scope of improvement. The Retrofit Tracing Grid Diagram presents all streams and heat exchangers in temperature scale and the heat exchangers are clearly separated from each other, enabling clear visualisation of the current state. The tool incorporates the previously developed Cross-Pinch Analysis as well as path approach for retrofit. Additionally, the non-vertical heat transfer can be evaluated. The application of the developed tool has been validated on an oil refinery case study. The applicability of the tool is evident as it can reveal additional options for modification that none of the previous methods considered.

Keywords Heat Integration retrofit Pinch Analysis thermodynamic approach oil refinery

Corresponding Author(s): Ji?í Jaromír KLEME?

Issue Date: 14 July 2015

Cite this article:

Andreja NEMET,Ji?í Jaromír KLEME?,Petar Sabev VARBANOV, et al. Heat Integration retrofit analysis—an oil refinery case study by Retrofit Tracing Grid Diagram[J]. Front. Chem. Sci. Eng., 2015, 9(2): 163-182.

URL:

https://academic.hep.com.cn/fcse/EN/10.1007/s11705-015-1520-8
https://academic.hep.com.cn/fcse/EN/Y2015/V9/I2/163

Fig.1 The plus-minus principle for heat integration

Fig.2 Algorithm of data reconciliation

Tab.1 Example of data arrangement

Fig.3 Area-Energy plot (after [4])

Fig.4 Possible violation of heat recovery pinch

Fig.5 Path in HEN [10]

Fig.6 Cross-pinch heat transfer

Fig.7 Possible modification of the HE with Cross-Pinch heat transfer

Fig.8 Non-vertical heat transfer

Fig.9 Possible modification of the heat exchanger with non-vertical heat transfer

Fig.10 Retrofit tracing grid diagram

Fig.11 Utility path in graphical representation, when the non-integrated part of hot stream is a) above and b) below temperature of the integrated part

Fig.12 a) Re-sequencing options in graphical representation and b) the proposed modification

Fig.13 Identification of enhancing heat recovery opportunities by applying a new HE

Fig.14 Possible modification in case of a) highly non-vertical heat transfer via b) removing one of HEs (with possibility of re-using it) and applying a new HE

Fig.15 Hot water and steam generation options

Fig.16 GCC for Unit 1900 when a) ΔT_min = 10 °C and b) ΔT_min = 20 °C

Fig.17 Current HEN in Unit 1900

Fig.18 Heat transfer across the pinch in Unit 1900 for scenario HSS

Fig.19 Utility path in Unit 1900 in scenario HSS

Tab.2 Pinch point and heat transfer across the pinch in Unit 1900 for each scenario

Fig.20 Possible modification involving streams H55-C28, H55-C23 or H55-C24, H53-C23 or H53-C24

Tab.3 Results of modification H55-C28, H55-C23 or C24, H53-C23 or C24

Tab.4 Results of modification H55-C28, H55-C23 or C24, H53-C23 or C24

Tab.5 Results of modification H55-C20, H55-C23, H53-C23

Fig.21 Possible modification involving streams H49-C19, H64-C19 and H64-C27

Tab.6 Results of modification H49-C19, H64-C19 and H64-C27

Tab.7 Results of modification H49-C19, H64-C19 and H64-C20

Tab.8 Heat transfer of new HE between H64-C20

Tab.9 Summary of the possible modification for enhancing heat recovery

Fig.22 Hot water and steam generation options in Unit 1900

Tab.10 Hot water generation options in Unit 1900

Tab.11 LP steam generation potential

Tab.12 MP steam generation options in Unit 1900

Tab.13 Economic assessment of modifications proposed for enhancing heat recovery

Tab.14 Economic assessment of hot water generation options

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