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2 pages, 165 KiB

Open AccessEditorial

Advances in Energy System Synthesis and the Energy–Water Nexus in Industry

by Yufei Wang, Jui-Yuan Lee and Haoran Zhang

Processes 2023, 11(7), 2212; https://doi.org/10.3390/pr11072212 - 23 Jul 2023

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Abstract

Energy and water are key resources for human life and industry production [...] Full article

(This article belongs to the Special Issue Advances in Energy System Synthesis and Energy-Water Nexus in Industry)

Research

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25 pages, 8260 KiB

Open AccessArticle

A Novel Step-by-Step Automated Heat Exchanger Network Retrofit Methodology Considering Different Heat Transfer Equipment

by Kexin Xu, Kang Qin, Hao Wu and Robin Smith

Processes 2022, 10(8), 1459; https://doi.org/10.3390/pr10081459 - 26 Jul 2022

Cited by 2 | Viewed by 3320

Abstract

Improving the energy efficiency in heat exchanger networks (HENs) remains a significant industrial problem, specifically in energy-intensive operations. A particular method for such an objective is the modification of HENs at the equipment-use level, where structural changes take place and units within the [...] Read more.

Improving the energy efficiency in heat exchanger networks (HENs) remains a significant industrial problem, specifically in energy-intensive operations. A particular method for such an objective is the modification of HENs at the equipment-use level, where structural changes take place and units within the network are moved, replaced and/or removed. This practice is usually known as retrofit. The objective of a retrofit is to maximize the heat recovery using the minimum modifications possible and minimum retrofit cost. Traditional retrofit techniques would normally consider one type of heat exchanger (based on the original network) with no additional design features (i.e., heat transfer enhancement technologies). The expansion of such alternatives is limited by practical use and availability of theoretical methods. In this context, the inclusion of high-performance heat exchangers such as plate heat exchangers (PHEs) has not been widely explored, even when their design and operational advantages are known. In this work, a new step-by-step automated HENs retrofit approach based on Pinch Analysis is proposed. The approach is possible to identify the best modification, its location within the network, and its cost simultaneously. Moreover, to increase energy savings, this work presents a strategy that seeks to utilize high efficiency heat exchangers such as plate heat exchangers for retrofit. A distinctive feature of this new method is the ability to handle different minimum approach temperatures, given the different types of exchangers, within the optimization of HENs. Three cases are studied using this methodology to quantify the potential benefits of including PHEs in HEN retrofits, via the analysis of the retrofit cost. Results are compared with a baseline consisting in the same network, where only Shell-and-Tube-Heat-Exchangers (STHXs) are used. In addition, the results demonstrate that this methodology is flexible enough to be applied in a wide range of retrofit problems. Full article

(This article belongs to the Special Issue Advances in Energy System Synthesis and Energy-Water Nexus in Industry)

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16 pages, 2266 KiB

Open AccessArticle

A New Computer-Aided Optimization-Based Method for the Design of Single Multi-Pass Plate Heat Exchangers

by Kexin Xu, Kang Qin, Hao Wu and Robin Smith

Processes 2022, 10(4), 767; https://doi.org/10.3390/pr10040767 - 14 Apr 2022

Cited by 8 | Viewed by 3688

Abstract

Plate heat exchangers (PHEs) have significant potential to improve energy efficiency in the process industries. However, realizing their full potential to achieve such energy savings requires a systematic approach to screen the many options available. Thus, this work presents a generalized novel approach [...] Read more.

Plate heat exchangers (PHEs) have significant potential to improve energy efficiency in the process industries. However, realizing their full potential to achieve such energy savings requires a systematic approach to screen the many options available. Thus, this work presents a generalized novel approach for the optimal design of both gasket and welded plate heat exchangers, with different plate geometries and flow configurations. A new design method coupled with an optimization framework is proposed to obtain the optimal solution with minimum total transfer area by setting up a series of relations between temperatures among each single-pass block with known inlet and outlet temperatures of process streams. An MINLP mathematical model is developed to select the best combination of the flow pass configuration and available commercial plate geometries within practical design constraints. The differences between the design methodology of gasket and welded PHEs are highlighted. Two case studies are used to demonstrate the proposed method for both gasket and welded PHEs. Results show that better design with reduced heat transfer area by 10.71% and design time by 83.3% is obtained compared with previously proposed approaches. Full article

(This article belongs to the Special Issue Advances in Energy System Synthesis and Energy-Water Nexus in Industry)

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12 pages, 3509 KiB

Open AccessArticle

Evaluation and Improvement of the Performance of a Wellhead Multistage Bundle Gas–Liquid Separator

by Xianglong Zhuge, Xiangdong Qi, Shanzhe Wang and Yang Liu

Processes 2022, 10(4), 632; https://doi.org/10.3390/pr10040632 - 24 Mar 2022

Cited by 3 | Viewed by 2323

Abstract

A wellhead multistage bundle gas–liquid separator combining a gas–liquid cylindrical cyclone (GLCC) with multi-tube bundle components is expected to improve the gas–liquid separation performance. However, there is no unified understanding of the factors influencing the separation performance of the separator. The continuous improvement [...] Read more.

A wellhead multistage bundle gas–liquid separator combining a gas–liquid cylindrical cyclone (GLCC) with multi-tube bundle components is expected to improve the gas–liquid separation performance. However, there is no unified understanding of the factors influencing the separation performance of the separator. The continuous improvement and applications of the separator are restricted. This paper evaluated the performance of the separator using a numerical simulation method. The results indicate that the separation flow field evolves to be uniform with the increased water cut when the gas–oil ratio and flow rate remain constant. Compared with a 30% water cut, the separation efficiency at a 50% water cut increased by 5.88%. When the gas–oil ratio and water cut remained constant, the swirl effect of the primary separation was enhanced. The separation efficiency increased to more than 70% when the flow rate was 15 m/s. When the flow rate and water cut remained unchanged, the pressure of the separation flow field was reduced. However, when the gas–oil ratio was greater than 160 m³/t, the flow field trace density of the secondary separation bundle was reduced, and the separation efficiency was also lower than 60%. The separation efficiency can be further improved by optimizing the number and diameter of secondary separation bundles. Full article

(This article belongs to the Special Issue Advances in Energy System Synthesis and Energy-Water Nexus in Industry)

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32 pages, 3940 KiB

Open AccessFeature PaperArticle

An Integrated Optimization Model for Industrial Energy System Retrofit with Process Scheduling, Heat Recovery, and Energy Supply System Synthesis

by Anton Beck, Sophie Knöttner, Julian Unterluggauer, Daniel Halmschlager and René Hofmann

Processes 2022, 10(3), 572; https://doi.org/10.3390/pr10030572 - 15 Mar 2022

Cited by 13 | Viewed by 4311

Abstract

The urgent need for CO

_{2}

reduction is calling upon the industry to contribute. However, changes within local energy supply systems including efficiency enhancement are bound to several economical and technical constraints, which results in interfering trade-offs that make it difficult to find [...] Read more.

The urgent need for CO

_{2}

reduction is calling upon the industry to contribute. However, changes within local energy supply systems including efficiency enhancement are bound to several economical and technical constraints, which results in interfering trade-offs that make it difficult to find the optimal investment option for CO

_{2}

mitigation. In this article, a new optimization model is presented that allows to optimize the design and operation of a supply and heat recovery system and production scheduling simultaneously. The model was used for retrofitting of a small brewery’s local energy system to identify decarbonization measures for eight potential future scenarios with different technical, economical and ecological boundary conditions. The results show that the proposed cost-optimized changes to the current energy system only slightly reduce carbon emissions if decarbonization is not enforced since the optimal solutions prioritize integration of photo voltaic (PV) modules that mainly substitute electricity purchase from grid, which is already assumed to be carbon free. However, enforcing decarbonization rates of 50% for the assumed future boundary conditions still results in cost savings compared to the current energy system. These systems contain heat pumps, thermal energy storages, electric boilers, and PV. Battery storages are only part of the optimal system configuration if low to moderate decarbonization rates below 50% are enforced. An analysis of marginal costs for units not considered in the optimal solutions shows that solar thermal collectors only require small decreases in collector cost to be selected by the solver. Full article

(This article belongs to the Special Issue Advances in Energy System Synthesis and Energy-Water Nexus in Industry)

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21 pages, 2909 KiB

Open AccessFeature PaperArticle

Optimal Design and Operation of Multi-Period Water Supply Network with Multiple Water Sources

by Wenjin Zhou, Kashif Iqbal, Xiaoming Lv and Chun Deng

Processes 2021, 9(12), 2143; https://doi.org/10.3390/pr9122143 - 27 Nov 2021

Cited by 6 | Viewed by 2859

Abstract

A water supply network is an essential part of industrial and urban water systems. The water intake in a conventional water supply network varies periodically over time, depending on the amount of available water resources and the demand at water sinks or water-using [...] Read more.

A water supply network is an essential part of industrial and urban water systems. The water intake in a conventional water supply network varies periodically over time, depending on the amount of available water resources and the demand at water sinks or water-using units. This paper establishes a super-structural mathematical model for the optimal design and operation of a multi-period water supply network with multiple water sources. It considers the flow rate fluctuation of raw water availability and the demand of water sinks during different periods. The influence of multi-period demand variation on technology and the capacity selection of desalination water stations is examined, which affects the overall cost of the water supply network. The operating cost penalty factor is introduced, which quantitatively clarifies how the network operating status influences the operating costs. The comparison results of three scenarios considering with and without multi-period variation of water demand verify the validity of the proposed model, i.e., for a municipal water price of 4 CNY·t⁻¹ and penalty factor of 0.3, one reverse osmosis desalination unit of capacity 800 t·h⁻¹ is selected. However, in the multi-period case, two reverse osmosis desalination units with capacities of 500 t·h⁻¹ and 300 t·h⁻¹ are selected. In both cases, the operating costs are different because of the different operating status of the network. The work can guide the design and operation of industrial and urban water supply networks. Full article

(This article belongs to the Special Issue Advances in Energy System Synthesis and Energy-Water Nexus in Industry)

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13 pages, 26642 KiB

Open AccessArticle

Study on the Flow Characteristics of Desulfurization Ash Fine Particles in a Circulating Fluidized Bed

by Xiao Yang, Chengxiu Wang, Xingying Lan and Jinsen Gao

Processes 2021, 9(8), 1343; https://doi.org/10.3390/pr9081343 - 30 Jul 2021

Cited by 11 | Viewed by 2585

Abstract

In view of the current status of catalytic cracking flue gas treatment, it is necessary to study the flow environment of desulfurization ash particles, which are a type of Geldart C particle, in a circulating fluidized bed (CFB) for semi-dry flue gas desulphurization [...] Read more.

In view of the current status of catalytic cracking flue gas treatment, it is necessary to study the flow environment of desulfurization ash particles, which are a type of Geldart C particle, in a circulating fluidized bed (CFB) for semi-dry flue gas desulphurization using CFB technology. This study investigated the flow characteristics of desulphurization ash particles in a riser with an inner diameter of 70 mm and a height of 12.6 m, at a gas velocity of 4–7 m/s and a solids circulation rate of 15–45 kg/m²·s. The solids holdup in the axial distribution is relatively high near the bottom of the riser, and gradually decreases as the riser height increases, with a stable value from the middle to the top of the riser. In the radial distribution, the solids holdup of desulfurization ash particles is low in the center and high in the wall region. Within the above operating conditions, the solids holdup ranges from 0.008 to 0.025. The particle-based Archimedes number has a linear relationship with the solids holdup at all operating conditions. Full article

(This article belongs to the Special Issue Advances in Energy System Synthesis and Energy-Water Nexus in Industry)

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19 pages, 3483 KiB

Open AccessArticle

Comparative Investigation of Different CO₂ Capture Technologies for Coal to Ethylene Glycol Process

by Yanqing Ma, Yitao Liao, Yi Su, Baojie Wang, Yong Yang, Dong Ji, Hongwei Li, Huairong Zhou and Dongliang Wang

Processes 2021, 9(2), 207; https://doi.org/10.3390/pr9020207 - 22 Jan 2021

Cited by 23 | Viewed by 6852

Abstract

The coal to ethylene glycol (CTEG) process has drawn much attention due to the serious conflict between supply and demand of ethylene glycol in China. However, it is inevitably accompanied by the problem of high CO₂ emissions. Carbon capture is one of [...] Read more.

The coal to ethylene glycol (CTEG) process has drawn much attention due to the serious conflict between supply and demand of ethylene glycol in China. However, it is inevitably accompanied by the problem of high CO₂ emissions. Carbon capture is one of the most promising potential effective ways to address this issue. However, the CTEG process, integrated with carbon capture technology, will lead to energy and economic penalties. Thus, a comprehensive evaluation of CTEG process with different CO₂ capture technologies is urgently needed. This study analyzed the technoeconomic performance of four CO₂ capture alternatives for the CTEG process: Rectisol, mono-ethanol amine (MEA), chilled ammonia process (CAP) and dimethyl carbonate (DMC) technologies. Results show the energy consumption of CO₂ capture of the Rectisol process is the lowest, 1.88 GJ/tCO₂, followed by the DMC process, 2.10 GJ/tCO₂, the CAP process, 3.64 GJ/tCO₂, and the MEA process, 5.20 GJ/tCO₂. The CO₂ capture cost of the Rectisol process is lowest, CNY 169.5/tCO₂, followed by the DMC process, CNY 193.2/tCO₂, the CAP process CNY 232.6/tCO₂, and the MEA process CNY 250.5/tCO₂. As the Rectisol technology has the best comprehensive performance, it is the best option for CTEG industry in comparison with the MEA, CAP, and DMC technologies. Full article

(This article belongs to the Special Issue Advances in Energy System Synthesis and Energy-Water Nexus in Industry)

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