Proposal and energy/exergy/economic analyses of a smart heat recovery for distillation tower of the Naphtha Hydrotreating Unit of the Petrochemical Plant; designing a low-carbon plant
-
Xiaoyue Lyu
and
Jinyue Wang
Abstract
This paper suggests a novel framework to retrieve the squandered heat of the Naphtha Hydrotreating Unit of the petrochemical plants. In this idea, the distillation tower’s output of the hydrotreating naphtha unit of the plant is employed as the working fluid to run an organic Rankine cycle with benzene. The procedure is evaluated comprehensively from energy, economic and exergetic point of view using Aspen Haysys software. An advanced case study, including sensitivity analysis, is provided for the Bouali petrochemical plant in Iran to realistically indicate the performance of the suggested configuration. The air cooler in the distillation unit of the aforementioned plant removes (squanders) about 3418 kW of energy, which an organic Rankine cycle can recover. Based on the findings, the exergetic and thermal efficiency of the suggested cycle is 82.53 % and 13.28 %, respectively, with a 1,3620kWh/day rate of energy production. According to the exergetic analysis, the ORC turbine has the highest exergy destruction rate of about 178.76 kW. Also, using the distillation tower squander heat as the heat source to the organic Rankine cycle leads to the least exergy destruction rate. Besides, the output exergy ratio of the whole integrated system to its input is 0.907. The suggested integrated system reduces the total energy consumption from 0.4 to 0.29 GJE/tonFeed with a total investment cost of 11.97 M$, in which the turbines have the highest portion of about 11.2 M$. Hence, the suggested plan’s total income is around 31.94 M$/year.
Acknowledgments
Guangdong Universities’ 2018 Young Innovative Talents Project (2018WQNCX308) produced ‘Research on the relationship between corporate value and CSR information disclosure.
-
Author contributions: All the authors have accepted responsibility for the entire content of this submitted manuscript and approved submission.
-
Research funding: None declared.
-
Conflict of interest statement: The authors declare no conflicts of interest regarding this article.
References
1. Ziapour, BM, Saadat, M, Palideh, V, Afzal, S. Power generation enhancement in a salinity-gradient solar pond power plant using thermoelectric generator. Energy Convers Manag 2017;136:283–93. https://doi.org/10.1016/j.enconman.2017.01.031.Search in Google Scholar
2. Haghghi, MA, Mohammadi, Z, Pesteei, SM, Chitsaz, A, Parham, K. Exergoeconomic evaluation of a system driven by parabolic trough solar collectors for combined cooling, heating, and power generation; a case study. Energy 2020;192:116594. https://doi.org/10.1016/j.energy.2019.116594.Search in Google Scholar
3. Han, Y, Wu, H, Geng, Z, Zhu, Q, Gu, X, Yu, B. Energy efficiency evaluation of complex petrochemical industries. Energy 2020;203:117893. https://doi.org/10.1016/j.energy.2020.117893.Search in Google Scholar
4. Wallin, J, Claesson, J. Investigating the efficiency of a vertical inline drain water heat recovery heat exchanger in a system boosted with a heat pump. Energy Build 2014;80:7–16. https://doi.org/10.1016/j.enbuild.2014.05.003.Search in Google Scholar
5. Shin, DH, Kim, S, Ko, HS, Shin, Y. Performance enhancement of heat recovery from engine exhaust gas using corona wind. Energy Convers Manag 2018;173:210–8. https://doi.org/10.1016/j.enconman.2018.07.060.Search in Google Scholar
6. Du, W-J, Yin, Q, Cheng, L. Experiments on novel heat recovery systems on rotary kilns. Appl Therm Eng 2018;139:535–41. https://doi.org/10.1016/j.applthermaleng.2018.04.125.Search in Google Scholar
7. Venturelli, M, Brough, D, Milani, M, Montorsi, L, Jouhara, H. Comprehensive numerical model for the analysis of potential heat recovery solutions in a ceramic industry. Int J Thermofluids 2021;10:100080. https://doi.org/10.1016/j.ijft.2021.100080.Search in Google Scholar
8. Ma, H, Liang, N, Liu, Y, Luo, X, Hou, C, Wang, G. Experimental study on novel waste heat recovery system for sulfide-containing flue gas. Energy 2021;227:120479. https://doi.org/10.1016/j.energy.2021.120479.Search in Google Scholar
9. Li, P, Cao, Q, Li, J, Lin, H, Wang, Y, Gao, G, et al.. An innovative approach to recovery of fluctuating industrial exhaust heat sources using cascade Rankine cycle and two-stage accumulators. Energy 2021;228:120587. https://doi.org/10.1016/j.energy.2021.120587.Search in Google Scholar
10. Cao, Y, Haghghi, MA, Shamsaiee, M, Athari, H, Ghaemi, M, Rosen, MA. Evaluation and optimization of a novel geothermal-driven hydrogen production system using an electrolyser fed by a two-stage organic Rankine cycle with different working fluids. J Energy Storage 2020;32:101766. https://doi.org/10.1016/j.est.2020.101766.Search in Google Scholar
11. Ahmadi, A, El Haj Assad, M, Jamali, DH, Kumar, R, Li, ZX, Salameh, T, et al.. Applications of geothermal organic Rankine Cycle for electricity production. J Clean Prod 2020;274:122950. https://doi.org/10.1016/j.jclepro.2020.122950.Search in Google Scholar
12. Acar, HI. Second law analysis of the reheat-regenerative Rankine cycle. Energy Convers Manag 1997;38:647–57. https://doi.org/10.1016/s0196-8904(96)00077-5.Search in Google Scholar
13. Angelino, G, Di Paliano, PC. Multicomponent working fluids for organic Rankine cycles (ORCs). Energy 1998;23:449–63. https://doi.org/10.1016/s0360-5442(98)00009-7.Search in Google Scholar
14. Wu, C. Intelligent computer aided sensitivity analysis of a multi-stage Brayton/Rankine combined cycle. Energy Convers Manag 1999;40:215–32. https://doi.org/10.1016/s0196-8904(98)00050-8.Search in Google Scholar
15. Hung, T-C. Waste heat recovery of organic Rankine cycle using dry fluids. Energy Convers Manag 2001;42:539–53. https://doi.org/10.1016/s0196-8904(00)00081-9.Search in Google Scholar
16. Agnew, B, Alaktiwi, A, Anderson, A, Potts, I. Simulation of a combined Rankine–absorption cycle. Appl Therm Eng 2004;24:1501–11. https://doi.org/10.1016/j.applthermaleng.2003.11.013.Search in Google Scholar
17. Badescu, V, Aboaltabooq, MHK, Pop, H, Apostol, V, Prisecaru, M, Prisecaru, T. Avoiding malfunction of ORC-based systems for heat recovery from internal combustion engines under multiple operation conditions. Appl Therm Eng 2019;150:977–86. https://doi.org/10.1016/j.applthermaleng.2019.01.046.Search in Google Scholar
18. Wang, F, Wang, L, Zhang, H, Xia, L, Miao, H, Yuan, J. Design and optimization of hydrogen production by solid oxide electrolyzer with marine engine waste heat recovery and ORC cycle. Energy Convers Manag 2021;229:113775. https://doi.org/10.1016/j.enconman.2020.113775.Search in Google Scholar
19. Wang, EH, Zhang, HG, Fan, BY, Ouyang, MG, Yang, FY, Yang, K, et al.. Parametric analysis of a dual-loop ORC system for waste heat recovery of a diesel engine. Appl Therm Eng 2014;67:168–78. https://doi.org/10.1016/j.applthermaleng.2014.03.023.Search in Google Scholar
20. Shu, G, Gao, Y, Tian, H, Wei, H, Liang, X. Study of mixtures based on hydrocarbons used in ORC (organic Rankine cycle) for engine waste heat recovery. Energy 2014;74:428–38. https://doi.org/10.1016/j.energy.2014.07.007.Search in Google Scholar
21. Surendran, A, Seshadri, S. Performance investigation of two stage organic Rankine cycle (ORC) architectures using induction turbine layouts in dual source waste heat recovery. Energy Convers Manag X 2020;6:100029. https://doi.org/10.1016/j.ecmx.2020.100029.Search in Google Scholar
22. Emadi, MA, Chitgar, N, Oyewunmi, OA, Markides, CN. Working-fluid selection and thermoeconomic optimisation of a combined cycle cogeneration dual-loop organic Rankine cycle (ORC) system for solid oxide fuel cell (SOFC) waste-heat recovery. Appl Energy 2020;261:114384. https://doi.org/10.1016/j.apenergy.2019.114384.Search in Google Scholar
23. Yilmaz, F, Ozturk, M. Parametric assessment of a novel renewable energy based integrated plant with thermal energy storage for hydrogen generation and cleaner products. Process Saf Environ Protect 2022;168:372–90. https://doi.org/10.1016/j.psep.2022.09.078.Search in Google Scholar
24. Georgousopoulos, S, Braimakis, K, Grimekis, D, Karellas, S. Thermodynamic and techno-economic assessment of pure and zeotropic fluid ORCs for waste heat recovery in a biomass IGCC plant. Appl Therm Eng 2021;183:116202. https://doi.org/10.1016/j.applthermaleng.2020.116202.Search in Google Scholar
25. Yilmaz, F, Ozturk, M, Selbas, R. Development and performance examination of an integrated plant with desalination process for multigeneration purposes. Energy Convers Manag 2021;240:114275. https://doi.org/10.1016/j.enconman.2021.114275.Search in Google Scholar
26. Behzadi, A, Gholamian, E, Houshfar, E, Habibollahzade, A. Multi-objective optimization and exergoeconomic analysis of waste heat recovery from Tehran’s waste-to-energy plant integrated with an ORC unit. Energy 2018;160:1055–68. https://doi.org/10.1016/j.energy.2018.07.074.Search in Google Scholar
27. Peris, B, Navarro-Esbrí, J, Molés, F, Mota-Babiloni, A. Experimental study of an ORC (organic Rankine cycle) for low grade waste heat recovery in a ceramic industry. Energy 2015;85:534–42. https://doi.org/10.1016/j.energy.2015.03.065.Search in Google Scholar
28. Yang, F, Zhang, H, Yu, Z, Wang, E, Meng, F, Liu, H, et al.. Parametric optimization and heat transfer analysis of a dual loop ORC (organic Rankine cycle) system for CNG engine waste heat recovery. Energy 2017;118:753–75. https://doi.org/10.1016/j.energy.2016.10.119.Search in Google Scholar
29. Liu, L, Fu, L, Zhang, S. The design and analysis of two exhaust heat recovery systems for public shower facilities. Appl Energy 2014;132:267–75. https://doi.org/10.1016/j.apenergy.2014.07.013.Search in Google Scholar
30. Pantaleo, AM, Fordham, J, Oyewunmi, OA, Markides, CN. Intermittent waste heat recovery via ORC in coffee torrefaction. Energy Proc 2017;142:1714–20. https://doi.org/10.1016/j.egypro.2017.12.554.Search in Google Scholar
31. Gómez-Aláez, SL, Brizzi, V, Alfani, D, Silva, P, Giostri, A, Astolfi, M. Off-design study of a waste heat recovery ORC module in gas pipelines recompression station. Energy Proc 2017;129:567–74. https://doi.org/10.1016/j.egypro.2017.09.205.Search in Google Scholar
32. Feng, X, Pu, J, Yang, J, Chu, KH. Energy recovery in petrochemical complexes through heat integration retrofit analysis. Appl Energy 2011;88:1965–82. https://doi.org/10.1016/j.apenergy.2010.12.027.Search in Google Scholar
33. Yang, H, Xu, C, Yang, B, Yu, X, Zhang, Y, Mu, Y. Performance analysis of an organic Rankine cycle system using evaporative condenser for sewage heat recovery in the petrochemical industry. Energy Convers Manag 2020;205:112402. https://doi.org/10.1016/j.enconman.2019.112402.Search in Google Scholar
34. Ahmadi, G, Toghraie, D, Akbari, OA. Technical and environmental analysis of repowering the existing CHP system in a petrochemical plant: a case study. Energy 2018;159:937–49. https://doi.org/10.1016/j.energy.2018.06.208.Search in Google Scholar
35. National Iranian Petrochemical Company; Bouali Sina Petrochemical Company. Naphta hydrotreating unit, stripping section DFT-3001. Petrochemical special economic zone. Iran: Bandar-e Mahshahr; 2022.Search in Google Scholar
36. Kumar, A, Shukla, SK. Analysis and performance of ORC based solar thermal power plant using benzene as a working fluid. Procedia Technol 2016;23:454–63. https://doi.org/10.1016/j.protcy.2016.03.050.Search in Google Scholar
37. Safarian, S, Aramoun, F. Energy and exergy assessments of modified organic rankine cycles (ORCs). Energy Rep 2015;1:1–7. https://doi.org/10.1016/j.egyr.2014.10.003.Search in Google Scholar
38. Turton, R, Bailie, RC, Whiting, WB, Shaeiwitz, JA. Analysis, synthesis and design of chemical processes. American: Pearson Education; 2008.Search in Google Scholar
39. Chauvy, R, Dubois, L, Lybaert, P, Thomas, D, De Weireld, G. Production of synthetic natural gas from industrial carbon dioxide. Appl Energy 2020;260:114249. https://doi.org/10.1016/j.apenergy.2019.114249.Search in Google Scholar
40. Abdelaziz, OY, Hosny, WM, Gadalla, MA, Ashour, FH, Ashour, IA, Hulteberg, CP. Novel process technologies for conversion of carbon dioxide from industrial flue gas streams into methanol. J CO2 Util 2017;21:52–63. https://doi.org/10.1016/j.jcou.2017.06.018.Search in Google Scholar
41. King, CJ. Separation processes. New York: Courier Corporation; 2013.Search in Google Scholar
42. Bina, SM, Jalilinasrabady, S, Fujii, H. Energy, economic and environmental (3E) aspects of internal heat exchanger for ORC geothermal power plants. Energy 2017;140:1096–106. https://doi.org/10.1016/j.energy.2017.09.045.Search in Google Scholar
43. Fan, G, Yang, B, Guo, P, Lin, S, Farkoush, SG, Afshar, N. Comprehensive analysis and multi-objective optimization of a power and hydrogen production system based on a combination of flash-binary geothermal and PEM electrolyzer. Int J Hydrogen Energy 2021;46:33718–37. https://doi.org/10.1016/j.ijhydene.2021.07.206.Search in Google Scholar
© 2023 Walter de Gruyter GmbH, Berlin/Boston
Articles in the same Issue
- Frontmatter
- Research Articles
- Tuning of PID controllers for unstable first-order plus dead time systems
- Oxygen excess ratio control of PEM fuel cell: fractional order modeling and fractional filter IMC-PID control
- Proposal and energy/exergy/economic analyses of a smart heat recovery for distillation tower of the Naphtha Hydrotreating Unit of the Petrochemical Plant; designing a low-carbon plant
- Three-dimensional CFD study on thermo-hydraulic behaviour of finned tubes in a heat exchange system for heat transfer enhancement
- A simulation and thermodynamic improvement of the methanol production process with economic analysis: natural gas vapor reforming and utilization of carbon capture
- Optimization of hydrogel composition for effective release of drug
- Mathematical modelling of water-based biogas scrubber operating at digester pressure
- COCO, a process simulator: methane oxidation simulation & its agreement with commercial simulator’s predictions
- Hydrodynamics of shear thinning fluid in a square microchannel: a numerical approach
- Parameter estimation in non-linear chemical processes: an opposite point-based differential evolution (OPDE) approach
Articles in the same Issue
- Frontmatter
- Research Articles
- Tuning of PID controllers for unstable first-order plus dead time systems
- Oxygen excess ratio control of PEM fuel cell: fractional order modeling and fractional filter IMC-PID control
- Proposal and energy/exergy/economic analyses of a smart heat recovery for distillation tower of the Naphtha Hydrotreating Unit of the Petrochemical Plant; designing a low-carbon plant
- Three-dimensional CFD study on thermo-hydraulic behaviour of finned tubes in a heat exchange system for heat transfer enhancement
- A simulation and thermodynamic improvement of the methanol production process with economic analysis: natural gas vapor reforming and utilization of carbon capture
- Optimization of hydrogel composition for effective release of drug
- Mathematical modelling of water-based biogas scrubber operating at digester pressure
- COCO, a process simulator: methane oxidation simulation & its agreement with commercial simulator’s predictions
- Hydrodynamics of shear thinning fluid in a square microchannel: a numerical approach
- Parameter estimation in non-linear chemical processes: an opposite point-based differential evolution (OPDE) approach
