Best Practice: Quick Energy Assessment Methodology For Energy Efficiency Optimization

Best Practice
SABP-A-005 28 December 2005 Quick Energy Assessment Methodology for Energy Efficiency Optimization Document Responsibility: Energy Systems Unit/ESD/CSD
Quick Energy Assessment Methodology for Energy Efficiency Optimization
Previous Issue: None Next Planned Update: 1 January 2009 Primary Contact: nourelmm@aramco.com, phone +966 (3) 873-6045
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Document Responsibility: Energy Systems Unit/ESD/CSD Issue date: 28 December 2005 Next Update: 1 January 2009
SABP-A-005 Quick Energy Assessment Methodology for Energy Efficiency Optimization
Table of Contents
Page 1.0 Introduction 1.1 1.2 1.3 1.4 2.0 Definition Purpose and Scope Intended Users Initial Assessment Objectives 3 3 3 4 4 4 4 5 3 Energy Flow Diagrams Steam and Power Diagram Fuel Diagram Energy Saving Housekeeping List Energy Saving Generic Checklist 7 11 12 13 14 16 16 18 52 54
Quick Energy Assessment Overview 2.1 2.2 Energy Efficiency Optimization Task Description Solution Method Using Decomposition Approach
3.0
Methodology 3.1 3.2 3.3 3.4 3.5
4A.0 Appendices for Short-cut Calculations and HGP Energy Study 4A.1 4A.2 4A.3 4A.4 Basic Steam Mass Balance Basic Energy Utility Targeting Using Pinch Method Basic Formulas for Some Quick Savings Estimation HGP Detailed Energy Assessment Study
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1.0
Introduction
Energy conservation in Saudi Aramco became everyones business. It is mandatory for each process facility to find cost effective solutions to save energy and achieve more with less in their facilities. Saudi Aramco has constituted a committee called EMSC Energy Management Steering Committee to direct and manage a sustainable process for energy conservation. A vital contribution towards the success of the company wide energy conservation policy comes through documenting the company best practices in methodology, tools and applications in the field of energy conservation and distributing such knowledge among our facilities. Hence, a consistent effort has been exerted in Saudi Aramco to produce Best Practices to help Saudi Aramco plants achieve their energy conservation targets and disseminate energy conservation knowledge. This particular Best Practice document for initial energy assessment is a contribution towards this goal. It is expected to draw the line in conducting energy assessments through a user-friendly methodology. The theme of this quick energy assessment methodology for energy efficiency optimization is, Big Picture First, Details Later. Energy assessments, also called energy audits, may be primitive or comprehensive and detailed. A variety of approaches, methods and tools are available to conduct such energy assessments to improve the energy efficiency of industrial processes.
1.1
Definition
The term Energy Assessment refers to the methodology of collecting and analyzing available energy utilities related data in order to establish the big picture of the breakdown of energy consumption for a particular facility and identify componentbased-energy saving opportunities within the facility.
1.2
Purpose and Scope

The purpose of this best practice document is to describe a methodology and introduce short cut tools by which quick assessment for energy efficiency improvement can be conducted faster, cheaper and better. Its scope include quick energy assessment methodology in a step-by-step manner, simple models for data representation, checklists for identifying areas for energy savings and short cut tools for creating and evaluating process initiatives for energy saving for common use in Saudi Aramco plants.
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1.3
Intended Users
This Best Practice manual is intended for use by the energy engineers working in Saudi Aramco plants, who are responsible for efficient operation of their facility. This particular document will enable them to conduct quick energy assessments systematically.
1.4
Initial Assessment Objectives

Preliminary review of plant process, system drawings and Data gathering Understand the Big Picture of the plant-wide operations Understand process energy and utility systems From the available data, establish your current reality Establish your desired result Targeting Identify All Opportunities for energy savings Propose Quick-hit savings Propose scope for definitive assessment with some economic analysis Propose plant-wide energy-utility strategy or Total energy Management
2.0
Quick Energy Assessment Overview

The first priority in any plant initial energy assessment effort is to define the quick hits for energy cost savings that can be achieved with little or no investment. The best practice document does not only help plants energy groups conduct a quick energy assessment for both short and long term energy savings opportunities but also establish the procedures and checklists that can enable process engineers and operators make intelligent choices on hour-to-hour basis.
2.1
Energy Efficiency Optimization Task Description

Energy Efficiency Optimization Task aims to specify the near-optimal operation targets/modes that minimize the plants energy consumption at minimum deficiency in energy supply of the utility systems to the plants process. Following that, the task will be to list all possible operational and design modifications necessary to achieve the specified/desired target(s). This includes identification of all related engineering activities in a minimum possible time using uncertain plant data and without any interruption to the plants normal production. This task shall achieve the following two objectives:
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1. Minimum disruption in the energy utility supply 2. Minimum consumption of energy utility.
Given an industrial facility that consists of several processes and utility plants, define; at minimum deficiency in energy utility systems supply to the process; near-optimal targets for energy consumption minimization, find a list of possible operational and design modifications to achieve desired target(s) and conduct the engineered solutions
2.2
Solution Method Using Decomposition Approach

For simplicity and timely results, Decomposition Techniques will be used in lieu of the time-consuming Mathematical Programming/Optimization Techniques. The plants energy utility needs will be defined with reasonable level of flexibility and the energy utility system; electricity, fuel, steam and other energy-related utilities will be scrutinized one by one to find the near- optimal consumption of such utilities that guarantee minimum deficiency in the utility supply to plant processes. On the macro level the energy system components are generation, distribution and utilization. The objective will be to minimize waste in energy fresh resources and capital (de-bottlenecking) in these three components. This can be done via the continuous upgrade of the efficiency of energy system components in generation, distribution and utilization. However, the utilization component has a unique feature, where its boundaries are not completely dictated by the process. Therefore the room of improvement in this component is much wider than the others.
3.0
Methodology
There are four essential tasks that can be conducted by a small energy focus group of three engineers: 1. 2. 3. 4. Data, Models and Targets Insights, Opportunities and Estimated savings potential Screen and Formulate Strategy Document, Report and Present
These tasks are exhibited in the 10-Steps procedures below. 1. Site survey through templates, checklists and interviewing of process owners/proponents to gather the right amount of data that enable the energy team build the plants big picture and understand the goals and the constraints of the facility( What to look for and what to ask)
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2. 3.
Define the criteria for focusing on potential areas of interest (when to be rigorous and get to the second level of details) Develop site energy/utility nominal design/normal operation models with the appropriate level of details in a high level generic path diagrams for, power, fuel, H2, steam, water, nitrogen and air. Preliminary purpose of these models will be to understand what is going on in the energy utility system, locate the energy consumption elephants (ECEs) in both process and utility plants and generate insights for energy saving opportunities Add more depth in the level of details of the energy utility model for each ECE and/or other criterion of focus Define the effect of disturbances and uncertainty on the energy utility system models a. b. c. d. Sources of disturbances Site energy utility balance under disturbances Nominal and dynamic targeting of energy utility systems (Check that the big picture depicted for the process and the utility plants is correct with enough degree of confidence before you proceed) _ Identify main processing issues that affect utility utilization _ Link utility-utility interactions _ Integrate and qualitatively optimize site utilities (If we do not coordinate between steam and fuel systems we may stop flaring steam but flaring fuel) for energy utility saving
4. 5.
6.
Target (order of magnitude targeting) a. b. c.
7. 8.
Integrate core processes among themselves and with utilities Develop a comprehensive initiatives list via identifying and estimating energy utility savings opportunities a. b. c. d. Housekeeping list Checklists (generic and process specific) Waste energy recovery (pinch method and others) In-process Modification (pinch method and others)
9.
Champion a cross-fertilizing discussion among plant disciplines to prioritize, screen the initiatives and writing a project sheet, for each initiative, including a description of the opportunity and energy utility savings estimate Develop word strategies for realizing savings from facility goals, analysis of the results and the mapping of the opportunities onto the facility strategy (remember, 50% of something is better than 100% of nothing). Then report and present results.
10.
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3.1
3.1.1
Energy Flow Diagrams

Overview
Fuel
Energy Sources
Energy Generation
Boilers & Cogeneration Steam Electricity
Energy Distribution
Buildings & Others
Process Energy Byproducts
Energy Utilization
The task now is to look for the Elephants in the energy-process system. The graphs below will enable the Energy Engineer to find the Elephants to focus his/her efforts and decide where to start and insist on accurate data collection to further proceed with the analysis. Money-based graphs will help quickly to pinpoint the areas of focus. Furthermore, the BTU-based graphs will double check the pre-defined priority list, direct the study towards the process reasons behind certain energy elephant and find more efficient ways to satisfy the process target(s).
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3.1.2
Overall Energy Flow Diagram ($/yr)
Typical Oil Refinery
$ 0.5 MM
Process Purchase
$ 0.9 MM
Other users
$ 24.4 MM $ 0.0 MM
Steam
$ 52.4 MM $ 45.9 MM
$ 0.8 MM $ 41.5 MM $ 0.4 MM
Machine Drive Re-boilers heaters
$ 21.5 MM $ 20.70 MM
Fuel
Flare
$ 51.2 MM $ 73.1 MM $ 0.0 MM $ 0.3 MM $ 18.4 MM $ 19.1 MM
furnaces
$ 16.9 MM
power
$ 2.2 MM
refrigeration
Motors
$ 0.40 MM Other users

Total Purchased
$ 37.6 MM
$ 0.0 MM
Export
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Typical Gas Plant
Purchase
SA Fuel Gas
Export
$ 0.0 MM/yr $ 0.0 MM/yr

Steam
$ 20.018 MM/yr 2.54 MM Ib/hr $19.618 MM/yr $0.11MM/yr $0.27 MM/yr
Flare Area
Inlet Area
$ 19.618 MM/yr $ 0.0 MM/yr

Fuel
$ 20.018MM/yr $ 0.0 MM/yr
$ 56.1 MM/yr
power Total Purchased
$ 0.0 MM/yr $ 56.1 MM/yr
$1.72MM/yr $2.8 MM/yr Utility Area $0.244MM/yr $ 0.4 MM/yr Sulfur Recovery Area $0.221MM/yr $16.6MM/yr Gas Treat $3.25 MM/yr Area $0.335MM/yr
Gas Comp.
$18.08 MM/yrArea $ 56.1 MM/yr 200 MW $0.609MM/yrLiquid Recovery $29.04 MM/yr Area
Note: These Data are Shedgums Gas Plant
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3.1.3
Overall Energy Flow Diagram (Trillion-Btu/yr)
Total Input= 10.56 TBtu 2 TBtu
8.38 TBtu
0.18 TBtu
Electricity
0.39 TBtu 1.8 TBtu Process -0.19 TBtu Boilers steam cogen 0.0 TBtu
Fuel
steam
0.5 TBtu Building
Building
5.46 TBtu 0.12 TBtu - 5.4 TBtu 2.11 TBtu 5.77 TBtu Boilers Boilers Process Process Building steam steam cogen cogen 5.59 TBtu 0.18 TBtu -5.4 TBtu 0.0 TBtu Conventional Electricity
-0.19 TBtu
Boiler Fuel
Conventional Electricity
Boiler Fuel
Conventional Electricity
Boiler Fuel
Area #1
#N
Area #1
#N
Area #1
#N
Unit #1
#N
Unit #1
#N
Unit #1
#N
Heating 7.56 TBtu
Cooling/Ref 0.55 TBtu
Machine Drive 1.24 TBtu
Electro-Chem 0.0 TBtu
Other use 0.02 TBtu
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3.2
Steam and Power Diagram

Steam big picture shall exhibit at least steam sources, pressure levels, mass balance, let down valves and turbines, main users and losses such as vents, let downs and condensate. These information can be used as depicted in the way below to generate ideas and opportunities for saving under the main theme of Big picture first, and details later.
Steam Targets
103 t/h
Consider replacing turbines with motors Enhance the recovery of Steam from condensate
Enhance condensate recovery By 10 % Shut down MP boiler
HP Boiler
98 t/h
Heat integration of process#1 and # 4 Estimated saving of 10%
HP
68 t/h 21 t/h 8 t/h
Proc. #1
0.0 t/h
0.0 t/h
Reduce letdown via turbine flow increase or new turbine
6.28 MW
Reduce it via operating at lower pressure
Proc. #2
4 t/h
MP Boiler
1 t/h
HP Process Condensate
chemicals
Eliminate vent
68 t/h 27 t/h 30 t/h 13 t/h

Proc. #1
0.0 t/h
MP
2 t/h
Vent
MP Process Condensate
Vent
2 t/h 18 t/h 40 t/h

Deaerator
Proc. #4
0.0 t/h 30 t/h 0.0 t/h 7 t/h

Proc. #1
Process Condensate Reduce and make use of boiler blow-down Est. 50 % Returned
1 t/h 4 t/h
Proc. #3
0.0 t/h
BFW 49 t/h Raw water Make-up Treatment Plant
LP
LP Process Condensate
Effluent
5 t/h
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3.3
Fuel Diagram
Fuel big picture shall exhibit at least fuel sources, pressure levels, mass balance, let down valves and compressors and main users. Hydrogen composition should also be considered to define the opportunities for recycles.
Hydrogen
400 psig 380 psig
PSA
Off-Gas
Fuel Gas
350 psig
180 psig
NG
150 psig
150 psig
52 psig
50 psig
boilers 15 psig
furnaces
5 psig
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3.4
Energy Saving Housekeeping list 1.

Establish steam trap auditing program to determine the number of traps (working, leaking, blockingetc.) and periodically check it and repair or replace the defected ones Condensate recovery (maintenance and operation) Piping insulation (maintenance) Shutting off equipment when not required (load management) Minimize slow rolling of steam turbines Boilers and furnaces tuning through better combustion control Preventive maintenance of energy system components such as heat exchangers, pumps, fans, compressors, turbines, furnaces, boilers (e.g., clean the fin fan tubes of gas coolers) Improved cooling water system (maintenance and operation) Optimize air compressors operation
2. 3. 4. 5. 6. 7.
8. 9.
10. Optimize BFW pumps load allocation 11. Energy monitoring and indices/ energy management system 12. Shut down compressors at low feed rate (load management) 13. Steam trap management (consider self regulating electrical tracing) 14. Booster, shipper and condensate pumps load management 15. Compressors load management 16. Consider the use of Economizers and Pre-heater in the boilers 17. Compressed air leaks (maintenance) 18. Minimize boilers and water coolers blow downs 19. Utilize boiler blow-down 20. Turbines load management 21. Upgrade sluggish response control valves since the delay might result in extra
flaring
22. Enhance the efficiency of boilers and furnaces through tight control 23. Enhance boilers and furnaces insulation 24. Optimize the CHP system
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25. Maintain plant steam reserve 26. Minimize/Eliminate the use of steam reducing stations and vents 27. Consider the reuse of turbo-expander to generate power in the HP/LP pressure
control valves
28. Enhance the combustion process in boilers and furnaces via using full additives
as a catalyst
3.5
Energy Saving Generic Checklist

1. 2. 3. 4. 5. 6. 7. 8. 9. Replace gas turbines with more efficient steam turbines Increase boiler steam pressure and temperature to the extent that matches process needs unless electricity generation is the controlling factor Use auxiliary turbines to minimize steam let downs Use steam in the process instead of venting it Preheat combustion air Use ASD on BFW pumps Reduce process variability using stable ops program Trim/Optimize the fired heaters excess oxygen Optimize the fired heaters stack temperature
10. Re-use the flue gases in process heating 11. Optimize your waste heat boilers 12. Recover valuable gases from your fuel gases 13. Reduce the H2 wheel in your plant 14. Cool down the inlet temperature to compressors 15. Reduce cooling medium return temperature in refrigeration cycles 16. Upgrade, regenerate and replace your catalyst 17. Optimize let down stations and steam turbine operation 18. Use highest efficiency turbines 19. Maintain your steam turbines to reduce steam consumption 20. Give frequent attention to steam traps and leaks 21. Replace turbine drives with electric motors if more economical since they are more efficient
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22. Boilers and furnaces efficiency enhancement through advanced process control, on-line performance monitoring and optimization 23. Recover condensate 24. Thermal Heat and power integration (CHP) 25. Better control for dispersion steam to flare stacks 26. Optimize steam use in strippers 27. Minimize live steam utilization 28. Mechanical energy integration 29. Reduce natural gas consumption by understanding fuel gas sinks and constraints 30. Reduce fuel gas use with energy integration 31. Keep H2 separate from fuel gas system 32. Measure the composition of off-gas streams and recover C2 and C3+ 33. Avoid unnecessary processing of off-gas 34. Avoid unnecessary processing of wastes and inert 35. Minimize the unnecessary production of off-gas 36. Use on-line monitoring and APC for furnaces and other control sensitive fuel users 37. Avoid unnecessary recycles 38. Avoid leaks in the pressure relieve valves to the fuel system 39. Adjust operating pressures and optimize process interaction 40. Clean and maintain pipelines and valves to minimize pressure drops 41. Clean and maintain Boiler tubes from deposits & scale for better operations 42. Treat and recycle blow down to force lower cycles of concentration in cooling towers and boilers 43. Use lowest quality water 44. Maximize use of stripped sour water 45. Minimize generation of wastewater 46. Seek out and repair all hydrocarbon leaks 47. Eliminate direct water injection for cooling purposes 48. Eliminate live steam used for re-boiling and stripping where it is only used for BTU value 49. Minimize or eliminate live steam consumption in sour water strippers by replacing it with re-boilers
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50. Boiler blow-down could be considered for cooling tower make-up 51. Extract the low pressure steam from the boiler blowdown 52. Consider re-using the boiler blowdown for reserving the boiler 53. Use process water effluent as a source on the next lower water quality level 54. Eliminate live steam usage since it becomes water and follows an energy path through the plant consuming more energy to process it 55. Should live steam becomes necessary optimize the amount used through pressure manipulation 56. Use lowest quality water possible for desalter operation 57. Minimize water used in desalter 58. Automate desalter operation, avoid water slipping through with crude during desalting/maximize the separation of free water upstream of the crude desalting (each Ib of water will require roughly Ib steam for processing) 59. Minimize the water-wheel in the plant 60. Maximize utilization of treated oily-water from the waste-water treatment plant 61. Install low NOX burners 62. Consider the use of Cogeneration 63. Adjustable speed motors/devices for pumps, compressors, etc. 64. Increase waste heat steam generation 65. Insulate condensate return lines, valves, flanges, etc. 66. Cooling- tower blow-down should not be treated but segregated to sewer 67. Boiler blow-down should not be sent to wastewater treatment but segregate to sewer.
28 December 2005
Revision Summary New Saudi Aramco Best Practice.
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4A.0 Appendices for Short-Cut Calculations and HGP Energy Study

4A.1 Basic Steam Mass Balance
The basic Steam Mass Balance does not require high accuracy as long as the developed model still makes sound engineering sense. (i.e., output is much higher than input). Common engineering sense shall be used to estimate what the unknowns. For example condensate return, blow-down and flares can be defined after getting good idea about main consumers.
98+5 t/h
HP Boiler
98 t/h
HP
68 t/h 21 t/h 8 t/h
Proc. #1
0.0 t/h
0.0 t/h 1 t/h
6.28 MW
Proc. #2
0.0 t/h chemicals

Vent Proc. #4 MP Boiler
68 t/h 27 t/h 30 t/h 9 t/h

Proc. #1
0.0 t/h
MP
2 t/h
Vent
18 t/h 38 t/h
Deaerator
0.0 t/h 30 t/h 0.0 t/h 7 t/h

Proc. #1
Process Condensate Est. 50 % Returned
1 t/h
0.0 t/h
BFW
Raw water Make-up Treatment Plant
(42+5) t/h
Effluent
LP
4 t/h
Proc. #3
5 t/h
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4A.2 Basic Energy Utility Targeting Using Pinch Method

The purpose of this section is not to conduct a pinch study but to get some energy targets regarding the utilities consumption for a desired plant area. This can be done essentially via three methods, graphical, algebraic and using mathematical programming/optimization. In this document the first two methods are going to be explained. Graphical Method: Background: Any heat exchanger can be represented as a hot stream that is cooled down by another cold stream and/or cold utility and a cold stream that is heated up by a hot stream and/or hot utility with a specified minimum temperature approach between the hot and the cold called Tmin. The process exhibited below in the graph shows the situation when the two streams do not have a chance of overlap that produce heat integration between the hot and the cold.
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Feed
PROCESS
Product
120
HOT UTILITY
100
80
60
40
20
0 0
COLD UTILITY
10
20
30
40
50
60
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Moving the cold stream to the left on the enthalpy axis without changing its supply and target temperatures till we have small vertical distance between the hot stream and the cold stream we obtain some overlap between the two streams that result in heat integration between the hot and the cold and less hot and cold utilities. As been depicted in the graph below with shrinkage in the hot and cold lines span.
Feed
PROCESS
Product
120
HOT UTILITY
100
80
HEAT RECOVERY
60
Pinch
(MAT)
40
20
0 0
COLD UTILITY
10
20
30
40
50
60
For demonstration, all hot streams will be represented in the process by one long hot stream to be called the hot composite curve. Same thing be done for all cold streams in the process.
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The next step will be drawing the two composite curves/lines on the same page in Temperature (T)-Enthalpy diagram with two conditions: 1- The cold composite curve should be completely below the hot composite curve, and 2- The vertical distance between the two lines/curves in terms of temperature should be greater than or equal to a selected minimum approach temperature called global Tmin The resulting graph is depicted below and known as thermal pinch diagram:
Net Heat Sink Above the Pinch
Opportunity for heat recovery Net Heat Source Below the Pinch
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1. Constructing the composite curves (step-by-step) The above mentioned process can proceed as follows:
Stream Type 1-Hot 2-Hot 3-Cold 4-Cold Supply Temperature (C) 170 120 50 20 Target Temperature (C) 70 30 90 110 FCp (kW/ C) 10 20 40 18
1- Draw the hot composite curve and the cold composite curve via developing the following tables. Note: The tables list all the hot and cold streams temperatures in an ascending order with the cumulative enthalpy corresponding to the lowest hot temperature and lowest cold temperature respectively equal to zero. 2- In every temperature interval the cumulative hot load is calculated using the following formula: H= FCp * (Tsupply Ttarget) 3- In every temperature interval the cumulative cold load is calculated using the following formula: H= FCp * (Ttarget Tsupply)
Hot streams temperature list T0=30 T1=70 T2=120 T3=170 Cumulative Enthalpy (H) H0=0.0 H1=800 H2=2300 H3=2800
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Cold streams temperature list T0=20 T1=50 T2=90 T3=110
Cumulative Enthalpy (H) H0=0.0 H1=540 H2=2860 H3=3220
Temperature (T)- Enthalpy (H) Diagram
Hot composite curve
Cold composite curve
30 20 Cold composite curve is not completely below the hot composite curve
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As we mentioned before the cold composite curve shall lie completely below the hot composite curve and this can be done via dragging the cold composite curve to the right on the enthalpy axis (H). This process shall stop at a vertical distance between the cold and the hot composite curve for a temperature equal to the minimum temperature approach selected earlier.
Temperature (T)- Enthalpy (H) Diagram

Minimum Heating Utility T Qh=480 kW
Hot composite curve
Cold composite curve
Minimum Temperature Approach 30 20 Qc=60 kW Minimum Cooling Utility
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Algebraic Method: Information needed Explained via another example Given a unit with a list of hot streams to be cooled and cold streams to be heated
Stream ID Type Flowrate*Average Specific heat (FCp) Supply temperature Target Temperature
1 2 3 4
hot hot cold cold
10 5 19 2
520 380 300 320
330 300 550 380
1. Constructing temperature interval diagram 1.1_ Draw two temperature scales one for the hot streams and another for the cold streams 1.2_ Select reasonable minimum temperature approach between the hot streams and the cold stream (for instance, 10C) 1.3_ Draw all the hot streams (in the table hot section) to be cooled according to the hot steam scale as arrows that start at the supply temperatures and end at the target temperatures 1.4_ Repeat step 1.3 for all cold streams in the cold section of the table 1.5_ Start at the highest temperature of any hot stream in the hot section and draw a horizontal line that span along the two sections of the table, the hot and the cold. 1.6_ Draw horizontal lines again at the start and the end of any arrow representing the hot streams in the hot section of the table 1.7_ Repeat step 1.6 for any arrow representing cold stream in the cold section (at the start and the end of any arrow) 1.8_ Count the number of segments generated and number them starting at the highest temperature (they are called temperature intervals) 1.9_ Make sure that each temperature interval has now temperature value on both the hot temperature scale and cold temperature scale. The difference is the desired minimum temperature approach (for instance the 10C used in this example)
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These procedures are depicted in the figure below: Note: This structure means that within any temperature interval it is thermodynamically feasible to transfer heat from the hot streams to cold streams. It is also feasible to transfer heat from a hot stream in an interval x to any cold stream which lies in an interval below.
The temperature Interval Diagram
T minimum = 10 K
T*
555 515
Interval
Hot Streams 560 H1 520
Cold Streams 550 510
2 385 375 310 305 295 3 4 5 6 H2 390 380 330 310 300 380 370 320 300 290 C1 C2
Hot Streams:H1; F1Cp1= 10 kW/K H2; F2Cp2= 5 kW/K
Cold Streams:C1; F1Cp1= 10 kW/K C2; F2Cp2= 5 kW/K
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Note: The temperature symbol T* is interval inlet temperature used later on selecting the suitable energy utility after calculating the targets using what is known as grand composite curve. To calculate T* we take the average interval inlet temperature of the hot and cold temperature scale. 2. Constructing tables of exchangeable heat loads and cooling capacities 2.1 Determining individual heating loads and cooling capacities of all process streams for all temperature intervals using this formula: Qnm = F1Cp1* (Ts-Te) in energy units (kW) Ts is the interval start temperature and Te is the interval end temperature n is stream number and m is the interval number Example 1: Interval # 1 in the hot section: The interval start temperature is 560 K The interval end temperature is 520 K Q11(Q for stream #1 in interval #1) = F1Cp1*(560-520) Since there is no H1 stream in this interval, hence, F1Cp1=0.0 Q stream # 1(exchangeable load) in this interval = 0.0*(560-520) = zero Example 2: Interval # 2 in the hot section: The interval start temperature is 520 K The interval end temperature is 390 K The flow specific heat F1Cp1= 10 kW/K
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Then, Q stream #1(exchangeable load) in interval #1 = 10*(520-390) = 1300 kW Example 3: Interval # 1 in the cold section: The interval start temperature is 550 K The interval end temperature is 520 K The flow specific heat of this cold stream is F1Cp1 = 119 kW/K Then, Q stream #1(cooling capacity) in interval #1= 19*(560-520) = 760 kW Upon the completion of this step 2.2 Obtain the collective loads (capacities) of the hot (cold) process streams. These collective loads (capacities) are calculated by summing up the individual loads of the hot process streams that pass through that interval and the collective cooling capacity of the cold streams within the same interval.
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These calculations for the above problem are shown in the following tables:
Table of Exchangeable Loads for Process Hot Streams Intervals
Interval 1 2 3 4 5 6
Load of H1, kW 0.0*(560-520)= 0.0
Load of H2, kW 0.0*(560-520)= 0.0
Total Load, kW 0.0+0.0= 0.0 1300+0.0= 1300 100+0.0= 100 500+250= 750 0.0+ 100= 100 0.0+50= 50
10*(520-390)= 1300 0.0*(520-390)= 0.0 10*(390-380)= 100 10*(380-350)= 500 0.0*(330-310)= 0.0 0.0*(310-300)= 0.0 0.0*(390-380)= 0.0 5*(380-330)= 250 5*(330-310)= 100 5*(310-300)= 50
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Table of Cooling Capacities for Process Cold Streams Intervals
Interval 1 2 3 4 5 6
Capacity of C1, kW Capacity of C2, kW 19*(550-510)= 760 0.0*(550-510)= 0.0
Total Load, kW 760+0.0= 760 2470+0.0= 2470 190+20= 210 950+100= 1050 380+ 0.0= 380 0.0+0.0= 0.0
19*(510-380)= 2470 0.0*(510-380)= 0.0 19*(380-370)= 190 19*(370-320)=950 19*(320-300)= 380 0.0*(300-290)= 0.0 2*(380-370)= 20 2*(370-320)= 100 0.0*(320-300)= 0.0 0.0*(300-290)= 0.0
3. Constructing thermal cascade diagrams This diagram is constructed using the total hot loads and cooling capacities obtained in the previous step for each temperature intervals. The temperature intervals are drawn as rectangular with two inlets and two outlets. The inlet from the left is the total hot load available in this interval (for instance, 1300 kW in case of interval # 2). The inlet from above is the utility input load, in case of the first interval, or the input from interval above in case of second, third,,N intervals. The output from the right is the total cooling capacity of this interval (for instance, 2470 kW in case of interval #2). The output from the bottom is the difference between the total inputs and the cooling capacity of the interval.
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The heat balance around each interval will be conducted as follows:
First Interval Heat Balance
Hot Load From Utility Source Top Input
Hot Load From Process Source Left Input
Cooling Capacity From Process Source
Right Output
Residual Hot to Subsequent Interval Bottom Output from first interval
Heat Balance Top Input+ Left Input- Right Output = Bottom Output
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Numerical Example of First Interval Heat Balance

Hot Load From Utility Source Top Input= 0.0 kW
Hot Load From Process Source Left Input= 0.0 kW
Right Output=760 kW
Residual Hot to Subsequent Interval Bottom Output from first interval
= - 760 kW
Heat Balance Top Input+ Left Input- Right Output = Bottom Output 0.0 + 0.0 - 760 = - 760 kW
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Subsequent Intervals Heat Balance
Hot Load From Above Interval Top Input
Hot Load From Process Source Left Input
Right Output
Residual Hot to Subsequent Interval Bottom Output
Heat Balance Top Input+ Left Input- Right Output = Bottom Output
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Numerical Example for Subsequent Intervals Heat Balance For instance; Interval # 2
Hot Load From Above Interval Top Input = -760
Hot Load From Process Source Left Input= 1300
Right Output= 2470
Residual Hot to Subsequent Interval Bottom Output = - 1930
Heat Balance Top Input+ Left Input- Right Output = Bottom Output - 760 + 1300 -2470 = -1930
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Upon the completion of heat balance around each interval the following diagram will be produced:
Thermal Cascade Diagram (Un-Balanced) Note: During this step the input from Hot Utility to the first interval is equal to zero 0.0 0.0 1300 100 750 100 50 1 - 760 2 - 1930 3 - 2040 4 -2340 5 - 2620 6 - 2570 0.0 380 1050 760 2470 210
The maximum difference between the available hot loads and cooling capacities from the heat balances of these intervals is 2620 kW. This deficiency in heat will be supplied via outside hot utility.
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This value will be the input (from the top of the first interval) and the same heat balance calculation conducted above will be repeated to produce the balanced thermal cascade diagram below.
Thermal Cascade Diagram (Balanced) Note: During this step the input from Hot Utility to the first interval is equal to zero Minimum Q-heating = 2620 kW 0.0 1300 100 750 100 50 760 1860 2 690 3 580 4 280 Thermal Pinch 5 0.0 6 0.0 380 1050 2470 210
Minimum Q-cooling = 50 kW
With the completion of this step, now the minimum heating utility and minimum cooling utility required are 2620 kW and 50 kW respectively. These targets can give some idea about the potential of utility saving in the facility. To get better idea in terms of utility types needed, diagram known as grand composite curve shall be drawn to be used in defining kind of utilities needed and compare it with the current facility needs from such utility. This step will help in capturing some potential savings upon the heat integration of certain process area.
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4. Constructing the grand composite curve (G.C.C) This curve will be drawn between T* calculated before and the corresponding top heat inputs to each interval. These data are depicted below:
Data Required To Construct The G.C.C
T* (K) 555 T* (K) 515 385 3 375 4 310 305

Thermal Pinch
Enthalpy ( kW) 2620 kW 1 1860 kW 2 690 kW 580 kW 280 kW 5 6 0.0 kW
295
50 kW Enthalpy ( kW)
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Drawing these data as T* versus Enthalpy results in the following diagram that can be used to define different levels of utilities that can be used to satisfy the process heating utility requirement as shown below.
Grand Composite Curve (G.C.C)

Should Be Drawn To Scale
T* (K) 600
Total hot utility required is equal to 2620 kW Hu3 Hu2
500 Hu1 400
300
200
Enthalpy ( kW) 700 1400 2100 2800
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Multiple utility targeting/selection using Grand Composite Curve (GCC) Upon maximizing heat recovery in the heat exchanger network, those heating duties and cooling duties not serviced by heat recovery must be provided by external utilities. The most common utility is steam. It is usually available at several levels. High temperature heating duties require furnace flue gas or a hot oil circuit. Cold utilities might be refrigeration, cooling water, air cooling, furnace air preheating, boiler feed water preheating, or even steam generation at higher temperatures. Although the composite curves can be used to set energy targets, they are not a suitable tool for the selection of utilities. The grand composite curve drawn above is a more appropriate tool for understanding the interface between the process and the utility system. It is also as will be shown in later chapters a very useful tool in studying of the interaction between heat-integrated reactors, separators and the rest of the process. The GCC is obtained via drawing the problem table cascade as we shown earlier. The graph shown above is a typical GCC. It shows the heat flow through the process against temperature. It should be noted that the temperature plotted here is the shifted temperature T* and not the actual temperature. Hot streams are represented by Tmin/2 colder and the cold streams Tmin/2 hotter tan they are in the streams problem definition. This method means that an allowance of Tmin is already built into the graph between the hot and the cold for both process and utility streams. The point of zero heat flow in the GCC is the pinch point. The open jaws at the top and the bottom represent QHmin and QCmin respectively. The grand composite curve (GCC) provides convenient tool for setting the targets for the multiple utility levels of heating utilities as illustrated above.
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The graphs below further illustrate such capability for both heating and cooling utilities.
The above figure (a) shows a situation where HP steam is used for heating and refrigeration is used for cooling the process. In order to reduce utilities cost, intermediate utilities MP steam and cooling water (CW) are introduced. The second graph (b) shows the targets for all the utilities. The target for the MP steam is set via simply drawing a horizontal line at the MP steam temperature level starting from the vertical axis until it touches the GCC. The remaining heat duty required is then satisfied by the HP steam. This maximizes the MP steam consumption prior to the remaining heating duty be fulfilled by the HP steam and therefore, minimizes the total utilities cost. Similar logic is followed below the pinch to maximize the use of the cooling water prior the use of the refrigeration.
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The points where the MP steam and CW levels touch the GCC are called utility pinches since these are caused by utility levels. The graph (C) below shows a different possibility of utility levels where furnace heating is used instead of HP steam. Considering that furnace heating is more expensive than MP steam, the use of the MP steam is first maximized. In the temperature range above the MP steam level, the heating duty has to be supplied by the furnace flue gas. The flue gas flowrate is set as shown in graph via drawing a sloping line starting from the MP steam to theoretical flame temperature Ttft. If the process pinch temperature is above the flue gas corrosion temperature, the heat available from the flue gas between the MP steam and pinch temperature can be used for process heating. This will reduce the MP steam consumption. In summary, the GCC is one of the basic tools used in pinch technology for the selection of appropriate utility levels and for targeting for a given set of multiple utility levels. The targeting involves setting appropriate loads for the various utility levels by maximizing cheaper utility loads and minimizing the loads on expensive utilities.
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(C) T*
T-tft
MP
CW
Refrigeration
Page 42 of 54
Normally, Plants Operations have choices of many hot and cold utilities and the graph below shows some of available options. Generally, it is recommended to use hot utilities at the lowest possible temperature while generating it at the highest possible temperature. And for the cold utilities it is recommended to use it at the highest possible temperature and generate at the lowest possible temperature. These recommendations are best addressed systematically using the grand composite curve.
Hot and cold utilities

Boiler House And Power Plant Fuel
Steam Turbines
W Gas Turbines W
Hot Oil Circuit
BFW preheat
Process
Heat Pump
Furnace
Cooling Towers Air preheat Refrigeration
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Understanding the Grand Composite Curve: The graph below shows that utility pinches are formed according to the number of utilities used. Each time a utility is used a utility pinch is created. It also shows that the GCC right noses sometimes known as pockets are areas of heat integration/energy recovery. In other words it does not need any external utilities. These right noses/pockets are caused by; Region of net heat availability above the pinch Region of net heat requirement below the pinch
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Applying the Grand Composite Curve: GCC curve can be used by engineers to select the best match between utility profile and process needs profile. For instance, the steam system shown below needs to be integrated with the process demands profile to minimize low pressure steam flaring and high or medium pressures steam let downs. Besides it helps selecting steam header pressure levels and loads.
HP Boiler
HP
Proc. #1
Proc. #2 MP Boiler
chemicals
Vent
MP
Proc. #4 Proc. #1 Vent Deaerator
BFW Raw water Make-up Treatment Plant
LP
Effluent Proc. #1
Process Condensate
Proc. #3
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Superimposed Utility Profile with Process Profile Nominal Case Supply-Demand Matching Problem
T
HP
MP
Process GCC
LP
BFW CW
H
The superimposed steam system on the process grand composite curve shows that while process heating needs can be achieved electricity can also be generated to satisfy process demands and/or export the surplus to the grid.
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The graph below shows how we can use the GCC not only to select utility type, load but also to define the steam headers minimum pressure/temperature to minimize driving force and save energy.
Qh
HP MP
LP
BFW
CW
Qc H
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Grand Composite Curve can also be utilized to select the load and return temperature of hot oil circuits. The graph below shows that while in many cases the process pinch can be our limiting point in defining the load (slop of the hot oil line) and the return temperature of the heating oil. In some other cases the topology of the GCC is the limiting point not the process pinch. This is also shown in the second graph below. This practical guide to select the load and the target temperature of the hot oil circuits is also applicable to furnaces as will be shown later in this chapter.
Process Pinch temperature is the Limiting temperature for the Hot oil return temperature
T*
T supply Hot Oil
T return Process Pinch
CW
Refrigeration
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Process Pinch temperature is not the Limiting temperature for the Hot oil return temperature But the topology of the GCC curve
T*
Hot Oil CP-min T return
T supply
Process Pinch
CW
Refrigeration
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Grand composite curve (GCC) can also be used to select the process refrigeration levels and the synthesis of the multiple-cycles refrigeration systems as we did in the steam system. The schematic graph below shows a simplified refrigeration system.
Schematic Diagram for multi-level Refrigeration System
Condenser
25C
CW -5C
Process 0C
Process -35C
-40C
Process -65C
-70C
Work Compressor
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The GCC as we mentioned before can be used to place the refrigeration levels as we did with steam levels. The graph below shows how we can do that.
We can place the refrigeration levels like steam levels. Maximizing the highest temperature load to minimize the lower temperature loads
Tcw
- 5 C
- 40 C - 70 C
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When a hot utility needs to be at a high temperature and/or provide high heat fluxes, radiant heat transfer is used from combustion of fuel in furnace. Furnace designs vary according to the function of the furnace, heating duty and type of fuel, and method of introducing combustion air.
4A.3 Basic Formulas for Some Quick Savings Estimation

_Compression Energy % Savings Due to Decrease in compressors Inlet temperature % Energy saving in a compressor energy consumption = {1- (Tnew/Told)} * 100 Tnew is the new inlet temperature Told is the old inlet temperature _ Turbines gland steam leakage: Steam leakage in kg/hr = Flow of steam measured- Flow of steam utilized/required Flow of steam required= work shaft required/ {Estimated Isentropic efficiency*(Inlet enthalpy- outlet isentropic enthalpy) Outlet isentropic enthalpy can be obtained from steam tables knowing outlet isentropic entropy and outlet temperature or pressure Outlet isentropic entropy = inlet entropy Inlet entropy can be obtained from steam tables at inlet temperature and pressure _ Back pressure turbines energy available for integration Thermal energy available for Integration (Q) = Outlet steam flow* (Vapor enthalpy- liquid enthalpy) Outlet steam flow= Inlet steam flow (1- actual wetting factor) Actual wetting factor can be assumed between (8 to 15) % _ % Energy saving in heat pumps/refrigeration cycles due to decrease in reject temperature
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W2/W1 = (T reject 2 Tc)/ (T reject 1 Tc) Treject is the temperature at which heat is rejected to the cooling medium (water) Tc is the temperature at which heat is taken into the refrigeration) cycle _ Material balance for the cooling tower Assuming the system is at equilibrium Make-up = Evaporation+ Blowdown+ Windage loss Cooling towers cycles of concentration (C) C= concentration of solids in the circulating water/ concentration of solids in make-up water _ Energy saving in adjusting of combustion in a natural gas fired boiler/furnace Analysis on the exhaust from the boilers sometimes or most of the times in some places reveals excess oxygen levels which result in unnecessary energy consumption. This excess air defines a low efficiency on the combustion process. Portable or even on-line flue gas analyzer can be used as a part of a rigorous boilers/furnaces inspection program. The optimum amount of O2 in the flue gas of a gas fired boiler is 2%, which corresponds to 10% excess air. Controlling the combustion process could lead to at least 2% fuel saving upon bringing the excess O2 from for instance 6% to 2%. Cost saving $/year= Energy usage per year* % possible fuel savings* fuel cost per unit of energy Energy saving in adjusting of combustion in a an oil fired boiler/furnace. Analysis on the exhaust from the boilers sometimes or most of the times in some places reveals excess oxygen levels which result in unnecessary energy consumption. This excess air defines a low efficiency on the combustion process. Portable or even on-line flue gas analyzer can be used as a part of a rigorous boilers/furnaces inspection program. The optimum amount of O2 in the flue gas of an oil fired boiler is 4%. Controlling the combustion process could lead to at least 1% fuel saving upon bringing the excess O2 from for instance 6% to 1%.
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Cost saving $/year= Energy usage per year* % possible fuel savings* fuel cost per unit of energy Energy saving in preheating boiler/furnace combustion air with stacks waste heat: If the intake air (air drawn from outside into the natural gas boiler) is at ambient outdoor temperature unnecessary fuel will be consumed to heat up this combustion air. In order to reduce fuel consumption, it is recommended to install recuperative air pre-heater on the air intake of the boiler to preheat combustion air using heat which is exhausted along with the combustion from the boiler. Stack exhaust losses are part of all fuel-fired processes. They increase with the exhaust temperature and the amount of excess air the exhaust contains. A high quality air pre-heater could recover more than 40% of this waste heat. Therefore, the potential savings from the installation of air pre-heater on the boiler is: Cost saving = fuel cost ($)/unit of energy* Energy Consumed/year*(boiler efficiency)*percent of energy recovered by air pre-heater Note: The following attached pages are two curves and a table that can be used to estimate the percentage of fuel savings.
4A.4 HGP Detailed Energy Assessment Study

Final Report, SAER # 5995,Detailed Energy Assessment at Hawiyah Gas Plant, June 26, 2005
Page 54 of 54

Best Practice: Quick Energy Assessment Methodology For Energy Efficiency Optimization

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Best Practice

Quick Energy Assessment Methodology for Energy Efficiency Optimization

SABP-A-005 Quick Energy Assessment Methodology for Energy Efficiency Optimization

Methodology 3.1 3.2 3.3 3.4 3.5

SABP-A-005 Quick Energy Assessment Methodology for Energy Efficiency Optimization

Purpose and Scope

SABP-A-005 Quick Energy Assessment Methodology for Energy Efficiency Optimization

Initial Assessment Objectives

Quick Energy Assessment Overview

Energy Efficiency Optimization Task Description

SABP-A-005 Quick Energy Assessment Methodology for Energy Efficiency Optimization

Solution Method Using Decomposition Approach

SABP-A-005 Quick Energy Assessment Methodology for Energy Efficiency Optimization

Target (order of magnitude targeting) a. b. c.

SABP-A-005 Quick Energy Assessment Methodology for Energy Efficiency Optimization

Energy Flow Diagrams

Buildings & Others

Process Energy Byproducts

SABP-A-005 Quick Energy Assessment Methodology for Energy Efficiency Optimization

Overall Energy Flow Diagram ($/yr)

Typical Oil Refinery

$ 0.8 MM $ 41.5 MM $ 0.4 MM

Machine Drive Re-boilers heaters

$ 51.2 MM $ 73.1 MM $ 0.0 MM $ 0.3 MM $ 18.4 MM $ 19.1 MM

$ 0.40 MM Other users

SABP-A-005 Quick Energy Assessment Methodology for Energy Efficiency Optimization

Typical Gas Plant

$ 0.0 MM/yr $ 0.0 MM/yr

$ 20.018 MM/yr 2.54 MM Ib/hr $19.618 MM/yr $0.11MM/yr $0.27 MM/yr

$ 19.618 MM/yr $ 0.0 MM/yr

$ 20.018MM/yr $ 0.0 MM/yr

$ 0.0 MM/yr $ 56.1 MM/yr

Note: These Data are Shedgums Gas Plant

SABP-A-005 Quick Energy Assessment Methodology for Energy Efficiency Optimization

Overall Energy Flow Diagram (Trillion-Btu/yr)

Total Input= 10.56 TBtu 2 TBtu

0.5 TBtu Building

Heating 7.56 TBtu

Cooling/Ref 0.55 TBtu

Machine Drive 1.24 TBtu

Electro-Chem 0.0 TBtu

Other use 0.02 TBtu

SABP-A-005 Quick Energy Assessment Methodology for Energy Efficiency Optimization

Steam and Power Diagram

Enhance condensate recovery By 10 % Shut down MP boiler

Heat integration of process#1 and # 4 Estimated saving of 10%

Reduce letdown via turbine flow increase or new turbine

68 t/h 27 t/h 30 t/h 13 t/h

2 t/h 18 t/h 40 t/h

0.0 t/h 30 t/h 0.0 t/h 7 t/h

BFW 49 t/h Raw water Make-up Treatment Plant

SABP-A-005 Quick Energy Assessment Methodology for Energy Efficiency Optimization

SABP-A-005 Quick Energy Assessment Methodology for Energy Efficiency Optimization

Energy Saving Housekeeping list 1.

SABP-A-005 Quick Energy Assessment Methodology for Energy Efficiency Optimization

Energy Saving Generic Checklist

SABP-A-005 Quick Energy Assessment Methodology for Energy Efficiency Optimization

SABP-A-005 Quick Energy Assessment Methodology for Energy Efficiency Optimization

Revision Summary New Saudi Aramco Best Practice.

SABP-A-005 Quick Energy Assessment Methodology for Energy Efficiency Optimization

4A.0 Appendices for Short-Cut Calculations and HGP Energy Study

0.0 t/h 1 t/h

Capacity of C1, kW Capacity of C2, kW 19(550-510)= 760 0.0(550-510)= 0.0