ENERGY CONSERVATION IN

CHEMICAL PROCESS
INDUSTRIES
Dr.V.SIVASUBRAMANIAN
Associate Professor
Former Head
Chemical Engineering
NIT Calicut

1
DEPARTMENT OF CHEMICAL
ENGINEERING
 Agenda
1. Introduction
2. Energy Conservation in Reactors
3. Energy Conservation in Packed Beds
4. Energy Conservation in Heat Exchangers
5. Energy Conservation in Evaporators
6. Energy Conservation in Crushers and Grinders
7. Heating and Cooling Requirement in Distillation
Columns
8. Energy Conservation in Dryers
9. Energy Conservation in Pumps
10. Methodology of Optimizing Energy Use
11. Areas of energy Optimization in CPI
12. Energy Efficiency Improvement and Cost Saving
Opportunities in Petrochemical Industry 3
1. Introduction
CHEMICAL
PROCESS

UNIT UNIT
PROCESS OPERATION

CHEMICAL ENGINEERING DEPT NIT CALICUT 4

 Figure I
Input Processing Output
System
RECYCLE DISPOSAL

WASTE

INPUT PROCESSING OUTPUT

CHEMICAL ENGINEERING DEPT NIT CALICUT

Chemical Reaction Types in
Petrochemical Industries
1 Pyrolysis 16 Oxidation

2 Alkylation 17 Hydrodealkylation

3 Hydrogenation 18 Isomerization

4 Dehydration 19 Oxyacetylation

5 Hydroformylation 20 Oligormerization

6 Halogenation 21 Nitration

7 Hydrolysis/Hydration 22 Hydrohalogenation

8 Dehydrogenation 23 Reduction

9 Esterification 24 Sulfonation

10 Dehydrohalogenation 25 Hydrocyanation

11 Ammonolysis 26 Neutralization

12 Reforming 27 Hydrodimerization

13 Oxyhalogenation 28 Miscellaneous
29 Nonreactor processes
14 Condensation

15 Cleavage

U.S.-EPA (1993) 6
Unit Operations
Liquid-vapor separation (distillation, evaporation,
stripping)
Liquid-liquid separation (extraction, decanting)

Solid-liquid separation (centrifugal, filtration)

Solid-gas separation (filtration)

Solid-solid separation (screening, gravity)

CHEMICAL ENGINEERING DEPT NIT CALICUT 7

 2.Energy Conservation in Reactors
Ideal Reactors

(a) Batch reactor, or BR (b) Plug flow reactor, or PFR and

(c) Mixed flow reactor, or MFR

8
Broad Classification of Reactor
Types

(a) The batch reactor. (b) The steady-state flow reactor. (c), (d), and
(e) Various forms of the semibatch reactor
CHEMICAL ENGINEERING DEPT NIT CALICUT 9
Material Balance for the
Element of Volume of Reactor

10
Material Balance for the
Element of Volume of Reactor

11
Energy Balance for the Element
of Volume of Reactor

12
Energy Balance for the Element
of Volume of Reactor

13
AGITATION PROCESS VESSEL

14
Mixing Impellers

(a) three-blade marine propeller; (b) open straight-blade

turbine; (c) bladed disk turbine; (d) vertical curved-blade
turbine; (e) pitched-blade turbine

15
Design of Agitated Vessel

16
17
Power Consumption in Agitated
Vessel

Np power no.
P power in kW
gc Newtons law proportionality factor
n rotational speed r/s
Da diameter of impeller in m

18
density in kg/m3
Power Correlation

S1, S2, Sn Shape factors

hc individual htc for outside of coil, W/m 2-C

Dc outside dia of coil tubing, m
k thermal conductivity, W/m-C
Cp specific heat @constant pressure, J/g-C
absolute viscosity, cP
w absolute viscosity @wall or surface temp
19
Swirling flow pattern with a radial-
flow turbine in an unbaffled vessel

20
Prevention of Swirling

21
Multiple turbines in tall tanks

22
Draft tubes, baffled tank

(a) Turbine (b) propeller

23
Energy Efficiency in Reactors

Agitator motor current monitoring:

VFD deployment feasibility.
Accurate mass transfer for reaction by mass
flow meters or vortex/magnetic flow meters.
Recovery of heat in case of Exothermic
Reaction
Batch Automation to control the reaction
within a narrow range, saving energy
consumed.
3. Energy Conservation in
Packed Beds

Nusselt Number
hw individual htc of gas film near tube wall
Dp diameter of particle
kg thermal conductivity of gas
Prandtl Number,

25
4. Energy Conservation in Heat
Exchangers

Single pass tubular condenser

26
27
Energy Balance in Heat
Exchangers

flow rate of stream

q = Q/t = rate of heat transfer into stream
Ha, Hb enthalpies per unit mass of stream at
entrance and exit

28
EXTENDED SURFACE
EQUIPMENT

Types of extended surface: (a) longitudinal fins;

(b) transverse fins.
29
5. Energy Conservation in
Evaporators
Types of Evaporators

30
Climbing-film, long-tube
vertical evaporator

31
Evaporator Capacity and
Economy

q rate of heat transfer through heating

surface from steam
Hs specific enthalpy of steam
Hc specific enthalpy of condensate
s latent heat of condensation of steam
rate of flow of steam
32
Methods of Feeding in Evaporator

Patterns of liquor flow

in multiple~effect
evaporators:
(a) forward feed
(b) backward feed
(c) mixed feed
(d) parallel feed

33
6. Energy Conservation in
Crushers and Grinders

Rittingers Law

Kicks Law

Bonds Law
34
7. Heating and Cooling Requirement
in Distillation Column
If saturated steam is used as the heating medium, the
steam required at the reboiler

steam consumption
vapor rate from reboiler
s latent heat of steam
molal latent heat of mixture

35
If water is used as the cooling medium in
the condenser and the condensate is not
subcooled, the cooling-water requirement is

water consumption
T2 - Tl = temperature rise of cooling
water

36
8. Energy Conservation in
Dryers

Tray Dryer
37
Temperature Patterns in Dryers

(a) batch dryer

(b) continuous countercurrent adiabatic dryer

38
Calculation of Heat Duty
Heat transferred per unit mass of solid

39
 9.ENERGY
CONSERVATION IN
PUMPS

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10. Methodology of Optimizing
Energy Use
1. Measure and benchmark consumption. Compare
with globally accepted norms.

2. Carryout energy audit and energy balance.

3. Examine availability of more energy efficient

processes and equipment with higher efficiencies.
Implement new technologies bringing in a reduction
in energy & raw material consumptions.

4. Reduce cycle time by eliminating non-value adding

activities. 58
5. Identify areas of losses and plan methods to reduce
losses.

6. Reuse waste, harness waste streams.

7. Replace higher form of energy use by low grade /

low cost / renewable energy.

8. Minimize transmission losses.

9. Measure and control.

59
11. Areas of energy
Optimization in CPI
1. BOILERS AND STEAM USAGE
a. For Solid fuel fired boilers: Convert stoker fired
boilers to FBC
b. Optimize excess air. Provide continuous monitoring
with auto adjustment of oxygen trim in large boilers
and periodical checking in smaller boilers.
c. Preheat combustion air with waste heat
d. Install variable frequency drives (VFD) on large
boiler combustion air fans having variable loads.
e. Burn waste stream if permitted, use bio waste like
coconut kernel, rice husk, instead of conventional
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fuels.
f. Recycle condensate.
g. Recover flash steam from higher pressure
condensate.
h. Pass steam through back pressure steam turbine
rather than through pressure reducing station for low
pressure steam.
i. Attend steam leakages and repair damaged
insulation.
j. Examine possibility of installation of cogeneration
systems (combined electricity and steam generation)
/ trigeneration system (combined electricity, steam &
refrigeration generation)
61
2. PUMPS
a. Select the right pump to match head and flow
requirements.
b. Make maximum use of gravity flow. Avoid
intermediate storages to avoid pumping. For
circulation system use siphon effect; avoid free fall
(gravity) return.
c. Avoid throttling / bypass; to control flow, prefer
speed controls or sequenced operation of pumps.
d. In pumping to systems having a number of non-
continuous users, auto ON-OFF valves / control
valves need to be provided on users and VFD on
pumps. 62
f.Segregate high head and low head loads and install
separate pumps.
g.Operate booster pumps for small loads requiring
higher heads, in place of operating complete system at
higher head.
h.Operator cooling/chilling system with higher fluid
differential temperature to decrease flow and hence
save pumping energy.
i.Replace old pumps by high efficiency pumps.

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j. Trim impellers wherever pumps are over designed.
k. Valve throttling indicates pump over design; replace
pump with correct size pump or install lower size
impeller
l. Coat hydraulic passages of pumps with resins
having better surface finish to reduce internal friction
and increase efficiency.
m. Minimize pressure drop in piping by rerouting of
pipeline, removing valves, which never need to be
operated, and resizing of pipeline.
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3. COOLING TOWERS
a. Control CT fans based on cold well temperature; use
two speed or VFD if fans are few and on-off stage
control if cells are many.
b. Select CT with low pressure drop, high efficiency
PVC cellular fills in place of splash bars.
c. Periodically clean, water distribution nozzles. Ensure
that no channeling of water flow is taking place.
Uniform flow distribution will improve performance of
cooling tower.
d. Optimize cooling water chemical treatment.
e. Replace aluminum fans by aerodynamic FRP fans.
65
4. REFRIGERATION
SYSTEMS
a. Challenge the need of refrigeration system,
particularly, for old batch processes. Optimise the
temperature requirement.

b. Examine the possibility of vapour absorption system

operating with waste heat streams in place of vapour
compression systems.

c. Check regularly for correct refrigerant charge levels.

66
d. Check for damaged insulation / sweating.

e. Select multistage compressors with inter cooling for

low temperature applications.

f. Operate chillers with lowest possible condensing

temperature and highest possible chiller (evaporator)
temperature.

g. Carryout regular cleaning of condenser to ensure

proper heat transfer.

67
5. LIGHTING
a. Select high efficiency lighting luminaries having
highest lumens / watt output. eg. Compact
fluorescent lamp (CFL), low pressure sodium vapour
lamp.

b. Provide lighting transformer to reduce the voltage of

lighting loads.

c. Make use of task lighting.

d. Make most use of day lighting by providing skylight. 68

e. Paint walls and ceiling with light colors.

f. Lower height of light fixtures.

g. Control lighting with clock timers, occupancy

sensors, photocells and master switch.

h. Select ballast with high efficiency and high power

factors.

i. Use LED lamps for indicating purpose.

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6. FANS & BLOWERS
a. Select fans with aerofoil fan blades; replace old
inefficient fans by modern high efficincy fans /
blowers.

b. Ensure that design of fans / blowers are matching

with operating conditions if not replace with correct
size fan / blower.

c. Replace throttle / bypass control by speed control.

70
d.Minimize speed to minimum possible.

e.Reduce pressure drops in system by proper design /

sizing of ducting. Minimize bends in ductings.

f.Eliminate leakages.

g.Clean screen, filters, fan blades regularly.

h.Avoid idle running of fans by interlocking with main

equipments.

71
7. MOTORS
a. Properly size the motor for the optimum efficiency.

b. Use energy efficient motors for continuous operating

loads.

c. Balance three phase loads. An imbalanced voltage

can reduce efficiency of motor by 3-5%.

d. Connect motors remaining under loaded (< 40%)

continuously, in star.
72
e. Rewound motors should be checked for
efficiency.
f. Provide capacitor banks at MMC to
correct PF.
g. Use soft starters / VFD instead of fluid
coupling for loads having high starting
torque or loads prone to jamming.

73
12. Energy Efficiency
Improvement and Cost
Saving Opportunities in
Petrochemical Industry

74
The U.S. Petrochemical
Industry
The North American Industry Classification (NAICS) distinguishes
seven 4-digit sub-sectors of the chemical industry:

3251 Basic chemical manufacturing

3252 Resin, synthetic rubber, and artificial synthetic fibers and
filaments manufacturing
3253 Pesticide, fertilizer and other agricultural chemical
manufacturing
3254 Pharmaceutical and medicine manufacturing
3255 Paint, coating, and adhesive manufacturing
3256 Soap, cleaning compound, and toilet preparation
manufacturing
3259 Other chemical product and preparation manufacturing
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Supporting Equipment and
Infrastructure
Emission abatement equipment.

Product storage and handling equipment

Boilers, Combined Heat and Power (CHP) plants and other parts
of the steam infrastructure including pipes and valves.
Furnaces and process heaters.

Pumps, compressors, vacuum, pressure relief equipment and

fans.

Heat exchangers, cooling and refrigeration.

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Energy use in the chemical industry by
fuels and feedstock category, 2002

77
Energy use by sub-sector,
2002

78
End use of electricity in the total
chemical industry and the sub-
sectors studied, 2002

79
Estimated final energy
consumption for selected key
chemicals

80
Main elements of a strategic
energy management program

81
Simplified schematic of a steam
production and distribution system

82
Summary of energy efficiency
measures in boilers (Steam Supply)

83
Steam Supply - Combined
Heat and Power

Steam injected gas turbines

High-temperature CHP
Steam expansion turbines

84
Summary of energy efficiency
measures in steam distribution
systems

85
Furnaces and Process Heaters
Heat Generation
Control the air-fuel ratio
Excess air should be limited to 2-3%
oxygen

86
Heat transfer and heat
containment in heaters
Use of soot blowers, burning off carbon and other
deposits from radiant tubes and cleaning the heat
exchange surfaces. Typical savings are 5-10%.
Ceramic coated furnace tubes can improve heat
transfer
Reducing wall heat losses (typical savings 2-5%),
furnace pressure control (5-10%), maintenance of door
and tube seals (up to 5%), reducing cooling of internal
parts (up to 5%) and reducing radiation heat losses (up
to 5%).

87
Flue gas heat recovery
Others controls, maintenance and
electric heaters

88
Electric Motors
Motor Management Plan

Creation of a motor survey and tracking program.

Development of guidelines for proactive repair/replace
decisions.
Preparation for motor failure by creating a spares
inventory.
Development of a purchasing specification.
Development of a repair specification.
Development and implementation of a predictive and
preventive maintenance program.

89
Strategic motor selection
Maintenance
Properly sized motors
Adjustable speed drives
Power factor correction
Minimizing voltage unbalances

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Pumps
Operations and maintenance
Monitoring
Reduce need
More efficient pumps
Correct sizing of pump(s) (matching pump to
intended duty)
Use multiple pumps
Trimming impeller (or shaving sheaves)
Controls

91
Adjustable speed drives (ASDs)
Avoid throttling valves
Correct sizing of pipes
Replace belt drives
Precision castings, surface coatings or polishing
Sealings
Curtailing leakage through clearance reduction
Dry vacuum pumps

92
Fans and Blowers
Fan oversizing
Adjustable speed drives (ASDs) and
improved controls
High efficiency belts (cog belts)

93
Compressors and Compressed
Air Systems
Compressed air maintenance
Monitoring
Reduce leaks (in pipes and equipment)
Reducing the inlet air temperature
Maximize allowable pressure dew point at air intake
Optimize the compressor to match load
Controls
Properly sized regulators
Sizing pipe diameter correctly
Heat recovery for water or space heating preheating
Adjustable speed drives (ASDs)
High efficiency motors
94
Distillation
Enhanced distillation controls
Optimization of reflux ratios
Check product purity
Seasonal operating pressure adjustments
Column insulation
Reducing reboiler duty
Feed conditioning
Upgrading column internals
Stripper optimization
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Buildings: HVAC and Lighting
Energy Efficiency Measures for HVAC Systems
Energy efficient system design
Recommissioning
Energy monitoring and control systems
Non-production hours set-back temperatures
Duct leakage repair
Variable-air-volume systems
Adjustable-speed drives (ASDs)
Heat recovery systems
Fan modification
Efficient exhaust fans
Use of ventilation fans
Cooling water recovery
Solar air heating
Building reflection
Building insulation
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Low emittance (Low-E) windows
Energy Efficiency Measures for
Lighting
Turning off lights in unoccupied areas
Lighting controls
Exit signs
Electronic ballasts
Replacement of T-12 tubes with T-8 tubes
Replacement of mercury lights
High-intensity discharge (HID) voltage reduction
High-intensity fluorescent light
Daylighting
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CONCLUSIONS
A key first step in any energy improvement initiative is to establish
a focused and strategic energy management program, which will
help to identify and implement energy efficiency measures and
practices across and organization and ensure continuous
improvement.
While the expected savings associated with some of the
individual measures may be relatively small, the cumulative effect
of these measures across an entire plant may potentially be quite
large.
The degree of implementation of these measures will vary by plant
and end use; continuous evaluation of these measures will help to
identify further cost savings in ongoing energy management
programs.
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ACKNOWLEDGEMENT
Octave Levenspiel, Chemical Reaction
Engineering, Wiley Eastern Limited.
McCabe, W.L. and Smith, J.C., Unit Operation of
Chemical Engineering, McGraw Hill, New York.
Internet sources

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THANK YOU