process - nrcan.gc.ca

CANMET Energy Technology Centre - Varennes

Ressources naturellesCanada

Natural ResourcesCanada Canada

ProcessIntegration

General Overview

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Outline

Industry issues

What is Process Integration (PI)?

Benefits of PI

Who can benefit from PI?

Main steps of a PI study

Case studies

The role of CETC-Varennes

Conclusions

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Industry Issues

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Energy is used extensively in industry

• Steam production

• Drying

• Process heating, etc.Energy costs

• Can represent more than 10% of total production costs

• Are very volatileTypical potential for energy savings: 10 to 40%

Efficient energy management is of prime importance for industry

Industry Issues

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Production costs =

Energy costs +

Salaries +

Cost of materials & supplies

1 Data from Statistic Canada, 2001

Industry Issues

IndustrialSectors

Energy / ProductionCosts1

Iron & Steel 13%Cement 38%Pulp and Paper 13%Petrochemicals 7%Fertilizers 17%Industrial gas 41%Sugar refining 7%Breweries 7%Distilleries 9%

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Industry IssuesEvolution of Natural Gas Cost

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Is there any systematic approach to addressenergy efficiency issues in large and complexsystems ?

Industry Issues

Install thermo-compressor ?Steam turbine ?

New boiler ? Heat exchanger ?

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ProcessIntegration

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What is Process Integration?

A systematic approach to identify and correct inefficiencies in industrial processes

Looks at the global process, and the interactions between its different parts rather than considering individual operations

Takes into account process and financial constraintsbefore detailed design

Provides advanced analysis software

Complements conventional energy audits

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Simplified Pulp and Paper Mill

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Help industries to solve four interrelated issues…

Typical payback periods for energy: 6 months to 3 years

Typical energy savings potential: 10 to 40%

Typical cost of a PI study: $30k to $250k

Benefits of PI

Reduces energy consumption and GHG emissions

Reduces water consumption & effluents generation

Reduces raw material losses

Increases profitability

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Pulp & Paper, Oil & Gas, Petrochemicals, Chemicals, Steel & Metallurgy,

Food & Drink are good candidates

Who Can Benefit from PI?

Process Integration can be used for companies that:• Use large amount of energy (oil, gas, coal)

o Energy bill > $2M / year

• Have complex water and energy networks

• Have utility or treatment systems bottleneck

• Have high wastewater treatment costs

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Thermal Pinch AnalysisThe most widely used PI method

Evidence of practical application comes from more than 5,000 projects world-wide

Identify the minimum utility requirements to heat and cool the process

Identify the non-optimal heat exchanges within the process

Select the most appropriate location for new heat exchangers or for additional heat transfer area

Identify potential for cogeneration and heat pumps

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Energy Savings Potentialthrough Pinch Analysis

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Main Steps of a PI Study1. Obtain the plant direction commitment

2. Create a project team including a PI specialist, plant personnel and process experts

3. Process data gathering and heat/mass balance

4. Application of PI methodologies with specialised software:

Potential for maximum savings

Design options taking into account all process constraints

5. Technical and economical pre-feasibility study

6. Selection of projects in line with company resources and acceptable payback, and development of an investment strategy road map

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Case Study:Increase Heat Recovery

in a Crude Oil Preheat Train

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Case study: Crude Oil Preheat Train

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Re-sequencing

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4

Energy consumption reduction of 4.5% by optimising the location of heat exchanger #4 (Source: UMIST)

Heat Exchanger Network

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Case Studies:A Few Other Examples

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CETC-Varennes / Smurfit-Stone (La Tuque, Quebec)

12 projects acceptedfor implementation. A few examples:

New heat exchangers

Increase of condensatereturn

Improvement of batch digester scheduling

Modification to the water network configuration

Case StudiesPulp and Paper Industry

Pulp & Paper Industry

Savings ($/year) 6,000,000

EnergyConsumption

-15% ofpurchases

Simple payback 10 months

CO2 reductions 49,000 t/year

Water reduction 5,000 m3/day

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CETC – Varennes(Textile dye house)

7 projects met technical andeconomical criteria. A few examples:

2 new heat exchangers

Better use of an existing direct contact economizer

Insulation of equipment and piping

Reduction of losses to vents

Case StudiesTextile industry

Textile Industry

Savings ($/year) 800,000

EnergyConsumption -30%

Simple payback 9 monthsCO2 reductions 6,400 t/year

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CANMET EnergyTechnology

Centre-Varennes(CETC-Varennes)

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CANMET Energy TechnologyCentre-Varennes (CETC-Varennes)

Research centre of Natural Resources Canada

One of the three research centres in energy in the Government of Canada

Facilities opened in 1992

The Centre is located in Varennes (south shore of Montréal)

Staff: 90 scientists, engineers and support staff

Budget: $10M / year

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Develop, demonstrate and promote innovative technologies in Energy Efficiency and Renewable Energy that:

• Foster sustainable development and efficient use of Natural Resources

• Contribute to the prosperity of Canadian enterprises

AND

CETC-Varennes Mission

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Our main activitiesProgram for Buildings

• Reduce energy consumption in commercial and institutionalbuildings while maximizing the well being of individuals

• Arenas, supermarkets, other large buildings

Program for Renewable Energies

• Increase the reliability and the competiveness, promote the use of renewable energies

• RETScreen International, Photovoltaïcs

Program for Industry

• Reduce greenhouse gas emissions through the optimisation of energy consumption in industrial processes

• Specific equipments, processes or entire plant

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R&D activities: adapt existing methodologies and develop new approches

Demontration projects: partnership with industry, engineering companies, other research centres and government organisations

Information dissemination: case studies and decision support tools to help industry understanding the benefits of PI

Capacity building: transfer of expertise to engineering companies

Development Demonstration Deployment Research

PI Group Objectives:Promote the use of PI in the Canadian Industry

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Process Integration can help Canadian industries to solve four interrelated issues…

• Energy efficiency and GHG emission reduction

• Profitability

• Water and wastewater minimization (material & energy)

• Efficient use of raw materials

... while respecting all process constraints and investment criteria of a given plant

• Typical payback for energy projects: 0.5 to 3 years

• Typical energy and water savings: 10 to 40%

Conclusions

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Contact information

CANMET Energy Technology Centre1615, Lionel-Boulet Blvd, P.O. Box 4800

Varennes QC J3X 1S6

E-mail: [email protected] Site: http://cetc-varennes.nrcan.gc.ca

process - nrcan.gc.ca

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