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Integração Energética na rede de BFW do Steam Cracker
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A Repsol Polímeros pretende proceder à eletrificação dos compressores de Etileno e Propileno no Steam Cracker (SC). Este projeto terá impacto na distribuição e consumo de vapor, sendo que corrobora com a redução de caudal de vapor expandido pelas turbinas de expansão para a rede de condensados.
Os objetivos são estudar o impacto da temperatura da Boiler FeedWater (BFW) no consumo de fuel gas (FG) e emissões de dióxido de carbono (CO2) nas fornalhas e aquecer a corrente importada de água desmineralizada (AD) – a 25°C – através de métodos de integração energética.
A simulação da rede de condensados (antes e após eletrificação) foi feita no Aspen Hysys (AH), a análise Pinch no Aspen Energy Analyzer (AEA) e o efeito da temperatura da BFW na fornalha no Spyro.
Concluiu-se a necessidade de importar mais 50t/h de AD. O estudo revelou um aumento no consumo de FG de 1,8% (consumo de mais 3,2ktFG/ano) e um aumento de 1,3% na emissão de CO2, igual a 10,5ktCO2/ano gerando custos anuais de 2,3M€.
No âmbito do aquecimento da corrente de AD, evidenciaram-se viáveis e rentáveis propostas como: a análise Pinch ao trem de Quench Oil (QO) com excesso de vapor no futuro onde se concluiu a necessidade de um novo permutador de calor (PC); o revamping da fornalha com aquisição de um novo bundle; revisão do dimensionamento da válvula de controlo do desarejador; reaproveitamento das purgas das caldeiras com aquisição de um novo PC e, destacando-se como mais promissora, a proposta de reaproveitamento do E9101, utilizando uma corrente de processo, Quench Water (QW), com um investimento de 135k€, um VAL de 1,3M€ e um PRC de 6,2 meses.
Estudou-se a otimização do aeroarrefecedor após eletrificação, reduzindo 61% das emissões de CO2 e uma poupança de 525k€/ano. O trem de QO foi otimizado alterando o tipo de utilidade quente gerada, sendo possível prescindir de um kettle e prevenção de 48 Mcal/h de energia dissipada pelas válvulas redutoras.
A combinação das propostas recomendadas, juntamente com o projeto de eletrificação, prevê uma redução de 32% das emissões de CO2 e 23% do consumo de FG no SC, representando uma poupança de 24M€ anualmente que, comparativamente com as metas da empresa, ambiciona reduzir 30% de emissões totais de CO2 até 2030.
Repsol Polímeros plans to electrify the ethylene and propylene compressors in the Steam Cracker (SC). This project is expected to impact the distribution and consumption of steam, thereby reducing the steam flow expanded by the expansion turbines into the conden sate network. The objectives of this study are to assess the impact of Boiler Feedwater (BFW) temper ature on fuel gas (FG) consumption and carbon dioxide (CO2) emissions in the furnaces, and to explore energy integration methods to heat the imported demineralized water (AD) stream, which is initially at 25°C. The condensate network, both before and after electrification, was simulated using As pen HYSYS (AH), while Pinch analysis was conducted in Aspen Energy Analyzer (AEA). The effect of BFW temperature on the furnace performance was evaluated using Spyro. The analysis concluded that an additional 50tph of AD would need to be imported. The study also revealed a 1,8% increase in FG consumption, amounting to an additional 3,2 ktpy, and a 1,3% increase in CO2 emissions, equivalent to 10,5 ktpy, resulting in annual costs of €2,3 million. In terms of heating the AD stream, several viable and cost-effective proposals were identified. These include a Pinch analysis of the Quench Oil (QO) train with excess steam in the future, which indicated the need for a new heat exchanger (PC); revamping the furnace by purchasing a new bundle; resizing the deaerator control valve; reusing boiler blowdowns with the purchase of a new heat exchanger (PC) and the most promising proposal, reusing E9101 by employing a process stream, Quench Water (QW). The latter proposal requires an invest ment of €135 000, with a net present value (NPV) of €1,3 million and a payback period (PRC) of 6,2 months. Additionally, the optimization of the air-cooler post-electrification was studied, lead ing to a 61% reduction in CO2 emissions and savings of €525 000 per year. The QO train was optimized by changing the type of hot utility generated, eliminating the need for a kettle, and preventing energy dissipation by the reducing valves. The combined implementation of the recommended proposals, alongside the electrifi cation project, is projected to achieve a 34% reduction in CO2 emissions and a 23% reduction in FG consumption in the SC, resulting in annual savings of €24 million. These outcomes align with the company's goal of reducing CO2 emissions by 30% by 2030.
Repsol Polímeros plans to electrify the ethylene and propylene compressors in the Steam Cracker (SC). This project is expected to impact the distribution and consumption of steam, thereby reducing the steam flow expanded by the expansion turbines into the conden sate network. The objectives of this study are to assess the impact of Boiler Feedwater (BFW) temper ature on fuel gas (FG) consumption and carbon dioxide (CO2) emissions in the furnaces, and to explore energy integration methods to heat the imported demineralized water (AD) stream, which is initially at 25°C. The condensate network, both before and after electrification, was simulated using As pen HYSYS (AH), while Pinch analysis was conducted in Aspen Energy Analyzer (AEA). The effect of BFW temperature on the furnace performance was evaluated using Spyro. The analysis concluded that an additional 50tph of AD would need to be imported. The study also revealed a 1,8% increase in FG consumption, amounting to an additional 3,2 ktpy, and a 1,3% increase in CO2 emissions, equivalent to 10,5 ktpy, resulting in annual costs of €2,3 million. In terms of heating the AD stream, several viable and cost-effective proposals were identified. These include a Pinch analysis of the Quench Oil (QO) train with excess steam in the future, which indicated the need for a new heat exchanger (PC); revamping the furnace by purchasing a new bundle; resizing the deaerator control valve; reusing boiler blowdowns with the purchase of a new heat exchanger (PC) and the most promising proposal, reusing E9101 by employing a process stream, Quench Water (QW). The latter proposal requires an invest ment of €135 000, with a net present value (NPV) of €1,3 million and a payback period (PRC) of 6,2 months. Additionally, the optimization of the air-cooler post-electrification was studied, lead ing to a 61% reduction in CO2 emissions and savings of €525 000 per year. The QO train was optimized by changing the type of hot utility generated, eliminating the need for a kettle, and preventing energy dissipation by the reducing valves. The combined implementation of the recommended proposals, alongside the electrifi cation project, is projected to achieve a 34% reduction in CO2 emissions and a 23% reduction in FG consumption in the SC, resulting in annual savings of €24 million. These outcomes align with the company's goal of reducing CO2 emissions by 30% by 2030.
Descrição
Palavras-chave
Rede de Condensados Pinch Integração Energética Descarbonização Fornalhas