Energy efficiency and cooling in large scale processing systems

Dr. Patrick LinkeQatar Shell Professor for Energy and Environment

Chair, Chemical Engineering ProgramExecutive Director, Office of Graduate Studies

Presented at

QNRF EU-GCC Conference on Energy Efficiency3 May 2017

Degrading Environment

Water Scarcity

Soil Exhaustion

Climate Change

Depleting Resources

…

Increasing Demands

Growing Population

Growing Income

Increasing Materials & Energy Intensity

In future we will need to support growth with much improved resource efficiency and reduced environmental impacts !

90%of all food consumed in

Qatar is imported

7 daysof potable water reserve

No. 1In per capita GDP and

GHG emissions

100%Dependency on seawater

desalination for potable water

supply

Local Situation in the State of Qatar

Direct result of

hydrocarbon resource

monetizationNo. 1In per capita GDP and

GHG emissions

Positives and negatives closely linked with process industries

Significant energy and

water footprints

Silo approach to projects

prevents efficiency at

systems level

Not integrated with other

sectors of the economy

(e.g. power/water)

Challenges for the process industries

How to make more money with lower footprints ?

How to enable additional efficiencies across silos ?

How to benefit other sectors (esp. water/power) ?

Better processes, better integration !

How to turn problems into opportunities with integrated process systems solutions ?

An example from RLC :

Once-through cooling seawater used for

process cooling

Dumping of many GW thermal energy

into the sea

Ignore it ? Avoid/reduce ? Reuse across

processes / sectors, … ? How ?

Does regulation allow synergy options ?

Why energy efficiency ?

Economics

Environment

Reduce cost of fuel and/or opportunity cost

Innovate technologies that can be exported

Reduce GHG emissions

Reduce negative impacts on air quality

Reduce impact on water resources (cooling water, …)

Where to draw the boundaries ?

Heat / power

centric view ?

Hydrocarbon-

centric view ?

How to reduce process energy requirements ?

How to utilize excess heat (power, water, …) ?

How to replace offset fossil energy inputs (solar, …) ?

How to best monetize hydrocarbon resources with

minimum footprints ?

Approaches to Design

- Trial & error- Brainstorming &

‘Experience’- Heuristics- Hierarchical approaches…C

on

ven

tio

na

l a

pp

roa

ches

Mo

re r

igo

rou

s a

lter

na

tive

- Limited time to search- Relatively few options considered- Likely to miss good options- Limited room for innovation:

Bias for conventional structures- Hope for ingenuity

- Capture all design alternatives in one model

- Search all options simultaneously- Identify highest performing

solutions against selected performance criteria

- Limited representations to capture design alternatives

- Existing representations often simplistic

- Optimal search of representations challenging (often MINLPs)

Process Systems Engineering approaches

Research Track: Sustainable Industrial Clusters

Systematic minimization of footprints through integrated resources management

Optimal design, multi-period planning, simultaneous nexus integration

Water CO2

Heat

Power

Nat. Gas

Other

materials

How to synergize within

and across processes &

plants?

How to synergize within

and across materials, energy?

(W-E, E-CO2, …)

Integrated process heat & water management

Desalinated water can be co-produced in large quantities at very low cost and without additional GHG emissions by energy integration.

Research under NPRP grant no. . 4-1191-2-468 from the Qatar National Research Fund

Water-Energy Nexus

12

Industrial clusters have high energy and water footprints, esp. in the GCC

Previous works have focused on water and energy integration independently

Significant interactions and trade-offs exist across the Water-Energy Nexus

Objective: To develop a representation to capturesignificant in-plant/inter-plant water and energymanagement options, initially focusing on

1. Process cooling requirements andCooling systems

2. Desalination and water treatment

Each plant has a (minimum) cooling requirement which creates:

Cooling costs associated with cooling (once-through seawater, cooling tower, air coolers)

Opportunity to generate power/steam and use in industrial park or regionally/nationally (electricity is easier to transport )

Seawater

Plant/Energy

Fuel

Net Power

Plant/Water

Fresh

Water

WW Brine

Streams

Plant

ii

Seawater

Plant/Energy

Fuel

Net Power

Plant/Water

Fresh

Water

WW Brine

Streams

Plant i

Q, Cooling

Q, Cooling

?

?

?

Research under NPRP grant no. 7-724-2-269 from the Qatar National Research Fund

Water-Energy Representation (one plant)

Cooling Systems: cooling towers, air coolers, or once-through seawater Cooling towers and seawater will have sources and sinks in water

network; however, air coolers only need energy (power)• Air coolers reduces water consumption but has the higher power

requirement• Both Cooling towers and Once-through cooling seawater requires

water mainly but need power as well Q, cooling can be satisfied directly by using cooling system options or

can be partially converted to power and be used in the plants (any cooling system, treatment or desalination unit)

Freshwater generation from desalination (incl import) considered in terms of wnergy and brine

Dashed box shows cooling systems in water profil: Once through cooling sweater which has 1 source, 1 sink: Cooling tower: 1 source (blowdown), 1 sink (make-up)

: Desalination plant: 1 sink (seawater), 2 sources (pot. water, brine)

: Water treatment: 1 sink (WW), 2 sources (treated water, brine)

: Process water sinks and sources: Offices sinks and sources which receives only potable water

CS

CT

Seawater

SeawaterCTCS

Desal / External

Utility

Sources

Sinks

AC

Needs to be cooled down using one of the

cooling systems option

Cooling requirement can be (partially) converted to power

(efficiency depends on the grade of heat)

Net power can be exported or imported (subject to policies, regulations, and infrastructure )

Q, Cooling

Plant EMS / Utility System

Net Power

Plant i

Illustration

14

Two Plants; Ammonia & Refinery (6 sources & 7 sinks)

Four Contaminants (TDS, Organics, Sulphate, Oil & Grease)

Ammonia plant has a cooling requirement of 167 MW

Scenario 1: Classical Water integration + Cooling syst. selection

• Selected Cooling System: Air Coolers

• Total Annual Cost: 4.30 (MM$/yr)

• Max water reuse: 372 ton/day

Scenario 2: Enabling other options incl. waste heat to power,

desalination of once-through seawater, and water export (which

is currently not allowed in Qatar)

• Selected Cooling System: Once-Through Seawater

• Profit of 113 MM$/yr

• Exporting approx. 410,000m3/d desalinated water

• Less Water Re-Used: 302 ton/day

• Cheaper water compared to other external utility,

reducing overall CO2 emissions by using power

generated from waste heat instead of fuel burnt in

desalination/power plant

Seawater

CTCS CTCS

Total water input required (t/d) 596

Fresh water –External Utility ($/m3)

1.5

Seawater Cost ($/m3) 0.02

Seawater

Seawater

11I11I

Water

Sup

ply

Carbon Emissions Reduction through Systematic CCUS

Emissions sourcesCapture or not?Purify or not?

Which separation technology?

Transport optionsCompression, pipes, …

CCU and CCS options (sinks)Which to feed ?

How much ? Purity?

Optimize

Min Cost vs. net CO2 reduction

CCUS network

Source to Sink connectivity

illustrated for one treatment technology

See our 2016 Journal of Cleaner Production (JCLP) papers.

I. DM Al-Mohannadi, P Linke, On the Systematic Carbon Integration of Industrial Parks for Climate Footprint Reduction. JCLP 112(5), 4053–4064

II. DM Al-Mohannadi, SY Alnouri, SK Bishnu, P Linke, Multi-period Carbon Integration, JCLP, 136B, 150-158

III. R Hassiba, DM Al-Mohannadi, P Linke, Carbon Dioxide and Heat Integration of Industrial Parks. JCLP, DOI: 10.1016/j.jclepro.2016.09.094

Now extended to simultaneously assess Renewable Energy options.

Simultaneous exploitation of synergies across carbon and energy management

VHP

P1 P3

P1

P2

P2

P1

HP

MP

LP

NGFuel

HRSG

GT

Boiler

Power Production and

Heat Utilization in CCUS network

Fuel input

Excess heat

from processes

/ plants

Solar thermal /

geothermal

Transitions towards future targets: Significant cost differences between policies

Generic plant moduleIllustration of natural gas and carbon dioxide network superstructure with 3 generic production plants, NG-fired power plant, and renewable power plant.

Moving towards the hydrocarbons(the ultimate source of profits and footprints)

• The approach can synthesize integrated natural gas and carbon dioxide networks for industrial cities that

can meet emissions constraints while maximizing the profitability of natural gas monetization

CO2 footprint constraint: 30% reduction of original emission

Profit of the cluster: 3.4 billion usd/y (unchanged)• Profit maintained due to EOR and methanol from CO2

• Renewable solar power used to max capacity (PV)• PV saves methane from combustion in power plant

(enables conversion into products to add value)

Example

No CO2 footprint constraint

Profit of the cluster: 3.4 billion usd/y

Continue to develop dimensions(heat, power, water, CO2, natural gas, intermediates)

Develop & integrate nexus representationsTo optimize across dimensions (e.g. W-E-CO2)

Incorporate other relevant objectives and aspects(sustainability metrics, reliability, uncertainty)

Ultimate goal: Explore all dimensions simultaneously

Link across scales & issuesDesign processes for performance in the big pictureLink to micro and macro economic modelling to better understand policy implicationsLink across borders (national vs. multinational footprints)

Outlook

OUTLOOK

Putting efficient solutions into practice

Sustainable Industrial Systems

Global markets &

environment

National economy &

environment

Industrial Park

Processing plant

Production process

EquipmentMaterials / Molecules

Rather: A System of Systems.

“Resource efficiency” “Economics” “Environmental footprints”

Large & slow Small & fast

The concerns are on the large scale …

Global markets &

environment

National economy &

environment

Industrial Park

Processing plant

Production process

EquipmentMaterials / Molecules

Large & slow Small & fast

… but they build up over the scales

Global markets &

environment

National economy &

environment

Industrial Park

Processing plant

Production process

EquipmentMaterials / Molecules

Large & slow Small & fastPUBLIC PRIVATE

Need to master the overall chain in light of stakeholder functions

Government IndustryUnderstand resourcesUnderstand impactsSet policy & strategyRegulateGuide sustainable developmentEnable sustainable solutions

Be profitableBe good citizensAvoid problemsComplianceInnovate as per business model

Academia | Research CommunityEducate, generate & disseminate new knowledge, serve / provide impartial advice

Provide fundamental knowledge (across the scales !) to enable government & industry

What’s needed ?

Holistic, evidenced-based policy making(GHG reductions including RE, CCUS)

Win-win economic models(incentive schemes, pricing, …)

Systems thinking ! (the silos tend to be efficient)

Thank you.