(512c) Analysis of the Energy Saving Potential In Chemical Batch Plants

Increasing prices of the primary energy-carriers together with rising environmental consciousness in recent years generate pressure on the efficiency of the energy usage. Therefore, methodologies allowing a systematic analysis and optimization of the specific energy utility consumption per tonne of production are of high interest for the process industry.

This paper deals with the development and testing of a systematic process data oriented methodology for identification of the energy-saving potential in the chemical batch plants based on the historical process data measured in the investigated plant. Steam and electricity were considered as the main energy carriers involved in the processes of the chemical batch plants.

First part of the methodology is focused on the energy-consumption model development for the particular energy carriers. The parameters of developed semi-empirical models were fitted according to measurements in particular equipment.

Identification of the energy-saving potential is based on the analysis of the results of the energy models for particular equipment, where the batch production was carried out. Significant energy consumption was identified within the synchronization steps which are representing a non-productive part of the batch production. It was identified that the high energy consumption in the synchronization steps was caused by overheating/overcooling problems of the temperature control loop together with long duration of the synchronization steps in the low-performing batches. Potential energy savings were estimated based on the minimal heating power consumption during the synchronization step and the minimal duration of this step considering several batches produced in these two investigated production lines. These energy savings were between 1 and 20% for the steam and 10 and 14% for the electricity of the average batch consumption respectively