Optimal Hydrogen Recycling Network Design of Petrochemical Complex

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1 Korean Chem. Eng. Res., Vol. 45, o. 1, February, 2007, pp l s m k n Šk oy ÇmzsÇ Ç p n ne k e 56-1 ( o 16p r, o 13p }ˆ) Optmal Hydrogen Recyclng etwork Desgn of Petrochemcal Complex Changhyun Jeong, Chul-Jn Lee, Dae-hyeon Km and Chonghun Han School of Chemcal and Bologcal Engneerng, Seoul atonal Unversty,GSan 56-1, Shnlm-dong, Gwanak-gu, Seoul , Korea (Receved 16 ovember 2006; accepted 13 December 2006) k h o v l o q ro q p l ql p pp, p q~rp l n p. l n p l vop o ˆ rp o q n n, q p l n p. l l o v q q n o m. p l l n p n rr p Ž k, o l n n ˆ rk s p r r l }(source)m n}(snk) q l rp q n o o m. Abstract In a petrochemcal complex, large amount of hydrogen s produced as a by-product and used as a fuel n petrochemcal and ol refnery plants. By recyclng ths byproduct hydrogen as a raw materal, the value of hydrogen can be greatly mproved. Ths paper proposes a desgn methodology for optmal hydrogen recycle network between plants n petrochemcal complex by analyzng the hydrogen pnch, requred cost and constrants. Key words: Hydrogen etwork, Hydrogen Pnch, etwork Modelng, Optmzaton 1. l k ~ rs, l rv, l v p kl p n pp, l l kl ~ p n rp v p p. o v l o q ro q p l ql p pp, q~rp l n p. p l n p l vop o ˆ rp o q n n, q p l n p. q n l l l l n (pnch analyss) p k l l v l m. p Lnhoff ll rp l v sl r k l l p n p [1], m k r r l rp p r lm [2-4]. Towler p l v l n p o To whom correspondence should be addressed. E-mal: chhan@snu.ac.kr }pp n m [5], Alvesm Towler p re ož Ž np o rp p rk m [6]. p p Hallalem Lu ro r l ƒ MILP o p rk m [7]. Lum Zhangp o l rr q p r k m [8]. l l o v r~rp q n o o r p re m. n n l o n s p r, o l n q n ˆ p rk s p l r ep l o v q np o r o m. 2. m n ql q n o Fg. 1l ˆ p k. n q n o n ql n p o 25

2 26 r} Ëp~vË Ë s Fg. 2. Typcal structure for hydrogen recycle network. Fg. 1. Hydrogen network overvew. rr q n, p p o Žp p k p n. l n ql ~ l np lk, n ql o p p o p o k p k. p r o, q n o p n, p nl rrp q n o l r p rl np om om o v l l n /r p q n o o p p r rp. 1) qp p }(source) rp, n qp n p n} (snk) rp. 2) p l l q n l n, p o rr rp lv, l f n. 3) n l vr q n, rr rp n, p Ž l~ n l p l n. 4) r rr q l rr, n l f n. plp q n p l n p l Fg. 2l ˆ p 2 v n l p. l n p r k p n p qp sq, p p r p l Žp p k o p. l n p k n l n p p o rr q m p o Žp p k k (hydrogen pnch) l l p l v p v l rn ƒ p. k p l, v, ož Ž edš qp l rn lm. o45 o k Fg. 3. Hydrogen composte curve [6, 7]. rl p }(source)m n}(snk) }, p np p p l p }. } p rp p, n} rp. }m n} }kv p Fg. 3 l ˆ } (hydrogen composte curve) p. p p m m lˆ e e p m o p e p rn p rp p l v m. p p r p ˆ d r lp p t. l Fg. 4. Hydrogen surplus dagram [6, 7].

3 n p t~ p }m n}p r p p, p p n p ˆ. on Fg. 4p pl (hydrogen surplus dagram) p. pl l rp n l o p p ˆ t. p p vrrp np r~rp n seˆv rp rr q p n l r pn p. v, pl l n } p p p n rr n}l p n l n (mathematcal programmng) r p x, r f(x), r s p lv r r. p rp p r s p seˆ xp o kl f(x)p p p xp p } p p. erp ˆ p. Mn x f(x) Subject to h(x) = 0 g(x) 0 where x T =[x 1 x 2 x k ] h T (x) = [h 1 (x) h 2 (x) h n (x)] g T (x) = [g 1 (x) g 2 (x) g m (x)] (1) rp p r m rks l LP(lnear programmng), LP(nonlnear programmng), MIP(mxed nteger programmng), MILP(mxed nteger lnear programmng), MILP (mxed nteger nonlnear programmng) p lv. q n o p o sl pv (bnary varable) m o l nl p MILP p lv. o m s(superstructure) rp o kp rk p, rp s k. o p kr p ov o n}p p } vrrp o l rn rr q o. p rk p r o tl r p rp o }. 3. m k Šk n o v l q n tn p q n p p p llk. lp o l rp p p l o q nl l ppp lp plk. q n r o } o r p r q n p f lp p ppp ˆ. p q n p f l p ~ o l p n, rr o rr q, n o Žp p k q n o n np l, }l q n p kp sr l q n p f lp p l ppp p r o v q n r o 27. l l n r r p p p r l r m. 1) l v rp v o l l. 2) p n p p n n l~l p. 3) l~ p lpv k. 4) o n p k. 5) p n o l~l p p r. 6) o e k }l sq k n, nr n p. 7) q }l pl l f n p. 8) ~ l np q e l o n. 9) rp r rs p ˆ p kp l p l p ˆ p k j l o p f r~rp p ˆ p kp p r. 10) p }(source) = {Î = 1,2,Ë,}p ˆ, p kp W, y. 11) p n}(snk) = {jîj = 1,2,Ë.,M}p ˆ, n p kp, z j. 12) rr r(ntermedate) = {kîk = 1,2,Ë,K}, n p rr. op p l r p r p p r. Max proft functon F = M C W j j = 1 C Compressor C ppe C fuel value W fuel, C fresh W fresh, j C PSA sr }l n} k(w)p sr p f r seˆ o }k. op r l v vep n p. p }(source)l p n n}(snk) vr, rr rp lv, q~rp l n n p. W M W j j p n}(snk)l n }(source) vr, rr rp rr, n l~ p l p p. n = + W, fuel + W = k p n}l p p p ep l lp p. G n n j z j W j + W kj + W fresh, j = W j y + W kj y k + W fresh, j y fresh j = 1 Korean Chem. Eng. Res., Vol. 45, o. 1, February, 2007 M (2) (3) (4) (5)

4 28 r} Ëp~vË Ë s p v n}l p m p p n}l n s p se k. mn n max ( n}l p n n ) (6) pp. pl rr kp v. pl tn pq n p ˆ m nr p q p k rk ˆ, q lm p p. mn n max z j z j z j ( n}l p n n ) (7) p l n l p k rr l r ks p. M j = 1 W fresh, j W k = 1 + = Pnch 3-1. h} (compressor) o o k p p p lrk. k p nr np, C Compressor = P bhp C kwh h year µ P bhp : brake horse power C kwh : electrcty cost h year : operatng hour µ: effcency Brake horse Power Peter and Tmmerhaus p ~p l k l p p rk m [10] γ P γ bhp = P (10) ηγ ( 1 n F out 1 ) P n γ: rato of specfc heat of gas at constant pressure to specfc heat of gas at constant volume η: effcency P n : ntake pressure P out : fnal delvery pressure F: the flowrate beng compressed k l np Marshall and Swft ndexl p p r l p. a, b: cost parameter o45 o k γ 1 C comp [ kus ] = a comp + b comp Power comp [ kw] (8) (9) (11) 3-2. PSA rr t v p PSA(pressure swng adsorpton), (membrane systems), rm (cryogenc systems) p. p p o pn l p l r p n. rp rp ˆ p rrp k rp kr, e, kp p v l l r. rr q l tn pq q l p R = ( 1 θ) ( P H P L )y f R: Hydrogen recovery θ: Adsorbent selectvty between 0 and 1 P H, P L : hgh and low pressure of PSA y PSA,f : PSA feed purty (12) pp l rr p p ˆ p. W k,fuel = ( 1 R) W k, (13) p rr rl p }l p m kp v p. W n n k y k = W k y ( rr rp lm p v v) (14) mn n max W k W k W k (rr p n n ) (15) mn max y y ( p n ) (16) k n y k k o PSA q n o k p rr p m k, o p rr, p k rr p k, q l n, q p nr s p. p n l p PSA q p q n n r nl m p. Ruthven p rr q p np r Shortcut p rk m [9]. Towler p rk Shortcut p q p nr s p re [5] C PSA [ US ] = C F n,psa Y Z PSA = a PSA + b PSA F n,psa (17) F: flowrate Y: recovery yeld Z: feed mole fracton of hydrogen a,b: cost data 3-3. (ppelne) o o q Žp pp e n. q l r p pp l pv, q v p o pp l p p n p. sp o l~l pp n n, p np p. Žp p np Žp p v l p. Žp p v p r n o~p, o, l p r.

5 Žp pp nl ep Peters and Tmmerhaus rk p Žp v p r l p r [10]. Parker Žp p nl Žp p q n, n, ˆ q p l e rp l p np rk m [11]. C Ppelne (da, length) = [a(da) 2 + b(da) + c](length) + d (18) da: ppe dameter(nch) length: nstalled dstance(mles) a,b,c,d: cost data Žp p v p l r. Žp p nl k p p Žp p v p nl tp v o lv p kl p v p v r p p. o vp n, l v Žp pp o q l. l vp n, p Œq Žp (ppe rack)l p np v lp. Žp pp Ž p p p k. Fg. 5p p, Žp p p l p r q, vr p Žp p vr p Žp o v p p, }l d, LPG p o l dž v pp ep k 70Í p p v p. p rp p o o p, n ož Žp n, q n, ˆ nr n p l p r. pt o p p v tp 80Í p p o e p q p p r rp v p. pl p p rp vrrp p m 30~50Í p r. p p p 80Íp p r, p l p n l p p r. o v q n r o q n o l p Table 1. p lp qp 6 p, n p r p 5 p. pnl p p l ~ sq, p Í p p r. o o n }m n} p Table 2l ˆ p tlv rl Fg. 6. o v l n p (99Í p ) p l pl l l pl p p(-)p p Table 1. Process data of snks and sources Flowrate(m 3 /hr) Purty( ) Source 1 10, , , , , , Snk A 15, B 25, C 15, D 8, E 10, Table 2. Dstances between sources and snks (km) Snk A Snk B Snk C Snk D Snk E Source Source Source Source Source Source Fg. 5. Evaluatng dstance between sources and snks. Fg. 6. Constructon of a hydrogen composte curve and a surplus dagram. Korean Chem. Eng. Res., Vol. 45, o. 1, February, 2007

6 30 r} Ëp~vË Ë s Fg. 7. Feasble hydrogen composte curve and a surplus dagram. ˆ p p p. p q o o p k pnl p p kp n p k t. q o l }m n}p p l p p. }(source) l p f pl l p kp p e rp ˆ p p p p p rp. Fg. 7p p } ˆ n lt p. Òp n n l o p ppp p p n ˆ p, Òp n rp ˆ n l p p r p np. rp n l n p p k t v p. rp p p kp. r k p r r l rr o rr q p n p k t. rr q l rr n l p p m l PSA p n p r p. p l r p n p r l rk s p l r o l t n l p m k n Šk q n o l r rp m s(superstructure) Fg. 2l ˆ p. n q n r o rp n p p r o p p kp pp p p l. p r~rp p p rr n l p k p, r r l np Table 3. Hydrogen network matrx wthout purfcaton process Snk A Snk B Snk C Snk D Snk E Fuel Source 1 10, Source , Source , ,000 Source , Source ,000 Source ,000 Fresh 5, ,000 10,000 0 o45 o k Table 4. Hydrogen network matrx wth purfcaton process Snk A Snk B Snk C Snk D Snk E Fuel Source 1 2, , Source , Source , Source , Source Source Fresh 3, PSA PSA PSA 3 2, PSA PSA 5 8, PSA ,000 0 p ~rp o p p. r (solver) What s Best n l p m. Table 3p p np rn r r l r o (matrx)p. p p }l n} kl ~rp r ˆ. Table 4 rr q l o p. PSA p }l rr q rr n} kp ˆ. v }l q, q l n } o p. p rk s l p r p m l rk s p seˆ n pp p. p l p v kp n rp kp rp l l n p p kp t p p. q np l r~rp rr ppp rlv. p rk s p l n}p p } p p p s r r. rr q o p l v kp nm srp p v k. p p n p p rr l rk s p l, o srp l m p v, nl o l qp ppp p p. o l rrp Table 5l ˆ p. o v kp nm, o v q n r o n p Œq np rn l 190lol 330lop lp p. Œq le 0.4~0.6 p ˆ Œq nl Ž rr v ppp k p. p l fp l om l p l ~ l op l p r. q B-Cop l p, p l fp p k 40Í p lv o p f rrp pp p lp p. l op p o p m p p

7 o v q n r o 31 Table 5. Hydrogen network results Exstng etwork (no network) ew network 1 (wthout PSA) ew network 2 (wth PSA) Hydrogen Purchased Costs ƒ 156 bllon/yr ƒ50 bllon/yr ƒ6.5 bllon/yr Hydrogen Fuel value ƒ 70 bllon/yr ƒ17 bllon/yr ƒ0 bllon/yr Captal costs Ppelne - -ƒ8 bllon/yr -ƒ14 bllon/yr PSA - - -ƒ7 bllon/yr Compressor(operatng) - -ƒ0.1 bllon/yr -ƒ0.2 bllon/yr Fuel costs - -ƒ53 bllon/yr -ƒ70 bllon/yr Hydrogen Sellng Proft - ƒ76 bllon/yr ƒ111 bllon/yr EP(economc potental) - ƒ19 bllon/yr ƒ33 bllon/yr Payback perod years 0.6years l l op p d p n ˆ p. l l rk q n o p p p p l fp r l p p, l p p kr kv n q n l o n l f n n j rrp. p l m p o v l n q n n p rrp r m p Ž, pl rp q n o p q nl sp kp n p Ž. 5. l l o v l l n p np p p p o r r o p re m. p o r p o }(source)m n}(snk) rp l o k tl pn o l n p kp rp l n o p np r neˆ pl. p p rr p r, o p np o q n p n r l ~rp o m. re o l pl p np l rrp ppp v p p p. q p o kp rk mv l ql rn o q p p v, r rp q rn, rk o l lp n l l m vp n. l lqo ~r vo (KCPC)m n k l p k l (BK21), l o (KIST), l v (l v qo l), q ( r l, R ), q vr pm l (AEBRC, R ) p l vop lp pl. y 1. Lnhoff, B., Townsend,D.W., Boland, D., Hewtt, G. F., Thomas, B. E. A., Gut, A. R. and Marsland, R. H., User Gude on Process Integraton for the Effcent Use of Energy, Ins. Chem. Eng., Rugby, UK (1982). 2. Lnhoff, B., Pnch Analyss: A State-of-the-Art Overvew, Chem. Eng. Res. Des., 71, (1993). 3. Shenoy, U. V., Heat Exchanger etwork Synthess: Process Optmzaton by Energy and Resource Analyss, Gulf Publshng Company, Houston(1995). 4. Smth, R., Chemcal Process Desgn, McGraw-Hll, Y(1995). 5. Towler, G. P., Mann, R., Serrere, A. J-L. and Gabaude, C. M. D., Refnery Hydrogen Management: Cost Analyss of Chemcally- Integrated Facltes, Ind. Eng. Chem. Res., 35(7), (1996). 6. Alves, J. J. and Towler, G. P., Analyss of Refnery Hydrogen Dstrbuton Systems, Ind. Eng. Chem. Res., 41(23), (2002). 7. Hallale,. and Lu, F., Refnery Hydrogen Management for Clean Fuels Producton, Adv. Enc. Res., 6, 81-98(2001). 8. Lu, F. and Zhang, F., Strategy of Purfer Selecton and Integraton n Hydrogen etworks, Chem. Eng. Res, Des., 82(20), (2004). 9. Ruthven, D., Farooq, S. and Knaebel, K., Pressure Swng Adsorpton, VCH, Y(1994). 10. Peters, M. and Tmmerhaus, K., Plant Desgn and Economcs for Chemcal Engneers, McGraw-Hll, Y(1991). 11 Parker,., Usng atural Gas Transmsson Ppelne Costs to Estmate Hydrogen Ppelne Costs, Ol & Gas Journal s annual Ppelne Economcs Report( ). Korean Chem. Eng. Res., Vol. 45, o. 1, February, 2007

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