Grassroots Plant Energy Assessment Check List


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Document Category Engineering
Document Target Users

In brief, any energy assessment study for grassroots application shall consider the following:

Grassroots Plant Energy Assessment Check List

  • Process and utility systems simultaneously and Optimizing the CHP system using process integration techniques (Pinch analysis and/or mathematical programming).
  • The use of cogeneration if power-to-heat ratio is rendering high cogeneration efficiency with respect to central power generation plants efficiency.
  • Tri-Generation and even Quadra-generation if water desalination process is part of the total-site.
  • Watching for mechanical energy integration, for instances through power generation from high pressure liquids or using pressure exchangers.
  • Conducting major equipment load management for several demand scenarios.
  • The use of variable speed drivers.
  • The optimization of CCP systems (combined cooling and power/refrigeration systems).
  • The use of air pre-heaters for combustion air.
  • Integrating the flue gases in with the rest of the process using grand composite curve of pinch technology.
  • Optimizing air and N2 compressors system design.
  • The use of economizers and pre-heater in the boilers.
  • The use of turbo-expander instead of JT valves and to drive gas compressors.
  • The use of gas turbines versus the more efficient steam turbines.
  • Optimizing boiler steam pressure and temperature to the extent that matches process needs unless electricity generation is the controlling factor.
  • Using auxiliary turbines to minimize steam let downs.
  • Utilizing steam in the process optimally to save capital cost.
  • Recovering valuable gases from fuel gases and fully utilize the streams pressure.
  • Minimizing the H2 and any other utility wheel in the plant.
  • Cool down the inlet temperature to compressors if possible, or avoid its heating in the process, while considering pressure drop trade-off.
  • Reducing cooling medium return temperature in refrigeration cycles.
  • Using sub-cooling in refrigeration cycles using water first and cold process streams second, while considering pressure drop and pumping cost.
  • Heat rejection of the refrigeration system to process cold or hot section, to the ambient and to another refrigerant.
  • Using highest efficiency turbines in the CHP system.
  • Optimizing steam use in strippers through optimal pressure design.
  • Minimizing live steam utilization.
  • Keeping H2 separate from fuel gas system and recover C2 and C3+.
  • Avoiding unnecessary processing of wastes and inert (off-gas).
  • Minimizing the unnecessary production of off-gas.
  • Avoiding unnecessary recycles.
  • Adjusting operating pressures and optimal pressure interaction.
  • Optimizing piping system to minimize excessive pressure drops.
  • Re-using lowest quality water.
  • Using multi-objective process units, if applicable.
  • Maximizing the use of stripped sour water and minimize generation of wastewater.
  • Eliminating direct water injection for cooling purposes.
  • Extracting the low pressure steam from the boiler blow-down.
  • Using process water effluent as a source on the next lower water quality level.
  • Increasing waste heat steam generation.

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