Course syllabus

Course-PM

KVM013 Industrial energy systems lp2 HT19 (7.5 hp)

Course is offered by the department of Space, Earth and Environment

Contact details

Course coordinator: Stavros Papadokonstantakis

Examiners: Stavros Papadokonstantakis

Administrator: Marie Iwanow

Lecturers: Stavros Papadokonstantakis, Simon Harvey, Lia Detterfelt (Renova), Johan Isaksson (Södra)

Project/Exercise supervisors: Holger Wiertzema, Christian Langner, Victor Purnomo, Stavros Papadokonstantakis, Elin Svensson

Visiting address: Div. of Energy Technology, M-building, floor 4

Course purpose

The aim of the course is to train students to use process integration methods and tools necessary for identifying and designing efficient energy system solutions for the process industry that contribute to sustainable development. Technical systems encountered in the course include steam networks, heat exchanger networks, boilers, heat pumps, and combined heat and power systems. Besides technical issues and economic assessment, the course also covers the role of industrial process energy systems for meeting greenhouse gas emissions reduction targets. The course also introduces a method to identify the cost-optimal mix of different process heating technologies for a given heat demand curve and analyse how future energy policy scenarios will influence this optimal solution.

Schedule

TimeEdit

Course literature

The course book is produced at the Division of Energy Technology, available in Canvas website of the course.

For further reading, the book “Pinch Analysis and Process Integration: A User Guide on Process Integration for the Efficient Use of Energy” by I.C. Kemp is recommended. The book is available as an e-book from Chalmers library.

Extra study material in Canvas

More exercise problems and material for self-studies will be made available in Canvas.

• Theory and calculation exercises from old exams

PDF document with questions arranged according to the course topics. Exam questions from last year(s).

• Extra reading material

Additional literature will be provided as complementary material to lecture notes and compendium chapters. 

Course design

The course includes 14 lectures, 5 non-compulsory exercises (E1-E5), one of which (E5) is combined with a compulsory industrial study visit, and 4 compulsory projects (P1-P4), one of which (P3) is a 2-weeks duration project with a full report and presentation.

As a rule, lecture handouts will be posted on the course website 24 hours before the lecture, at the latest. The students are strongly encouraged to bring laptops, phones, etc., in the lecture, as an online platform for interaction will be used.

The description of the tasks for all projects and exercises, except P3 and E5, will be posted on the course web-site from the beginning of the course. E5 will be posted after the Renova industrial visit sessions are over. P3 will be introduced on the first day of the 2-weeks project session.

Students are asked to join one of the “two-students” groups in Canvas for exercises E1-E5 and projects P1, P2, and P4. Please sign up in Canvas in order to be able to submit your reports via the Canvas interface. Students will be randomly into “four-students” groups in Canvas for project P3.

The groups will be divided in the rooms indicated in the course schedule table presented above (e.g., for E1 some of the groups will work in the room KD1, some in the room KD2). The distribution of the groups in the rooms will be announced in Canvas. Please, have a look before the respective exercise and project sessions to know which room your group belongs to!

For the non-compulsory exercises (E1–E5) solutions will be posted in Canvas after the exercise session.

The projects P1 to P4 are compulsory, which means that completed and approved projects are a course requirement. Projects P1, P2 should be reported in written format according to the provided report template and P3 with a full written report and presentation. Project P4 can be examined either orally during the last sessions (18/12 or 20/12) or with a written report.

Report requirements. Each “two-students” group should submit one common project report (P1, P2) in electronic format (*.docx* or *.pdf*) via Canvas according to the following rules:

1. The name(s) and group number must appear clearly.
2. All reports must be written in English.
3. The reports should be neat and easy to follow, according to the corresponding report template that will be available at the beginning of the respective project.
4. Name your reports according to group number and project number (e.g. “report_P1_group_11”).

Each “four-students” group should submit one common full report for P3 in electronic format (*.doc*, *.docx* or *.pdf*) via Canvas according to the same rules as for P1, P2 but no template will be provided. Each “four-students” group should present their report and also act as an opponent for another group. The presentation will be on Thursday, December 19^th, and the respective time for every group will be announced in Canvas.

Please respect the due date for submitting your reports. The submission possibility in Canvas is automatically closed after the deadline. Deadlines for compulsory project reports:

P1:         Monday, November 18

P2:         Monday, November 25

P3:         Friday, December 13

P4:         Monday, December 23 (if not examined orally)

Results and solutions: Results and feedback for the corrected reports will be provided through Canvas (e.g., approximately 1 week after the report submission deadline).

If your report is not approved, written guidance will be provided to improve the report. You are expected to resubmit the revised report as soon as possible via Canvas.

Non-compulsory exercises

E1: Steam system networks

Enthalpy and mass balance calculations around turbines, steam boilers and heaters of a steam network for combined production of heat and power for an industrial process.

E2: Fundamentals of energy targeting

Pinch analysis for energy targeting using composite curves and heat cascade calculations.

E3: Supertargeting

Choosing ΔT_min based on minimum total annualized cost.

E4: Utility targeting for CHP units

Analysis of opportunities for integration of gas turbine CHP units with a background process, based on the background process GCC.

E5: Performance analysis of the low-temperature section of Renova WtE plant

Evaluation of the energy conversion performance of absorption heat pump and district heating system in the Renova plant

 Compulsory projects

 P1: Basic pinch analysis and heat exchanger network design

Pinch analysis for energy and cost targeting and design of a heat exchanger network for energy recovery and effluent cooling at a TMP (Thermo Mechanical Pulp) plant.

P2: Process integration of industrial heat pumps

Integration of heat pumps in industrial processes. Simple project investment evaluation. Impact of parameters such as electricity price, COP and temperature lift in the heat pump on economic performance of heat pump projects.

P3: Heat exchanger network retrofitting

Stream data extraction from a given process, identification of possible retrofit measures that improve energy efficiency, and prioritization according to their economic performance.

P4: Optimising process heat production options with respect to costs and CO₂ emissions

Assessing investment options in an industrial process energy system considering possible future increased costs associated with CO₂ emissions.

Lectures

L1: Introduction to industrial energy systems

Course contents, concepts and scope.

L2: Industrial process steam networks

Major equipment units in industrial steam networks, mass and energy balances, and energy performance indicators.

L3: Fundamentals of pinch analysis: Energy targeting

 Introduction to pinch analysis. Pinch temperature. Targeting for minimum heating and cooling demands. Composite curves, heat cascade and the grand composite curve.

L4: Stream data extraction. Utility, area and number of units targeting

Stream data extraction. Targeting for optimal utility distribution, minimum heat exchanger network area and number of heat exchanger units.

L5: Advanced design strategies for heat exchanger networks

 Network design strategies for maximum energy recovery: stream splitting and cyclic matching. Practical design considerations: Network relaxation.

L6: Basic economics of process integration. Cost targeting.

Capital and operating costs of heat exchangers and heat exchanger networks, profitability of energy saving projects. Targeting for minimum total network cost. Supertargeting.

L7: Integration of industrial heat pumps

Overview of heat pump technologies and their integration in industrial processes.

L8: Integration of combined heat and power units

Overview of CHP technologies (gas turbines and steam turbine systems) and their integration in industrial processes.

L9: Total site analysis. Renova waste to energy plant

Extending pinch analysis concepts to multi-process sites – Total site analysis.

Guest lecture from Renova. Overview of process technology for waste incineration systems with energy recovery. Presentation of the Sävenäs waste-to-energy plant.

L10: Heat exchanger network retrofitting

Basic methods for retrofitting of heat exchanger networks (HEN).

L11: Industrial heat integration projects

Guest lecture from Södra. Presentation of heat integration in industrial projects focusing on, but not limited to, applications of pinch analysis method. Presentation related research projects in the Division of Energy Technology.

L12: Characteristics of industrial heat loads and heat production technologies

Process heat load duration curves. Heat production costs for boilers, heat pumps and CHP units. GHG emissions and associated costs.

L13: Optimisation of heat and power production considering GHG emissions

Methodology to identify best mix of technologies to cover a given heat demand profile considering costs and GHG emissions.

L14: Course summary - Exercises

Short review of the course contents, principles and methods. Exercises demonstrating selected previous exam topics.

The January study week also has time scheduled for consultation (from 7/1 to 9/1, between 1 pm and 4 pm, online consultation (Canvas) and on 14/1, between 9 am and 12 pm, in the Division of Energy Technology).

Industrial study visit and respective exercise (Renova)

• This 3-hours study visit is compulsory, which means that attendance is a course requirement.
• You must sign up to attend 1 of the 4 scheduled sessions. The study visit takes place outside of the regular schedule hours, during study week 4 (calendar week 48). Sign up takes place in Canvas for a maximum of 25 students per session. No exceptions will be allowed. You are not allowed to change session without permission from the supervisor.
• Make sure that you attend Lecture L9 about the energy system at Renova's Waste-to-Energy plant.
• You must arrange your own transportation to Renova Savenäs. Please allow plenty of time for bus transportation. Latecomers can be forbidden to join an ongoing study visit. The closest bus stop is “Lemmingsgatan” and proper connections (Buses 58 and 519) can be found at vasttrafik.se. Be sure to get there at least 10 minutes before the lab starts, as you have to walk a bit from the bus stop. At bus stop Lemmingsgatan just walk back to the roundabout and turn left down Lemmingsgatan to cross the river Säveån and finally get to Renova. Please wait in the reception area.

Changes made since the last occasion

• the course compendium is updated, by omitting the pulp mill example, and more importantly updating Appendix B for the foreground/background example.
• the industrial visit to Renova will now contain a 30-minutes session where the students will draw the absorption heat pump GCC using plant data with the guidance of project assistants and plant engineers.
• a new guest lecturer from industry will illustrate industrial heat integration projects; related research projects in the Division of Energy Technology will also be presented.
• the P3 project is revised to increase the scope of potential retrofitting options and decrease the work load by eliminating the "network pinch" approach.
• the uploaded exercise material for exam preparation is updated to better reflect the present contents of the course.

Learning objectives and syllabus

• identify the major equipment units in an industrial steam network, perform mass balance calculations at steam headers, and calculate relevant energy performance indicators
• calculate energy conversion performance characteristics for process utility boilers, heat pumps, and combined heat and power (CHP) units based on steam turbine or gas turbine cycles, for given energy conversion process parameters
• determine the pinch temperature and the minimum heating and cooling requirements for a given industrial process and a given value of minimum acceptable temperature difference for heat exchanging
• determine target values for the number of heat exchanger units, the heat exchanger network surface area, and the investment cost for a heat exchanger network that meets the above energy targets, and analyse the impact of choice of minimum temperature difference for heat exchanging on these energy and cost targets (supertargeting)
• design a heat exchanger network for maximum heat recovery for a given new (greenfield) process and improve this design by relaxation of the requirement for maximum heat recovery
• identify and quantify inefficiencies (pinch violations) in the heat exchanger network of an existing process and suggest design modifications to reduce the heating and cooling demands of the existing network (retrofit)
• identify opportunities and quantify the potential for integration of high-efficiency energy conversion technologies and advanced utility systems (heat pumps, combined heat and power units, district heating) at an industrial process site
• evaluate designs of new heat exchanger networks, retrofit modifications of existing heat exchanger networks and the integration of heat pumps and combined heat and power unit with respect to energy efficiency, greenhouse gas emissions and economic performance
• identify the cost-optimal mix of technologies for satisfying an industrial process heat demand with given load characteristics, accounting for current and possible future energy market conditions, including costs associated with emissions of greenhouse gases

The course contains the following parts:

Introduction to industrial process energy systems: Basic concepts, illustrating example from the pulping industry and description of industrial steam networks.

Process integration: Basics of process integration methodologies with emphasis on pinch analysis (Pinch temperature, minimum process heating and cooling requirements, composite curves and grand composite curve, utility targeting, targeting for minimum number of heat exchanger units, and heat exchanger surface area costs). Design of heat exchanger networks for maximum heat recovery and network relaxation. Process integration principles for high-efficiency energy conversion technologies and advanced utility systems (heat pumps, combined heat and power units, district heating). Process integration methodologies for retrofit applications in existing industrial energy systems. Energy efficiency and economic performance evaluation of process integration measures.

Energy conversion technologies in industrial energy systems: Overview of utility boilers, steam networks, heat pumps, steam turbine combined heat and power (CHP) and gas turbine CHP. Characteristics of heat pumps and CHP units (performance, investment costs). Optimization of size and various design parameters based on process integration principles. Methodology for identifying the cost-optimal mix of technologies for satisfying a process heat demand, accounting for heat load variation over the course of the year.

Greenhouse gas emissions consequences of energy efficiency measures in industry: Greenhouse gas emissions from industrial energy systems. Optimisation of industrial energy systems considering future costs associated with greenhouse gas emissions.

Study plan

Examination form

The written 4-hour examination includes theory and problem solving (with non-comprehensive calculations). According to Chalmers policy, the examination will be conducted in English. The standard Chalmers grade scale is used (Fail, 3, 4, 5). Optional calculator with cleared memory, as well as dictionaries, are approved aids at the exam.

The regular examination is scheduled on January 15, 2020, from 14:00-18:00. The first re-sit examination is scheduled on April 7, 2020, from 14:00-18:00. The second re-sit examination is scheduled on August 18, 2020, from 14:00-18:00.

Completed and approved reports for the compulsory projects (P1-P4) and participation in the industrial visit are a course requirement.

Exercises and compulsory projects are equally significant in terms of the course learning objectives and are as likely to be reflected in the final exam.