화학공학소재연구정보센터
Industrial & Engineering Chemistry Research, Vol.52, No.44, 15635-15647, 2013
Industrial Documentation-Based Approach for Modeling the Process Steam Consumption in Chemical Batch Plants
One of the key principles of green chemistry is the minimization of energy consumption in the chemical industry. Besides continuous production processes, which have traditionally been the focus of energy saving potential studies, batch processes have also gained attention in recent years. To this end, detailed bottom-up approaches have been proposed for the modeling of energy utility consumption in multipurpose batch plants based on process documentation and high resolution sensor data. However, a simple procedure of general applicability for data extraction from process documentation facilitating the shortcut energy modeling approach for fast screening in multipurpose batch plants is still missing. In this paper, we introduce a new methodology for modeling the steam consumption in multipurpose chemical batch plants. This methodology is based on standard process documentation, rules of thumb, expert opinion, and thermodynamic principles. Additionally, we propose uncertainty intervals for the model outputs based on fuzzy set theory. Two case studies using production data from multipurpose batch plants of two different chemical companies have been carried out for parametrization and validation of the proposed methodology. In both cases, the steam consumption in several pieces of equipment involved in reaction and workup processes has been modeled and validated against reference values. The validation results showed that the new shortcut models provide acceptable estimations of steam consumption in multipurpose batch plants, and that the uncertainty intervals are in agreement with the batch-to-batch variability of the steam consumption. The output of these energy models can be used for the allocation of steam consumption to individual processes and products, enabling the identification of energy optimization potentials.