Industrial Energy Retrofit Planning Using Automated Retrofit Targeting
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ORIGINAL RESEARCH PAPER
Industrial Energy Retrofit Planning Using Automated Retrofit Targeting Nathan S. Lal 1 & Timothy G. Walmsley 1
&
Martin J. Atkins 1 & Michael R. W. Walmsley 1
Received: 14 April 2020 / Revised: 2 October 2020 / Accepted: 5 October 2020 # Springer Nature Singapore Pte Ltd. 2020
Abstract There is increasing pressure for industrial sites to minimise energy consumption. A long-term energy reduction strategy plays a critical role in realising energy savings. A key exchange mechanism of energy for sites is the heat exchanger network, which can be revamped and retrofitted to lift process energy efficiency. Retrofit analysis of heat exchanger networks commonly looks for a modified design that could provide significant energy savings for a comparatively modest investment but rarely does the analysis consider how retrofit projects can be sequenced as part of an energy retrofit plan while staying with capital investment constraints. The challenge in developing a long-term plan is the identification of projects and their ideal order out of the numerous possible combinations. This paper aims at developing an energy retrofit planning tool by performing a multi-stage retrofit analysis based on the automated retrofit targeting algorithm used to search for retrofit designs. The key output of the energy retrofit planning analysis is several sets of retrofit plans that can be further analysed for case-specific practicality (e.g., space, distance, and fluid compatibility) and developed into an energy retrofit plan, forming a part of a company’s overall energy strategy. The method is demonstrated using two industrial case studies with complex features and room for multiple sets of retrofit modifications. For the petrochemical complex case study, the study concludes that a 4-stage retrofit plan could be undertaken under a strategic investment plan that in total requires 11 modifications to the system, which generates 1.47 million EUR in annual profit with a payback of 1.75 years. Keywords Process integration . Energy retrofit . Automated retrofit targeting . Energy strategy
Introduction As concerns over global environmental issues rise, countries are investing more in renewable and sustainable energy technology. A significant amount of current dialogue focuses on renewable energy in the electricity sector. The process heat sector of industry users requires vastly different technologies because the quantum of energy tends to be high while the quality is less than electricity. Current industrial process heat is mostly based on fossil fuels such as coal and gas. On the supply side, many industries have attempted to shift away from fossil fuels to renewable energy sources to reduce emissions. However, availability, variability (Tietjen et al. 2016), high investment cost * Timothy G. Walmsley [email protected] 1
Energy Systems Integration Group, School of Engineering, University of Waikato, Hamilton, New Zealand
(Painuly 2001), and social barriers (Seetharaman et al. 2019) often present significant ec
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