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Analysis of Fuel Reduction Strategies for Crude Distillation Unit

ZULKAFLI, NUR IZYAN BINTI (2011) Analysis of Fuel Reduction Strategies for Crude Distillation Unit. Masters thesis, UTP.

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There is greater awareness today on the depleting fossil energy resources and the growing problem of atmospheric pollution. Engineers are developing practical techniques to ensure energy processes are designed and operated efficiently. Inefficient furnaces and heat exchangers contribute to the problem due to higher fuel demand and higher carbon emission. In crude preheat train (CPT), fouling causes the reduction of heat transfer efficiency, which leads to higher furnace fuel consumption, and exert additional cost for heat exchanger cleaning and lost production. This thesis presents strategies to reduce fuel consumption in the furnace, which will lead to reductions of operational cost and environmental emission. The method of exergy analysis is applied to determine the baseline energy efficiency of the furnace and CPT in a crude distillation unit (CDU). The strategies consist of locating and reducing exergy lost through process modifications of the energy system and developing optimum scheduling for retrofit and/or cleaning of heat exchangers in the CPT. There are two options for achieving fuel savings in the furnace. The options are reduction of heat lost from furnace stack and enhancement of heat recovery in the CPT. The second option involves plant shutdown for overall cleaning of CPT (Case 1), online cleaning of heat exchangers (Case 2) and combined online cleaning with retrofit of high efficiency heat exchangers (Case 3). Reduction of heat loss from furnace stack contributes to the smallest cost saving of 6.44% without carbon credit. With carbon credit, the saving is increased to 6.70%. The largest energy and carbon dioxide emission savings are found from Case 3. The installation of high efficiency heat exchangers improves furnace inlet temperature (FIT) from 215oC to 227oC. Furthermore, Case 3 results in the highest percentage of cost saving by about 71% and 62% with and without carbon credit, respectively. The payback period for investment in high efficiency heat exchangers is 3 months, with carbon credit, and 4 months, without carbon credit, respectively. Thus, Case 3 is the most cost effective option for reductions of energy consumption and carbon dioxide emission in the CDU.

Item Type: Thesis (Masters)
Divisions: Engineering > Chemical
Depositing User: Users 5 not found.
Date Deposited: 05 Jun 2012 08:22
Last Modified: 25 Jan 2017 09:42
URI: http://utpedia.utp.edu.my/id/eprint/2842

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