Jou nal o Sus ainable De elopmen o Ene gy, Wa e and
En i onmen Sys ems
h p://www.sdewes.o g/jsdewes
Yea 2022, Volume 10, Issue 2, 100396
1
Jou nal o Sus ainable De elopmen
W a e and En i onmen , o E ne g y
Sy s ems
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O iginal Resea ch A icle
Concep ual Design Me hod o Ene gy Re o i o Was e
Gas- o-Ene gy Uni s
Ví F eisleben1, Zdeněk Jegla*2
1Ins i u e o P ocess Enginee ing, Facul y o Mechanical Enginee ing,
B no Uni e si y o Technology, Technická 2896/2, B no, Czechia
e-mail: Vi .F eisleben@ u b .cz
2Ins i u e o P ocess Enginee ing, Facul y o Mechanical Enginee ing,
B no Uni e si y o Technology, Technická 2896/2, B no, Czechia
e-mail: zdenek.jegla@ u .cz
Ci e as: F eisleben, V., Jegla, Z., Concep ual Design Me hod o Ene gy Re o i o Was e Gas o Ene gy Uni s, J.
sus ain. de . ene gy wa e en i on. sys ., 10(2), 1090396, 2022, DOI: h ps://doi.o g/10.13044/j.sdewes.d9.0396
ABSTRACT
Many indus ial was e gasses, especially om chemical and pe ochemical p ocesses,
con ain combus ible subs ances enabling hei u iliza ion as a p omising ene gy sou ce.
The mal oxida ion ep esen s a sui able and p o en echnology, which is, howe e , e y
ene gy in ensi e in e ms o ex e nal uel demand dependen on exhaus hea eco e y
e iciency. This pape p esen s a sys ema ic me hod de eloped o he Ene gy Re o i o
indus ial uni s o he mal oxida ion o was e gases (was e gas- o-ene gy uni s) in o de
o imp o e he uni s´ was e hea eco e y and hus o educe he ex e nal ene gy demand.
This esul s in he educ ion o ope a ional cos s and emissions and imp o es was e gas
ene gy u iliza ion. The me hod p ocedu e is u he applied o Ene gy Re o i o a
speci ic was e gas- o-ene gy uni , whe e he uel sa ing o o e 30% was achie ed by he
p oposed concep ual modi ica ions wi h a payback pe iod o only 5.5 mon hs. Finally,
he de eloped me hod accu acy was success ully e i ied by compa ison wi h esul s o
non-linea simula ion.
KEYWORDS
The mal oxida ion, Shi ing Flue Gas Line me hod, was e gas- o-ene gy uni , Ene gy Re o i ,
uel sa ing, VOC, CO.
INTRODUCTION
Many indus ial p ocesses gene a e was e gases. The composi ion o was e gas (WG)
is dependen on many aspec s (such as he ype o p oduc p oduced in a p ocess plan ,
used echnology, e c.). Howe e , i usually con ains ha m ul subs ances, he e o e an
app op ia e cleaning echnology mus be employed o p e en he emissions o he
en i onmen . Fo example, he WGs p oduced in chemical and pe ochemical plan s
o en con ain Vola ile O ganic Compounds (VOC) o ca bon monoxide (CO), which a e
ha m ul o human heal h and he en i onmen . The a ious p oduc ion p ocesses, such as
pain p oduc ion, oil e ine y, o ganic acid p oduc ion and o he s, gene a e ai pollu ed
wi h some amoun o VOC and/o CO. Fu he , a huge amoun o he ai con amina ed
wi h VOC is gene a ed in p in ing shops, especially in he au omo i e indus y. This
pollu ed ai (as an indus ial WG) mus be ea ed be o e i s discha ge o he en i onmen .
To con ol he VOC and CO emissions con ained in WGs a small concen a ion, he
he mal oxida ion echnology has been ound an e ec i e and eliable aba emen
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echnique which commonly eaches he pollu an emo al e iciency o o e 99%. I is
applied o p ocessing la ge quan i ies o WG wi h a low concen a ion o combus ible
subs ances (VOC/CO). The pollu an he mal oxida ion (decomposi ion) is in p inciple a
con aminan lameless igni ion which esul s in a sudden empe a u e inc ease o
p ocessed was e gas and pollu an he mal decomposi ion o ca bon dioxide (CO2) and
wa e . The mal oxida ion akes place in a combus ion chambe (CC) a high empe a u es
commonly anging be ween 730–850°C wi h necessa y esidence ime while lue gas
(FG) is p oduced [1]. Main aining he p esc ibed empe a u es in he CC o he pollu an
igni ion equi es in ensi e ene gy demand p o ided by a supplemen al uel, which is
associa ed wi h high ope a ing cos s. In o de o imp o e he economic aspec o he
uni ´s ope a ion, he was e hea con ained in a gene a ed lue gas is ypically used o
ene gy pu poses (e.g., s eam gene a ion) and echnology pu poses (WG p ehea ing
be o e i s en e ing CC o educe he supplemen al uel demand) h ough se ies o
indi idual was e hea eco e y exchange s, i.e., h ough he Hea Reco e y Sys em
(HRS). Fu he , FG cleaning echnology ( il e s, abso be s, sc ubbe s…) could be
employed o emo e acid compounds, solid pa icles, o o he gaseous pollu an s i
necessa y. A ho ough e iew o he ai pollu ion con ol echniques including he
aba emen o VOC pollu ion was published by Schnelle e al.[1]. A simpli ied
echnological layou o such was e gas o ene gy (WG E) uni is illus a ed in Figu e 1.
Figu e 1. S anda d was e gas- o-ene gy uni
Due o he con inuous uel p ice ise, he e is an e o o imp o e he exis ing WG E
uni s in e ms o he uni s´ uel demand educ ion, i.e., pe o ming he Ene gy Re o i
(ER). As sugges ed abo e, uel sa ing in a s anda d WG E uni is achie ed by p ehea ing
he WG s eam be o e i s he mal p ocessing in he CC. As he WG p ehea ing is ealized
by u iliza ion o he was e hea con ained in he lue gas (i.e., h ough some hea
exchange s om HRS), he uel sa ings could be eached by he In eg a ion and
In ensi ica ion o he exis ing HRS (Klemeš e al. [2]).
A g ea e o has been pu in he las decades in o he esea ch o inc easing he
p ocess e iciency in o de o educe he ex e nal u ili y demand ( uel, wa e esou ces)
wi h espec o minimum in es men cos s. Mos cu en echniques and me hodologies
ocused on e ec i e e o i and in ensi ica ion o hea exchange ne wo k (HEN) a e
inspi ed by o a di ec ou come o he ini ial wo ks and p inciples o P ocess In eg a ion
da ed in he la e 1970s wi h he disco e y o he Pinch Analysis concep (Linnho and
Flowe [3]). Akpomiemie and Smi h [4], o example, b ough a no el me hodology o
he cos -e ec i e hea ans e enhancemen in he exis ing HEN. Fu he , Jiang e al. [5]
discussed a possibili y o he HEN e o i by eusing he exis ing hea exchange s. To
imp o e he quali y o HEN e o i design, Lai e al. [6] also conside ed he in luence o
physical dis ance be ween hea exchange s, p essu e d op and a ailable space o
equipmen . The ad an ages o an indus ial plan ´s e o i on a p ac ical example o an
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oil e ine y we e published by Ma on e al. [7].The comp ehensi e summa y o
adi ional and mode n me hods o HEN e o i was published by Klemeš e al. [8].
The P ocess In eg a ion is no limi ed only o he opic o hea exchange in HENs.
The mal ene gy con ained in he p ocess s eams is only a pa o he o al ene gy con en .
P essu e le els o he p ocess s eams, o example, e lec he necessi y o mechanical
wo k inpu , i.e., he pumping powe , which esul s in conside able elec ici y demand.
Indus ial p ocesses can be designed o e o i ed wi h espec o minimiza ion o bo h,
he hea du y and powe du y. Fu e al. [9] p esen ed he ad an ages o simul aneous wo k
and hea in eg a ion applying g aphical and ma hema ical app oaches. Deng e al. [10]
p oposed a me hod o u iliza ion o esidual p essu e ene gy based on Pinch Analysis. In
summa y, Yu e al. [11] published a e iew o wo k and hea exchange ne wo ks
(WHENs) e lec ing he cu en s a e-o - he-a .
The e a e a ailable many analy ical me hods enabling ene gy eco e y imp o emen
wi hin he s udied p ocess, bu he p ocess in eg a ion o la ge indus ial p ocesses
ep esen s a complex p oblem, whe e ma hema ical p og amming is applied. Wissocq e
al. [12], o example, p oposed a me hod based on a mixed-in ege -linea -p og amming
(MILP) model o an op imal design o la ge indus ial plan s enabling a sui able
echnology selec ion. Linea models´ applica ions equi e many simpli ica ions, which is
associa ed wi h a educ ion in he esul s´ accu acy. To o e come his sho coming,
Neme e al. [13] p oposed a wo-s age me hod inco po a ing he MILP model in
combina ion wi h a mixed-in ege -nonlinea -p og amming (MINLP) model.
Addi ionally, San os e al. [14] applied a MINLP model o pe o m he p ocess
op imiza ion in e ms o hea and wo k du y minimiza ion.
E en hough he p esen ed ad anced me hods can be used o educe he ene gy
demand o indus ial p ocesses, hei achie able ene gy e iciency is s ill
he modynamically limi ed. The e o e a eliable and sus ainable hea and powe sou ce is
necessa y. Nowadays a numbe o mode n echnologies a e a ailable o he e ec i e
p oduc ion o hea and powe . Fo example, he e is an e o o e o i he adi ional
ene gy p oduce s, such as coal- i ed plan s, by cos e ec i e co-gene a ion echnology
in oduc ion. The main goal is a deepe implemen a ion o enewable ene gy sou ces. The
po en ial o in oducing co-gene a ion blocks p oducing powe om biomass o he
exis ing coal- i ed plan was s udied by Kalina [15]. The mal and economic op imiza ion
o his echnological solu ion was pe o med by Tańczuk e al. [16]. Fu he mo e, he
ene gy sou ces could be used o gene a e powe and o p o ide hea ing and cooling
simul aneously. Ka sa os e al. [17], o example, p oposed such a i-gene a ion sys em
based on municipal was e gasi ica ion.
As men ioned abo e, he e is a con inuous e o o implemen mo e enewable
ene gy sou ces (e.g., sola and wind ene gy) o he cu en ene gy sys em. Howe e ,
ene gy p oduc ion om hese sou ces is uns able, which can cause s abili y issues in he
powe g id. The powe g id capaci y o accep ance o a ious enewable ene gy sou ces
was s udied by Taseska-Gjo gie ska e al. [18]. Fu he , Mo el e al. [19] p oposed a
po en ial o powe g id capaci y inc ease by implemen a ion o ba e ies and exploi ing
he kine ic ene gy o wind u bines.
Va ious ypes o indus ial and municipal was es ep esen ano he signi ican ene gy
sou ces wi h g ea po en ial o co e a pa o hea and powe consump ion. Compa ed o
discussed sola and wind ene gy, an ad an age o indus ial plan s p ocessing was e is
hei ela i ely s able ene gy gene a ion. On he o he hand, he main disad an age is he
necessi y o supplemen al uel o he mal was e p ocessing. Howe e , in case o WG E
uni s, he amoun o supplemen al uel can be signi ican ly educed by imp o ing he
was e hea eco e y (as discussed abo e). The ER o WG E uni s can he e o e educe
ope a ional cos s due o he uel demand educ ion, while he ene gy p oduc ion (e.g.,
s eam p oduc ion, he mal oil hea ing, e c.) is main ained.
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Howe e , om he abo e desc ip ion o WG E uni s, i is ob ious ha he ER o he
WG E p ocess canno employ hese sophis ica ed HEN e o i s a egies since HRS o
WG E p ocess has subs an ially di e en speci ici y han he s anda d p ocess HEN,
especially ha HRS does no con ain any U ili y Pa h. E en hough some me hods a e
a ailable o an e icien e o i o HENs no con aining U ili y Pa h (such as Jegla and
F eisleben [20]), none o hese me hods can be applied o he case o WG E uni s, as hei
HRS does no allow c ea ing a new U ili y Pa h due o he absence o ho and cold u ili y.
So, o ER o WG E uni s, i is necessa y o apply some speci ic e o i app oaches
ocusing on he lue gas s eam as a was e hea sou ce and aking in o accoun he
speci ici y o he WG E p ocess. As no sui able app oaches a e cu en ly a ailable o he
ER o he WG E uni s, his esea ch wo k p esen s a decision making and e alua ing
me hod, which is called he Shi ing Flue Gas Line (SFGL) me hod, ha ep esen s a
concep ual design me hod o ER o WG E uni s. The SFGL me hod will be p esen ed in
de ail in his a icle. I is a me hod de eloped o he e o i o WG E uni s in o de o
educe hei ene gy demand, while high pollu an emo al e iciency is main ained.
An accu a e e alua ion o uel sa ings is ano he impo an aspec o he p ope ER o
WG E uni s. I could be pe o med by he p ocess non-linea simula ion using
comme cial so wa e. This ad anced sys em modelling migh howe e be a d awback in
e ms o acquisi ion cos s and also in e ms o applicabili y o WG E p ocess e o i
a ge ing, whe e concep ual modi ica ions enabling he desi ed ene gy sa ings should be
p oposed. The e o e, he non-linea simula ion does no ha e o be necessa ily
con enien du ing he a ge ing and concep ual design s age.
F eisleben and Jegla [21] p esen ed a simple and ai ly accu a e me hod o calcula e
he uel sa ings o uni s o was e he mal p ocessing which does no equi e an ad anced
non-linea sys em modelling. This analy ical me hod is based only on he ini ial
empe a u e o he supplemen al uel/oxidize (Tini ), he Theo e ical Flame Tempe a u e
(TTFT), he uel Lowe Hea ing Value (LHV), and he lue gas empe a u e (TCC)
p esc ibed o su icien pollu an emo al (see Figu e 1). This calcula ion p ocedu e
was applied in he de eloped SFGL me hod p esen ed in his pape .
I should be emphasized ha he pu pose o he de eloped me hod is o enable ai ly
accu a e WG E uni s modelling and a speci ic ER e alua ion and no ha o inding an
op imal solu ion o ER. I is an analy ical app oach, which does no equi e in oduc ion
o ad anced ma hema ical models and op imiza ion app oach p esen ed abo e.
The de eloped SFGL me hod is desc ibed in he pape and u he p ac ically
in oduced by i s applica ion o a case s udy o a speci ic WG E uni ´s Ene gy Re o i .
The ob ained esul s a e hen compa ed o he non-linea simula ion o e i y he
accu acy o he de eloped me hod. The non-linea simula ion was ca ied ou in so wa e
CHEMCAD (in he la es e sion CHEMCAD 7) om Chems a ions Inc. [22] in
combina ion wi h so wa e Xchange Sui e® om Hea T ans e Resea ch Inc. (HTRI)
[23].
METHODS
As men ioned in he In oduc ion sec ion, he Shi ing Flue Gas Line (SFGL) me hod
is designed o ER o s anda d WG E uni s, i.e., he uni s o he mal p ocessing o was e
gases, speci ically was e gases con aining combus ible subs ances such as VOC o CO. I
bene i s om a ela i ely simple WG E uni echnological a angemen , whe e only a
small numbe o WG p ocessing and hea eco e y equipmen is employed. The me hod
enables es ima ing se e al key ea u es, such as he ollowing:
• Flue gas hea eco e y e iciency and Ene gy Re o i a ge ing. The amoun o he
lue gas was e hea which is cu en ly los is calcula ed and could be u ilized o
educe he supplemen al uel demand.
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• The concep ual design o he echnological modi ica ions ha a e equi ed o
achie e he desi ed ene gy sa ings.
• P ocess pa ame e s e-e alua ion, such as empe a u e p o iles and low a es o
p ocess s eams and basic pa ame e s o newly added o modi ied equipmen (as
e.g., hea exchange s´ hea loads).
The main ad an age o he de eloped me hod is i s p ac icabili y and simplici y. I is
based on a linea model o s udied p ocesses ha employs a limi ed numbe o WG
p ocessing and FG hea eco e y equipmen , so he me hod can be pe o med by simple
desk calcula ion.
The main d awback o he de eloped me hod is i s limi ed applicabili y. I canno be
e ec i ely applied o he wide ange o indus ial p ocesses as i was ailo -made o
WG E uni s using hei speci ic cha ac e is ics, which a e discussed u he in he
pape .The SFGL me hod is in p inciple a simple calcula ion p ocedu e suppo ed by
g aphical ep esen a ion o pe o med modi ica ions o p omo e he designe ’s
in e ac i i y when pe o ming he ER.
The key equipmen is an indus ial u nace whe e he pollu an he mal oxida ion akes
place. The SFGL me hod is he e o e inspi ed by analy ical app oaches o Fu nace Hea
In eg a ion, especially by lue gas line ep esen a ion (o lue gas empe a u e-en halpy
p o ile). The FG line was i s p oposed by Linnho and de Leu [24] and la e jus i ied
by S ehlík e al. [25]. Following hese wo ks, Jegla e al. [26] hen in oduced he speci ic
manipula ion wi h he FG p o ile o e icien u nace e o i . Inspi ed by his FG line
ope a ion, he SGFL me hod p esen ed he e is di ided in o se e al sys ema ic s ages,
which a e desc ibed below.
The s udied uni da a ex ac ion
The Ene gy Re o i p ocedu e s a s wi h a p epa a ion s age, whe e all key pa ame e s
o he exis ing uni a e ob ained. I consis s o se e al poin s:
• P ocess s eams and equipmen cha ac e is ics including he empe a u es,
p essu es, composi ion, a e age speci ic hea capaci ies and low a es o all
s eams p esen in he cu en WG E uni (FG, WG, s eam, ho wa e o ano he
ene gy medium…). Fu he , he cha ac e is ics o applied hea exchange s a e
ob ained, like ype, geome y, and hea loads.
• Supplemen al uel/oxidize cha ac e is ics, which includes a uel Lowe Hea ing
Value (LHV), Theo e ical Flame Tempe a u e (TTFT), ini ial empe a u e (Tini ),
and mixing a io (K) o oxidize / uel mix u e being combus ed in WG E uni ´s
u nace.
• D awing o he empe a u e-en halpy diag am con aining empe a u e-en halpy
p o iles (–he ea e e e ed o as jus p o iles) o all (ho and cold) p esen
s eams. An example o such a diag am, co esponding o he uni echnological
layou p esen ed in Figu e 1, is shown in Figu e 2.
WG E uni s con ain ypically only one ho s eam, which is he FG coming ou o CC.
In p ac ice, he spli ing o he FG s eam is no applied in WG E uni s due o he
addi ional in es men cos s o he FG duc and dec eased ope a ional eliabili y. The FG
p o ile (o FG line) is plo ed in an in e al be ween a CC ou le empe a u e (TCC) and a
s ack empe a u e (Ts ack). This in e al ep esen s he amoun o hea , which is u ilized in
he exis ing uni .The FG line is hen linea ly ex apola ed o he dew poin empe a u e
(TDP), whe e he condensa ion is expec ed o occu .
The in e al be ween Ts ack and TDP ep esen s an app oxima e alue o he amoun o
hea wi h a po en ial o be u ilized bu is cu en ly los (Qloss). TDP is chosen as a limi
empe a u e o a oid he gene a ion o he condensed subs ances (especially acidic) in FG
o p e en he equipmen om co osion and damage.

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The cold s eam p o iles a e no combined in o a Cold Composi e Cu e (unlike he
s anda d p ac ice in he adi ional P ocess In eg a ion app oach based on Pinch Analysis
[2]), bu hey a e plo ed sepa a ely. As he FG s eam is no usually spli , his g aphical
ep esen a ion (shown in Figu e 2) e lec s he ac ual hea exchange a angemen in he
exis ing HRS, whe e he FG hea is used a i s o a s eam gene a ion (Qs eam) and hen
o WG p ehea ing (QWG).
Figu e 2.Tempe a u e-en halpy diag am o exis ing Was e Gas- o-Ene gy uni
Was e gas hea e in ensi ica ion
As men ioned in he In oduc ion, he hea con ained in FG is commonly used o p ehea
he WG s eam in o de o educe he uni ´s ene gy demand. Fo ha eason, he WG hea e
is commonly employed as shown in Figu e 1. The WG p ehea ing enhancemen is
ecommended as he i s hing o conside while he ER o he exis ing WG E uni is
desi ed. This could be pe o med, o example, by inc easing hea ans e a ea (usually
ela i ely cos ly), o implemen a ion o hea ans e in ensi ica ion echnology o he
exis ing WG hea e , which p o ides a cheap solu ion o each he exchange enhancemen .
The selec ion o app op ia e in ensi ica ion echnology depends on se e al aspec s, such as
a ype and geome y o he exis ing WG hea e and media p ocess pa ame e s, such as
empe a u es, ouling sensi i i y, o allowed p essu e d op. The analysis and compa ison o
he mos sui able and e icien hea ans e enhancemen echnologies o ube WG hea e
was pe o med, o example, in [27].
A e a sui able me hod o WG p ehea ing in ensi ica ion is selec ed, he uel sa ing
could be e alua ed acco ding o he ollowing s eps:
• Hea ans e inc ease e alua ion. Based on he selec ed enhancemen echnology
o me hod, he in ensi ied hea ans e (Qin ) o he WG s eam is e alua ed.
• Fuel sa ing calcula ion. I is pe o med using he equa ions (1) and (2) below [21].
𝐹𝐹𝐹𝐹𝑉𝑉𝐶𝐶𝐶𝐶 =𝑛𝑛𝑐𝑐×𝐿𝐿𝐹𝐹𝑉𝑉 ×
𝑇𝑇
𝑇𝑇𝑇𝑇𝑇𝑇
− 𝑇𝑇
𝐶𝐶𝐶𝐶
𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 − 𝑇𝑇𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖
(1)
𝛥𝛥𝑓𝑓
𝑠𝑠=
𝑄𝑄
𝑖𝑖𝑖𝑖𝑖𝑖
𝐹𝐹𝐹𝐹𝑉𝑉𝐶𝐶𝐶𝐶
(2)
FHVCC de ines he uel ene gy con en u ilizable o keep he high empe a u e inside
CC, Δ s is an achie ed uel sa ing and nc is a co ec ion ac o anging be ween 1.07-1.09.
F eisleben, V., Jegla, Z.
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• Flue gas low a e eassessmen . Because he supplemen al uel combus ed in CC is
a pa o he FG s eam and uel sa ings a e achie ed by WG p ehea ing
in ensi ica ion, he amoun o FG is educed by he alue o Δ s oge he wi h he
co esponding amoun o combus ion ai (as an oxidize ) calcula ed acco ding o
he oxidize / uel a io K (see equa ion (5) below).
• Modi ied diag am plo . While he FG low a e is co ec ed, he diag am o he
exis ing uni (Figu e 2) is modi ied as illus a ed in Figu e 3. By designed hea
ans e in ensi ica ion, he WG p o ile is ex ended by he alue Qin , which causes
a shi o he FG p o ile by he same alue o he igh . The FG g adien is also
sligh ly inc eased due o he educed low a e.
F om he abo e p ocedu e desc ibed and Figu e 3, he FG high sensi i i y o he ER
modi ica ions is ob ious. This is an impo an aspec o be conside ed ca e ully du ing he
concep ual design s age because i conside ably in luences he accu acy o he ob ained
esul s.
The FG p o ile shi causes a change o hea exchange d i ing o ces in pa icula hea
exchange s, hus i is ecommended o e-e alua e he hea loads and o epea he
calcula ion p ocedu e se e al imes un il he FG p o ile shi be ween i e a ions is educed
o a minimum.
Figu e 3. The exis ing WG hea e in ensi ica ion
Inse ion o a new p ehea e
Acco ding o he ene gy balance o a combus ion chambe , whe e he pollu an he mal
decomposi ion akes place, he uel sa ings could be eached by p ehea ing any s eam
en e ing he CC. Besides he WG p ehea ing, which is commonly employed (see Figu e 1),
ano he iable choice is, o example, p ehea ing he combus ion ai (CA). I he WG E uni
p ocesses se e al WG s eams, while some o hem a e no p ehea ed (mos ly mino
s eams), he addi ional hea exchange s (p ehea e s) could be inse ed in o de o imp o e
he FG hea u iliza ion by p ehea ing hose s eams.
The usual ER equi emen is i s minimal impac on he gene a ion o ene gy media (e.g.
s eam gene a ion illus a ed in Figu e 1). Fo his eason, new p ehea e s a e ecommended
o be placed downs eam o he ene gy media gene a o s. A sui able posi ion is commonly a
he end o he FG low pa h, whe e he was e hea (Qloss) could be di ec ly u ilized o educe
he cu en uel demand wi hou signi ican in luence on o he hea exchange s in HRS.
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The inse ion o a new p ehea e , howe e , in luences he FG low a e acco ding o he
same p inciple as in he case o he exis ing WG hea e in ensi ica ion discussed p e iously.
The p ocedu e o new p ehea e inse ion consis s o he ollowing s eps:
• Exchange minimum app oach empe a u e (EMAT) alue de e mina ion. EMAT
e alua ion is dependen on he exis ing HRS pa ame e s and is discussed, o
example, by Zhu and Asan e [28].
• New p ehea e hea load calcula ion. Acco ding o he se EMAT alue and known
s eam p ope ies, he hea load (Qp h) and co esponding media (FG and, o
example, CA) inle /ou le empe a u es a e calcula ed.
• Fuel sa ing calcula ion and lue gas low a e eassessmen . Ob aining he uel
sa ing alue Δ s and FG low a e co ec ion ollows he same ules as in he case
o he exis ing WG hea e in ensi ica ion.
• Modi ied diag am plo . A g aphical ep esen a ion o he SFGL me hod is
pe o med acco ding o sligh ly di e en ules han in he case o exis ing WG hea e
in ensi ica ion. I is p esen ed in he case o CA p ehea e inse ion. When he FG
low a e is co ec ed, he modi ied diag am can be plo ed as shown in Figu e 4.
The di e ence be ween he in ensi ica ion o he exis ing p ehea e (Figu e 3)
and he inse ion o he new one (Figu e 4) is ha he new p ehea e is placed o
he le o he T-axis. This app oach causes only he FG line o a ion ins ead o
shi ing o he igh as in he case o he exis ing p ehea e in ensi ica ion.
Figu e 4. The new p ehea e inse ion
The o a ion o he FG p o ile (as shown in Figu e 4) causes b eaking he CA p ehea e
EMAT alue in an ini ial i e a ion. The CA low a e is also changed due o he eached uel
sa ings. Fo hese easons, i is necessa y o pe o m se e al i e a ions o he p ocedu e
desc ibed abo e un il he CA p o ile and FG p o ile (SFGL) a e s able and he EMAT alue
equi emen is ul illed.
The ER pe o med by he inse ion o a new p ehea e in luences he hea exchange
d i ing o ces in exis ing hea exchange s in he same way as in he case o exis ing WG
hea e in ensi ica ion desc ibed ea lie . Thus he e-e alua ion o hea loads in exis ing hea
exchange s is ecommended. Howe e , i he FG low a e change is small, he dec ease in
he hea ans e in exis ing hea exchange s could be neglec ed.
The de eloped SFGL me hod is u he applied o a case s udy o a speci ic WG E uni
p ocessing he WGs gene a ed in an ac ylic acid p oduc ion plan .
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CASE STUDY
The de eloped SFGL me hod he e is p ac ically in oduced by i s applica ion o he
ER design o a speci ic indus ial WG E uni , which se es he mal ea men o was e
gas p oduced mainly om an ac ylic acid p oducing p ocess. The p oduc ion p ocess is a
sou ce o se e al was e gases con aining VOC and CO in low concen a ions (0.85 and 0.5
% ol). The cu en supplemen al uel consump ion is equi ed o be educed by a leas 30
% wi h as li le modi ica ion o he cu en uni as possible. The pa ag aphs below
in oduce he s udied WG E uni wi h all key equipmen .
Desc ip ion o he s udied uni
The uni consis s o a u nace, e e ed o as a combus ion chambe (CC), whe e wo
WG s eams a e he mally ea ed – main was e gas (MWG) and seconda y was e gas
(SWG). The na u al gas bu ne is employed in he u nace o p omo e he mal oxida ion o
he pollu an s and hus o gene a e a lue gas (FG) a a high empe a u e (800 °C). FG was e
hea is a i s used o gene a e high-p essu e (HP) sa u a ed s eam, as a supplemen al
hea ing medium in he plan , and o supe hea a medium-p essu e (MP) s eam as a medium
o powe cycle (elec ici y gene a ion).The MWG is hen p ehea ed in he main was e gas
hea e be o e en e ing he u nace (CC) o educe he supplemen al ene gy demand. The uni
is illus a ed in Figu e 5.
Figu e 5. S udied WG E uni
The cu en uni is ene gy e y in ensi e, he e o e he Ene gy Re o i is eques ed in
o de o educe he uni ´s uel consump ion. The SFGL me hod was applied o design he
echnological modi ica ions in he cu en HRS enabling i o each he desi ed uel sa ing
by imp o ing he FG hea eco e y.
RESULTS AND DISCUSSION
The uni ´s HRS consis s o h ee hea exchange s – HP s eam gene a o , MP s eam
supe hea e , and MWG hea e as shown in Figu e 5. In he uni da a ex ac ion s age,
hei basic p ocess and geome y cha ac e is ics we e p o ided (see Table 1). Acco ding
o he desc ibed SFGL p ocedu e, he p ocess s eam cha ac e is ics a e gi en in Table 2
and uel/oxidize cha ac e is ics in Table 3.
Wi h he ob ained da a, he empe a u e-en halpy diag am o he cu en uni was
gene a ed (see Figu e 6). The FG line was ex apola ed o he dew poin empe a u e
(TDP = 68.5 °C), which is acco ding o he FG composi ion calcula ed as he empe a u e
o wa e apou condensa ion.
F eisleben, V., Jegla, Z.
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Jou nal o Sus ainable De elopmen o Ene gy, Wa e and En i onmen Sys ems 16
TDP
lue gas dew poin empe a u e
[°C]
Tin
inle empe a u e
[°C]
Tini
ini ial empe a u e o oxidize / uel mix u e
[°C]
Tou
ou le empe a u e
[°C]
Ts ack
lue gas s ack empe a u e
[°C]
TTFT
Theo e ical Flame Tempe a u e
[°C]
Δ s
uel sa ing
[kg/h]
ΔmCA
combus ion ai low a e educ ion
[kg/h]
ηDP
lue gas u iliza ion he mal e iciency ela ed o dew poin ,
[%]
Abb e ia ions
CA
combus ion ai
CC
combus ion chambe
EMAT
exchange minimum app oach empe a u e
ER
Ene gy Re o i
FG
lue gas
HEN
Hea Exchange Ne wo k
HP
high-p essu e (s eam)
HRS
Hea Reco e y Sys em
LHV
Lowe Hea ing Value
MP
medium-p essu e (s eam)
MWG
main was e gas
SFGL
Shi ing Flue Gas Line
SWG
seconda y was e gas
VOC
Vola ile O ganic Compound
WG
was e gas
WG E
Was e Gas- o-Ene gy (uni )
ACKNOWLEDGMENT
This esea ch has been suppo ed by he p ojec LTACH19033 “T ansmission
Enhancemen and Ene gy Op imised In eg a ion o Hea Exchange s in Pe ochemical
Indus y Was e Hea U ilisa ion”, unde he bila e al collabo a ion o he Czech Republic
and he People´s Republic o China (pa ne s Xi´an Jiao ong Uni e si y and Sinopec
Resea ch Ins i u e Shanghai; SPIL VUT, B no Uni e si y o Technology and EVECO
B no s. .o.), p og am INTER-EXCELLENCE, INTER-ACTION o he Czech Minis y
o Educa ion, You h and Spo s; and by Na ional Key Resea ch and De elopmen
P og am o China (2018YFE0108900).
Fu he , his esea ch has been also suppo ed by he EU p ojec S a egic Pa ne ship
o En i onmen al Technologies and Ene gy P oduc ion, unded as p ojec No.
CZ.02.1.01/0.0/0.0/16_026/0008413 by Czech Republic Ope a ional P og amme
Resea ch, De elopmen and Educa ion, P io i y Axis 1: S eng hening capaci y o
high-quali y esea ch.
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