Improved energy efficiency in the processus industries

European Commission Directorate-General For The Information Society And Media Directorate-General For Research And Innovation

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Proceedings of a European Seminar, Brussels, 23 and 24 October 1990
Energy research
Energy policy

Informations

• Publié par: EUROPEAN-COMMISSION-DIRECTORATE-GENERAL-FOR-THE-INFORMATION-SOCIETY-AND-MEDIA-DI
• Nombre de lectures: 6
• Langue: English
• Poids de l'ouvrage: 5 Mo

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Commission of the European Communities
energy
Improved energy efficiency
in the process industries
Proceedings of a European Seminar
Brussels, 23 and 24 October 1 990 Commission of the European Communities
nerg
Improved energy efficiency
in the process industries
Proceedings of a European Seminar
Brussels, 23 and 24 October 1990
Edited by P. A. Pilavachi
Commission of the European Communities
Rue de la Loi, 200
B-1049 Brussels
Joule R&D programme:
Rational use of energy
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Directorate General
Science, Research and Development
Joint Research Centre
EUR 13541 EN-FR 1991 Published by the
COMMISSION OF THE EUROPEAN COMMUNITIES
Directorate-General
Telecommunications, Information Industries and Innovation
L-2920 Luxembourg
LEGAL NOTICE
Neither the Commission of the European Communities nor any person acting on
behalf of then is responsible for the use which might be made of the
following information
Cataloguing data can be found at the end of this publication
Luxembourg: Office for Official Publications of the European Communities, 1991
ISBN 92-826-2550-8 Catalogue number: CD-NA-13541-2A-C
© ECSC-EEC-EAEC, Brussels • Luxembourg, 1991
Printed in Belgium SUMMARY
The European Commission, in its continuing effort to conserve energy within the Community,
at the same time improving the environment in which its inhabitants live, sees improved energy
efficiency in industrial processes as a major aim. In promoting energy efficient technologies in
the process industries, through Non Nuclear Energy Programmes like JOULE, the Commission
is influencing a sector which accounts for over 34% of the primary energy use in the
Community, representing annually in excess of 350 mtoe (million tonnes of oil equivalent).
The current Non-Nuclear Energy R&D Programme, JOULE, covers the areas of: Rational Use of
Energy, Energy from Fossil Sources, and Renewable Energies. Within the context of "Rational
Use of Energy", the Commission has funded a number of important collaborative projects
directed at achieving improved energy efficiency in the process industries.
Preliminary results from current projects carried out within the JOULE Programme were
presented in a European Seminar on "Improved Energy Efficiency in the Process Industries" in
October 1990, which also comprised a workshop.
Topics covered, relating to present R&D activities within JOULE, included the following:
Heat exchangers: enhanced evaporation, shell and tube heat exchangers including distribution
of fluids, and fouling.
Low energy separation processes: adsorption, melt-crystallisation and supercritical extraction.
Chemical reactors: methanol synthesis and reactors with integral heat exchangers.
Other unit operations: evaporators, glass-melting furnaces, cement kilns and baking ovens,
dryers and packed columns and replacements for R12 in refrigeration.
Energy and system process models: batch processes, simulation and control of transients and
energy synthesis.
Development of advanced sensors.
The workshop was made up of 13 working groups, formed to discuss future R&D needs. This
identified sectors of great significance, both in terms of potential energy savings and,
increasingly important, with regard to their prospects for reducing the detrimental impact of the
process industries on the environment. The following were covered:
Chemical reactors, heat exchanger intensification, process plant intensification, heat exchanger
fouling, gas-adsorption, melt crystallisation, glass-making and ceramic furnaces, cement kilns
and baking ovens, dryers, refrigeration (replacement of CFCs), energy and environmental
process integration, advanced sensors for process control, catalytic combustion, efficient use of
electricity.
The working groups came up with a number of recommendations for future R&D, many of
which were detailed in terms of the content and the impact which such R&D might have on
energy use and the environment.
The Seminar was attended by approximately 150 participants from industry, research
laboratories and academic institutions.
Further information on the Seminar may be obtained by writing to Dr. P. A. Pilavachi, DG XII,
Commission of the European Communities.
— Ill — CONTENTS
Page
SUMMARY III
INTRODUCTION 1
OPENING ADDRESS: Prof. Ph. BOURDEAU 3
OVERVIEW: Dr. P. A. PILAVACHI 5
PRESENT R&D ACTIVITIES 7
HEAT EXCHANGERS 9
Enhanced evaporation heat transfer surfaces
Rapporteur: Prof. M. Groll, Universitàt Stuttgart 11
Improving the performance of shell and tube heat exchangers
Rapporteur: Dr. J. Hesselgreaves, National Engineering Laboratory 19
Study of the distribution of vapour-liquid mixtures in the tube
side of a tube and shell heat exchanger
Rapporteur: Mr. F. Lauro, CEA - GRETh 31
Generic studies for industrial heat exchanger fouling
Rapporteur: Dr. J.D. Isdale, National Engineering Laboratory 43
LOW ENERGY SEPARATION PROCESSES 59
The methodology of gas-adsorption process design
Rapporteur: Dr. E. Macdonald, Harwell Laboratory 61
Improvement of melt crystallization's efficiency
Rapporteur: Dr. J. G. Arkenbout, TNO - Division of Technology 73
for Society
Phase equilibria and process simulation for high-pressure
supercritical extraction processes
Rapporteur: Dr. J. M. S0rensen, Technical University of Denmark 87
CHEMICAL REACTORS 99
Reversed flow synthesis of methanol
Rapporteur: Prof. G. Froment, Rijksuniversiteit van Gent 101
Fixed bed reactor with integrated heat exchanger
Rapporteur: Dr. G. Heijkoop, VEG-Gasinstituut 113
— v — OTHER UNIT OPERATIONS 127
Absorption driven multiple effect evaporators
Rapporteur: Prof. S. Yanniotis, Hellas Energy9
Energy saving and pollution abatement in glass making furnaces,
cement kilns and baking ovens
Rapporteur: Prof. M. G. Carvalho, Instituto Superior Tecnico 141
Advanced flow modelling for applications in the process industries
Rapporteur: Prof. N. C. Markatos, National Technical University Athens 161
Replacement for R12 in refrigeration systems
Rapporteur: Prof. J. McMullan, University of Ulster 177
ENERGY AND PROCESS SYSTEM MODELS 189
Design and operation of energy efficient batch processes
Rapporteur: Mr. P. M. M. Brown, Linhoff March 191
Simulation and control of fast transients in process and utility systems
Rapporteur: Prof. P. Hutchinson, Cranfield Institute of Technology 203
Energy synthesis in industrial processes
Rapporteur: Prof. B. Kalitventzeff, Université de Liège 217
SENSORS AND INSTRUMENTATION 229
Development of advanced sensors
Rapporteur: Prof. F. Durst, Universitat Erlangen-Niirnberg 231
DISCUSSION 243
— VI — FUTURE R&D REQUIREMENTS 251
THE NEW JOULE PROGRAMME: Ir. P. ZEGERS 253
ORGANISATION OF THE WORKSHOP: Dr. P. A. PILAVACHI 255
REPORTS ON WORKING GROUPS 257
CHEMICAL REACTORS9
HEAT EXCHANGERS INTENSIFICATION 261
PROCESS PLANTN3
HEAT EXCHANGERS FOULING5
ADSORPTION AS A LOW ENERGY SEPARATION AND
PURIFICATION PROCESS 269
MELT CRYSTALLISATION 273
GLASS MAKING AND CERAMIC FURNACES, CEMENT KILNS AND
BAKING OVENS5
DRYERS
REFRIGERATION (REPLACEMENT OF CFCs) 281
ENERGY AND THE ENVIRONMENT
(Chemical process + paper production process)
ADVANCED SENSORS FOR PROCESS CONTROL IN THE
PROCESS INDUSTRIES 287
CATALYTIC COMBUSTION9
EFFICIENT USE OF ELECTRICITY 291
LIST OF PARTICIPANTS3
VII