Title of Paper Waste Heat Recovery from Process Plants

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Author 1 I R Calcott
Company Foster Wheeler Energy Limited
Address Foley House
5 Seaward Place
Glasgow
Scotland
G41 1HH
e-mail iain_calcott@fwuk.fwc.com

Author Background

Iain is a Principal Process Engineer for Foster Wheeler Energy Limited Glasgow Operations.
He holds a BSc (Hons) in Chemical Engineering from Heriot Watt University and has worked
for over 17 years in process design and plant operation.

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Author 2 A J Tuckett
Company Foster Wheeler Energy Limited
Address Foley House
5 Seaward Place
Glasgow
Scotland
G41 1HH
e-mail andy_tuckett@fwuk.fwc.com

Author Background

Andy is Chief Process Engineer for Foster Wheeler Energy Limited Glasgow Operations. He
has a BSc (Hons) in Chemical Engineering from Loughborough University. He has over 20
years experience in process design and engineering of oil and gas projects.

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Author 3 A H Bell
Company Foster Wheeler Energy Limited
Address Foley House
5 Seaward Place
Glasgow
G41 1HH
e-mail alasdair_bell@fwuk.fwc.com

Author Background

Alasdair is a Senior Process Engineer for Foster Wheeler Energy Limited Glasgow
Operations. He holds a BSc (Hons) in Chemical Engineering from Strathclyde University
and has worked for over 15 years in a process design and plant operations role.
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INTRODUCTION

Process plants, especially oil refineries, petrochemical complexes and gas plants generate
large quantities of low grade heat.

This energy is typically rejected to atmosphere using either air or cooling water systems.
There are, however, opportunities to recover some of this energy, and utilise it, either as part
of a process integration scheme, or for heating in domestic and commercial properties by the
installation of a hot water system.
Recovery of waste heat provides both financial and environmental benefits to process plant
operators.

In various countries throughout the world it is becoming more common for combined heat
and power (CHP) plant to be installed, which can also produce hot water for domestic
heating as a means of utilising low grade heat and improving the overall efficiency of the
CHP. It is less common to install heat recovery systems on existing process plant for use in
domestic heating systems.

Foster Wheeler has recently been involved in the design of systems for the recovery of heat
from oil refinery and gas plant process units. This paper describes the design
considerations made by Foster Wheeler for these projects which have been designed and
installed in order to recover and utilise heat that otherwise would have continued to be
rejected to the atmosphere. The recovered heat has been used for both domestic heating
and as part of a process integration scheme.

SYSTEM DESCRIPTION

Energy is recovered into a heating medium, which is circulated in a closed loop system.
Generally hot oil or water has been used on previous projects, water for temperatures up to
approximately 150 oC and hot oil for higher temperatures.

The process description of a typical heat recovery system is outlined below, refer also to the
process schematic provided as figure 1.

Heating media is circulated from the heat sink, E-5, at low temperature via the heating media
expansion drum (V-1) by heating media circulation pumps (P-1). During periods of low
overall heating demand, typically the Summer months for district heating systems, the duty
supplied by the heat recovery scheme exceeds that required by the users. A heating media
trim cooler (E-1) is thus provided to remove excess heat and to ensure a constant heating
media temperature to the process heat recovery exchangers. The trim cooler also ensures
controllability across the full range of operating conditions of the system.

The heating media then flows through the process heat recovery exchanger E-2, E-3 and
E-4. Exchanger E-2 is used to recover low-grade heat, and is unable to meet the required
heating media temperature. The temperature is boosted by passing in series through E-4
which is installed in the flue gas of a fired heater.

The heating media is then used as a source of heat for either a district heating system or for
process duties by passing through exchanger E-5.

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 E-1
( TRIM COOLER ) TC

E-2

E-3

TC

TC
V-1

HEAT
SINK

P-1 E-4
TC

E-5

Figure 1: Typical process schematic of a heat recovery system

RECOVERY OF HEAT FROM REFINERY PROCESS UNITS

Heat tends to be available from the following sources:

- Column overheads condensers

- Reflux and pump around systems
- Product rundown coolers
- Fired heater flue gas

The choice of which are the most attractive sources of heat is dependent on the duty
available, and the desired temperature of the circulating fluid.

Condensing duties in column overheads systems are very attractive from a heat recovery
view as they tend to be large loads. However, the temperature at which they are available
tends to be low usually in the region of 100 to 130 oC. This presents a problem, as it results
in a close approach temperature to the heating media which normally is required at
approximately 100oC. To accommodate these low approach temperatures, large,
complicated heat exchangers may be required. This problem can be countered by accepting
a lower outlet heating media temperature and then boosting the heating media temperature
by recovering heat from a higher grade source, such as a fired heater flue gas system in
series with the overheads condenser.

There can be major economic benefit to the plant operator in installing heat recovery in
columns overheads systems. These systems are often constrained on overhead cooling
capacity limited during Summer months, due to higher than normal air or cooling water
temperatures. Installation of a heat recovery exchanger can significantly increase the duty
available and thus remove constraints allowing higher process unit throughputs.

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Even with integration with higher grade heat sources the approach temperatures will still
tend to be relatively low, therefore the heat recovery exchangers in column overhead
systems tend to be large double shell units. Care needs to be taken in the installation and
design of these units such that the back pressure and hence operating pressure of the
distillation column is not increased significantly. An increased operating pressure will impact
reboiler duty, any other heat integration that maybe present and separation efficiency in the
column. Care must also be taken in the design of the pipework so that flow distribution
between the overheads condensers remains balanced.

Recovery of heat from fired heater flue gas is a very attractive option as it is a source of high
grade heat and can be used to boost the temperature of the heat recovered from lower
grade sources. The major concern with flue gas is to ensure that the temperature is
maintained above that for which condensation of water within the flue gas occurs. As this
liquid, once condensed, can be acidic and give rise to severe corrosion, the control system
of the heat recovery process must be designed to ensure that condensation does not occur.
Typically it is necessary to ensure that the flue gas remains above 200 oC. However this is
dependent on the quality of the fired heater fuel. With a clean fuel, where the concentration
of sulphur, etc is such that the formation of acidic water is not a concern, the limitation
becomes the buoyancy of the exhaust gas, and the selection of the temperature is
dependent on achieving air quality standards for ground level concentration of the exhaust
gas components such as NOx and SOx.

Installation of heat recovery exchangers represents a significant modification to the Process

Unit. As these Units normally operate on a continuous basis, installation of the recovery
system has to be undertaken at a planned major maintenance turnaround. The installation
philosophy is dependent on local circumstances, but is usually either by installing the
majority of the heat recovery system prior to the turnaround, and then undertaking tie-ins
during the shutdown. Or alternatively by providing tie-in at the shutdown and installing the
rest of the system later.

Also, when new process units are added to the refinery complex, there exists the opportunity
to capture waste heat potential at the design stage. Where there is the possibility of a future
heat recovery system, the plot space and piping design can be developed prior to
construction of the main process unit.

HEAT RECOVERY FROM GAS TURBINE EXHAUST

The exhaust gas stream from Gas Turbines (GT) represents a potential source of high grade
heat, which is often not recovered. Foster Wheeler has experience of retrofitting waste heat
recovery units (WHRU) in the exhaust systems of gas turbines.

The exhaust gas temperature from a GT is typically in the order of 500oC. This temperature
allows heat to be recovered at a high temperature, and allows use for process heating
applications, for example by heating hot oil to around 300oC.

Retrofitting a waste heat recovery unit presents a number of challenges which need to be
overcome..

Firstly a shutdown of the gas turbine is required in order to enable the exhaust system to be
modified. The gas turbine is usually an integral, and often not spared, part of the process
plant so a suitable shutdown has to be found. This typically takes place during a planned
maintenance period for the process unit.

By maximising pre-assembly of the WHRU, we have succeeded in retrofitting WHRUs to GT

exhaust systems within a planned seven day maintenance turnaround. By providing a
bypass stack and guillotine isolation between the WHRU and GT it is possible to complete
the piping and instrumentation with the GT back on-line.

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Secondly, the installation of a WHRU increases the back pressure on the GT, which will
adversely impact its efficiency and hence power output. This is a serious consideration in
cases where the GT is operating close to its maximum rated output. To minimise the back
pressure the design of the WHRU must ensure that there is always a full flow path available
to the exhaust gas.

A typical GT WHRU is shown in figure 2 below.

Bypass Stack

Guillotine

Damper
TC

Heating Media
Return From Gas
Turbine Exhaust

Heating Media
Supply

Heating Coil Damper

Figure 2: Typical gas turbine waste heat recovery unit

RECOVERED HEAT USES

Domestic/Commercial Heating

Domestic and commercial heating systems require hot water at between 60 and 105oC;
higher temperatures are not favoured due to the potential safety risks to the public. The heat
recovery system water will typically be at 150oC.

Also piping the heating media directly outside the factory fence is not favoured due to the
possibility of hydrocarbon contamination.

To overcome these issues a heat exchanger is provided between the heat recovery media
and the hot water system. For this duty, plate exchangers have typically been installed as
these minimise the potential for cross contamination.

Process Integration

Where heat has been recovered from high grade sources such as gas turbines, the heating
media is available at between 250 and 350oC. These temperatures are sufficiently high for
the heat to be used for process duties such as reboilers, gas heaters, and regeneration
duties. Depending on the duty the hot oil is circulated to either the shell or tube side of shell
and tube heat exchangers with the process fluid on the other side.

The potential for cross contamination of the process and heating media streams must be
considered and if necessary relief devices provided should over pressure of either system
from the other be possible.

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BENEFITS

Installation of a heat recovery system provides additional revenue to process plant pperators
when the recovered heat is used outside the factory fence.

Dependent on the legislation within the country there may be tax benefits with respect to the
flue gas temperatures and reduction on CO2 emissions.

Note that in the UK there is a scheme for 100% enhanced capital allowances for energy-
saving investments, introduced by the Finance Act 2001 and expanded by Finance Act
2002.

Under the scheme, businesses can claim up-front tax relief on their capital spending from 1
April 2001 on designated energy-saving plant and machinery.

The scheme aims to encourage businesses to invest in energy-saving equipment to help

reduce their energy use, leading to lower carbon emissions. It is an integral part of the
climate change levy programme that has been introduced to help the UK reduce its carbon
emissions under the international Kyoto Protocol, and move towards its domestic target of a
20% reduction in carbon emissions

For cases when the heat is used for heat integration it reduces operational costs by reducing
fuel gas consumption.

Heat recovery schemes can also improve summer production by removal of bottlenecks in
column overheads systems, that are constrained due to availability of cooling, whether this
be air or cooling water during Summer months when the ambient air temperature is higher.

Operators can also benefit from reduced operating costs by less dependence on existing
cooling systems.

Apart from economic benefits, there are also environmental benefits in installing a heat
recovery system as emissions to atmosphere are reduced, by reducing fuel gas
consumption.

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