【Q&A Question 235】December 11, 2016
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This post was last edited by liuquan1100 on 2016-12-11 10:10. [Q&A Question 235] 2016.12.11: How can device energy consumption be reduced while ensuring stable operation of the device? (Taking the hydrogenation unit as an example, the hydrogenation section only features questions related to hydrogenation.) ) The reference answers will be visible after *replying*; points can be earned by identifying the key points. 1. Close the viewing ports as needed. 2. Turn off the emergency lighting and the lighting in the compressor building once it gets light. 3. Do not use an excessive amount of nitrogen. 4. Produce as much steam as possible; avoid venting steam. 5. Minimize the flow in the E-102 bypass line so that the mixed hydrogen oil can exchange heat with the reaction products, thereby reducing gas consumption in F-101 (the reaction feed heater). 6. Under stable CAT conditions, increase the outlet temperature of the refining reactor as much as possible and reduce the amount of cold hydrogen used. 7. Use nitrogen only where gas sealing is feasible; avoid using nitrogen in such cases. 8. Reduce the circulation water flow in the interstage coolers of the standby compressors. Summary post of Q&A from 2016 (updated up to December~~~~) http://bbs.hcbbs.com/thread-1597792-1-1.html Seeking sponsors for the “2016 Haichuan Top 10 Members Selection Contest” http://bbs.hcbbs.com/thread-1628108-1-1.html (Source: Haichuan Chemicals Forum)
Maintaining the stable operation of the equipment, reducing unplanned shutdowns, and preventing leaks are the fundamentals of energy conservation and cost reduction. On this basis, consumption can be reduced through optimizing process operations, strengthening management, and implementing technical upgrades and improvements.
Reduce circulating water consumption, minimize air leakage in the heating furnace, optimize its combustion conditions, and improve thermal efficiency
I. Start the machine and pump properly. II. Adjust the process parameters to their optimal values. III. Reduce leaks in the system.
1. Close the viewing ports as needed. 2. Turn off the emergency lighting and the lighting in the compressor building once it gets light. 3. Do not use an excessive amount of nitrogen. 4. Produce as much steam as possible; avoid venting steam. 5. Minimize the flow in the E-102 bypass line so that the mixed hydrogen oil can exchange heat with the reaction products, thereby reducing gas consumption in F-101 (the reaction feed heater). 6. Under stable CAT conditions, increase the outlet temperature of the refining reactor as much as possible and reduce the amount of cold hydrogen used. 7. Use nitrogen only where gas sealing is feasible; avoid using nitrogen in such cases. 8. Reduce the circulation water flow in the interstage coolers of the standby compressors.
The cycle ratio, hydrogen-to-oil ratio, and reflux ratio should not be set too high; high values require larger amounts of heating and cooling energy. Therefore, proper adjustment of these three parameters is essential to save energy!
First, improve the process flow by identifying and modifying the unreasonable aspects within it. For example: Is the voltage drop between various points too high? Is the heat exchange process reasonable? Second is to improve equipment efficiency – are the efficiencies of various heat exchangers, heaters, pumps, etc., good enough? Third is to optimize the operations, by conducting comparisons during these operations to determine which approach is more reasonable and more energy-efficient (within the limits permitted by the equipment). Fourth is to use advanced automation control systems, such as variable frequency drives for pumps and air preheating for furnaces. Additionally, I feel that more freedom and room for initiative should be given to employees in terms of energy conservation and cost reduction. The supervisors in each workshop set a target (within reasonable limits), and if you exceed this target, unfortunately penalties will be imposed; whereas if you fall below it, I will give you a reward! Fully mobilizing everyone’s initiative should yield good results!
1. Close the viewing ports as needed. 2. Turn off the emergency lighting and the lighting in the compressor building once it gets light. 3. Do not use an excessive amount of nitrogen. 4. Produce as much steam as possible; avoid venting steam. 5. Minimize the flow in the E-102 bypass line so that the mixed hydrogen oil can exchange heat with the reaction products, thereby reducing gas consumption in F-101 (the reaction feed heater). 6. Under stable CAT conditions, increase the outlet temperature of the refining reactor as much as possible and reduce the amount of cold hydrogen used. 7. Use nitrogen only where gas sealing is feasible; avoid using nitrogen in such cases. 8. Reduce the circulation water flow in the interstage coolers of the standby compressors.