Methods for simultaneous process and utility systems synthesis in partially and fully decentralized environments

• US 9,606,594 B2
• Filed: 02/01/2013
• Issued: 03/28/2017
• Est. Priority Date: 03/19/2012
• Status: Active Grant

• Current Assignee: Saudi Arabian Oil Company (Government of Saudi Arabia)
• Original Assignee: Saudi Arabian Oil Company (Government of Saudi Arabia)
• Inventors: Noureldin, Mahmoud Bahy, Al-Owaidh, Mana M., Al-Nutaifi, Abdulaziz, Al-Musa, Faisal F.
• Primary Examiner(s): Everett, Christopher E
• Application Number:
  US13/757,467
• Publication Number:
  US 20130245844A1
• Time in Patent Office: 1,516 Days
• US Class Current: 1/1
• CPC Class Codes: G05B 17/00 Systems involving the use of models or simulators of said systems G05B13/00, G05B15/00, G05B19/00 take precedence
• CPC Class Codes: G05B 17/02 electric
• CPC Class Codes: G06F 1/26 Power supply means, e.g. regulation thereof for memories G11C
• CPC Class Codes: Y02E 20/14 Combined heat and power generation [CHP]

Abstract

Methods of providing a combined synthesis of cost-effective heat and power (CHP) utility systems and the key process systems are provided. An exemplary method includes process steps for identifying the best key subsystem design and operating conditions for both the process and the utility systems. The method can include the step of determining an optimal allocation of steam and power between both process and utility systems for one or more industrial process facilities in both partially and totally decentralized environments. This can include defining rigorously bounded decision variables as model input data, processing the model input data by a combined heat and power utility and process subsystem mathematical program model, and determining a plurality of at least substantially optimal process and utility subsystem conditions.

Claims

1. A method for simultaneous synthesis of combined heat and power utility and process subsystems for a process facility, the method comprising the steps of:

defining model input data for a combined heat and power utility and process subsystem mathematical program model, the model comprising a cost function configured to minimize a total cost of combined heat and power utility and process subsystems of a process facility, the combined heat and power utility and process subsystems comprising a utility subsystem configured to generate steam and a process subsystem configured to consume steam generated by the utility subsystem, and the model input data comprising a plurality of rigorously bounded process variables for one or more key process of the process facility, the plurality of rigorously bounded process variables comprising, for each of the one or more key processes;

process steam demand intervals for the key process, the process steam demand intervals comprising a process steam demand interval for each of a plurality of different steam pressure levels, wherein each process steam demand interval for a steam pressure level comprises an upper bound and a lower bound of process steam demand for the key process at the steam pressure level; and

a process power generation interval for the key process, the process power generation interval comprising an upper bound and a lower bound of power generation for the key process; and

processing, by a computer, the model input data through application of the combined heat and power utility and process subsystem mathematical program model to determine model output data comprising process subsystem conditions and utility subsystem conditions, the process subsystem conditions comprising, for each of the one or more key processes;

process steam demand load values corresponding to the process steam demand intervals for the key process, the process steam demand load values comprising a process steam demand load value for each of the plurality of different steam pressure levels; and

a process power generation value corresponding to the process power generation interval.

2. A method as defined in claim 1,

wherein the process subsystem conditions and the utility subsystem conditions are determined simultaneously through application of the combined heat and power utility and process subsystem mathematical program model;

and

wherein the utility subsystem conditions include combined heat and power utility subsystem steam and power generation and allocation values.

3. A method as defined in claim 1, wherein the utility subsystem conditions comprise a number of steam headers for the utility subsystem and operating conditions of each steam header.

4. A method as defined in claim 1, wherein the utility subsystem conditions comprise a number of boilers for the modeled utility subsystem and designated capacities of each boiler.

5. A method as defined in claim 1, wherein the utility subsystem conditions comprise a number of steam turbine generators for the utility subsystem and capacity of each steam turbine generator.

6. A method as defined in claim 1, wherein the utility subsystem conditions comprise a number of cogeneration units for the utility subsystem and designated capacities of each cogeneration unit.

7. A method as defined in claim 1, wherein the process subsystem conditions comprise a number of electrical motors and steam turbines for process equipment driving and size of each.

8. A method as defined in claim 1, wherein the utility subsystem conditions comprise a size and location of solar power system for the modeled utility subsystem.

9. A method as defined in claim 1, further comprising:

determining a first cost associated with the utility subsystem;

determining a second cost associated with the process subsystem;

determining a greater of the first cost associated with the utility subsystem and the second cost second cost associated with the process subsystem;

in response to determining that the first cost associated with the utility subsystem is greater than the second cost associated with the process subsystem, determining the utility subsystem conditions; and

determining the process subsystem conditions based on the utility subsystem conditions determined.

10. A method as defined in claim 1, further comprising one or more of the following steps:

defining a number of steam headers and conditions thereof of the utility subsystem; and

determining a shaft work network configuration of the utility subsystem, wherein the shaft work network configuration is indicative of a configuration of physical equipment.

11. A method as defined in claim 1, wherein determining the process subsystem conditions and the utility subsystem conditions comprises determining main design and operating conditions of a heat exchanger network (HEN) design and distillation network sequence for the process facility for possible combinations of process operation parametric changes for fully decentralized, partially decentralized, or both fully and partially decentralized process and utility systems design environments.

12. A method as defined in claim 11,

wherein the main design and operating conditions of a HEN network design and distillation network sequence is determined using sources of fuel or energy available to a provider of the utility subsystem;

and

wherein the main design and operating conditions of a HEN network design and distillation network sequence is determined responsive to receiving, determining, or receiving and determining a plurality of sets of values each defining a potential range of attribute values of a separate one of a corresponding plurality of process operation parametric changes.

13. A method as defined in claim 1, wherein the process subsystem conditions render a minimum number of heat exchanger network (HEN) units for the process facility for possible distillation columns sequences.

14. A method as defined in claim 1, wherein the process subsystem conditions render a minimum total heat exchanger surface area of a heat exchanger network (HEN) design for the process facility and define the surface area of each heat exchanger unit in the HEN.

15. A method as defined in claim 14, wherein determining the process subsystem conditions which render the minimum total heat exchanger surface area comprises determining process subsystem conditions for:

one or more possible combinations of steam generation and demand loads'"'"' levels; and

one or more combinations of steam generation and demand loads'"'"' levels.

16. A method as defined in claim 14, wherein determining the process subsystem conditions which render the minimum total heat exchanger surface area comprises determining process subsystem conditions for:

one or more possible distillation columns sequences;

one or more possible distillation columns sequences in conjunction with one or more possible combinations of steam generation and demand loads'"'"' levels; and

one or more possible distillation columns sequences and one or more combinations of steam generation and demand loads'"'"' levels.

17. A method as defined in claim 14, wherein determining the process subsystem conditions which render the minimum total heat exchanger surface area comprises determining process subsystem conditions for:

one or more possible HEN configurations and one or more possible combinations of steam generation and demand loads'"'"' levels; and

one or more possible HEN configurations and one or more combinations of steam generation and demand loads'"'"' levels.

18. A method as defined in claim 1, further comprising designing the process facility based on the process subsystem conditions and utility subsystem conditions.

19. A method for simultaneous synthesis of combined heat and power utility and process systems for a chemical plant, the method comprising the step of:

defining model input data for a combined heat and power utility and process subsystem mathematical program model, the model comprising a cost function configured to minimize a total cost of combined heat and power utility and process subsystems of a chemical plant, the combined heat and power utility and process subsystems comprising a utility subsystem configured to generate steam and a process subsystem configured to consume steam generated by the utility subsystem, and the model input data comprising a plurality of rigorously bounded process variables for one or more key process of the chemical plant, the plurality of rigorously bounded process variables comprising, for each of the one or more key processes;

process steam demand intervals for the key process, the process steam demand intervals comprising a process steam demand interval for each of a plurality of different steam pressure levels, wherein each process steam demand interval for a steam pressure level comprises an upper bound and a lower bound of process steam demand for the key process at the steam pressure level; and

a process power generation interval for the key process, the process power generation interval comprising an upper bound and a lower bound of power generation for the key process; and

processing, by a computer, the model input data through application of the combined heat and power utility and process subsystem mathematical program model to determine model output data comprising process subsystem conditions and utility subsystem conditions, the process subsystem conditions comprising, for each of the one or more key processes;

process steam demand load values corresponding to the process steam demand intervals for the key process, the process steam demand load values comprising a process steam demand load value for each of the plurality of different steam pressure levels; and

a process power generation value corresponding to the process power generation interval.

20. A method as defined in claim 19, wherein the process subsystem conditions and the utility subsystem conditions are determined simultaneously through application of the combined heat and power utility and process subsystem mathematical program model.

21. A method as defined in claim 19, further comprising:

determining a first cost associated with the utility subsystem;

determining a second cost associated with the process subsystem;

determining a greater of the first cost associated with the utility subsystem and the second cost second cost associated with the process subsystem;

in response to determining that the first cost associated with the utility subsystem is greater than the second cost associated with the process subsystem, determining the utility subsystem conditions; and

determining the process system conditions based on the utility subsystem conditions determined.

22. A method as defined in claim 19, further comprising the steps of:

defining a number of steam headers and conditions thereof of the utility system; and

determining a shaft work network configuration of the utility system, wherein the shaft work network configuration is indicative of a configuration of physical equipment.

23. A method as defined in claim 19, wherein determining the process subsystem conditions and the utility subsystem conditions comprises determining a main design and operating conditions of a heat exchanger network (HEN) design and distillation network sequence for the chemical plant under possible combinations of process operation parametric changes for fully decentralized, partially decentralized, or both fully and partially decentralized process and utility systems design environments.

24. A method as defined in claim 23, wherein the main design and operating conditions of a HEN network design and distillation network sequence is determined using all generally available sources of fuel or energy available to the chemical plant.

25. A method as defined in claim 23, wherein the step of determining a main design and operating conditions of a HEN network design and distillation network sequence is determined responsive to receiving, determining, or receiving and determining a plurality of sets of values each defining a potential range of attribute values of a separate one of a corresponding plurality of process operation parametric changes.

26. A method as defined in claim 19, wherein the processing comprises determining the process subsystem conditions and the utility subsystem conditions based on possible combinations of process design parametric changes using sources of fuel or energy available to the utility system for both fully and partially decentralized process and utility systems design environments.

27. A method as defined in claim 19, wherein the processing comprises determining the process subsystem conditions and the utility subsystem conditions based on possible combinations of process design and operation parametric changes using sources of fuel or energy available to the utility system for both fully and partially decentralized process and utility systems design environments.

28. A method as defined in claim 19, wherein the processing comprises determining the process subsystem conditions and the utility subsystem conditions based on possible distillation sequences using sources of fuel or energy available to the utility system for both fully and partially decentralized process and utility systems design environments.

29. A method as defined in claim 19, wherein the processing comprises determining the process subsystem conditions and the utility subsystem conditions based on possible distillation sequences and under all reasonably possible combinations of process design and operation parametric changes using sources of fuel or energy available to the utility system for both fully and partially decentralized process and utility systems design environments.

30. A method as defined in claim 19, wherein the processing comprises determining the process subsystem conditions and the utility subsystem conditions based on possible heat exchanger network (HEN) designs using sources of fuel or energy available to the utility system for both fully and partially decentralized process and utility systems design environments.

31. A method as defined in claim 19, wherein the processing comprises determining the process subsystem conditions and the utility subsystem conditions based on possible heat exchanger network (HEN) designs and under all possible combinations of process design and operation parametric changes using sources of fuel or energy available to the utility system for both fully and partially decentralized process and utility systems design environments.

32. A method as defined in claim 19, wherein the processing comprises determining the process subsystem conditions and the utility subsystem conditions based on possible distillation columns sequences and heat exchanger network (HEN) designs using sources of fuel or energy available to the utility system for both fully and partially decentralized process and utility systems design environments.

33. A method as defined in claim 19, wherein the processing comprises determining the process subsystem conditions and the utility subsystem conditions based on possible distillation columns sequences and heat exchanger network (HEN) designs under possible combinations of process design and operation parametric changes using sources of fuel or energy available to the utility system for both fully and partially decentralized process and utility systems design environments.

34. A method as defined in claim 19, wherein the process subsystem conditions render a minimum number of heat exchanger network (HEN) units for the chemical plant for all possible distillation columns sequences.

35. A method as defined in claim 19, wherein the process subsystem conditions render a minimum total heat exchanger surface area of a heat exchanger network (HEN) design for the chemical plant and define the surface area of each heat exchanger unit in the HEN.

36. A method as defined in claim 35, wherein determining the process subsystem conditions which render the minimum total heat exchanger surface area comprises determining process subsystem conditions for one or more possible combinations of steam generation and demand loads'"'"' levels.

37. A method as defined in claim 35, wherein determining the process subsystem conditions which render the minimum total heat exchanger surface area comprises determining process subsystem conditions for one or more combinations of steam generation and demand loads'"'"' levels.

38. A method as defined in claim 35, wherein determining the process subsystem conditions which render the minimum total heat exchanger surface area comprises determining process subsystem conditions for one or more possible distillation columns sequences.

39. A method as defined in claim 35, wherein determining the process subsystem conditions which render the minimum total heat exchanger surface area comprises determining process subsystem conditions for one or more possible distillation columns sequences in conjunction with one or more possible combinations of steam generation and demand loads'"'"' levels.

40. A method as defined in claim 35, wherein determining the process subsystem conditions which render the minimum total heat exchanger surface area comprises determining process subsystem conditions for one or more possible distillation columns sequences and one or more combinations of steam generation and demand loads'"'"' levels.

41. A method as defined in claim 35, wherein determining the process subsystem conditions which render the minimum total heat exchanger surface area comprises determining process subsystem conditions for one or more possible HEN configurations and one or more possible combinations of steam generation and demand loads'"'"' levels.

42. A method as defined in claim 35, wherein determining the process subsystem conditions which render the minimum total heat exchanger surface area comprises determining process subsystem conditions for one or more possible HEN configurations and one or more combinations of steam generation and demand loads'"'"' levels.

43. A method as defined in 19, further comprising designing the chemical plant based on the process subsystem conditions and utility subsystem conditions.