Industrial Gas Feed Pressure Control With Storage Buffering
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Solution Overview
Problem
The variability and intermittency of renewable energy sources, such as wind and solar power, pose challenges for industrial gas plants, leading to inefficient operation and potential shutdowns due to sub-optimal power management, particularly in processes like ammonia synthesis which is sensitive to energy fluctuations.
Innovation Solution
A method and system for controlling the supply of feedstock gas by determining pressure in the supply feed line and using a control system to regulate it at a set point pressure, and adjusting the flow rate based on operational parameters of the gas storage resource, including valves and gain scheduling to manage variable production rates from renewable power sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If renewable energy sources are used to power industrial gas plants, then environmental sustainability is improved, but operational stability deteriorates due to variable and intermittent power supply
Solution Approach 1:
The system performs preliminary actions by storing excess gas produced during high renewable energy availability periods into a storage resource. This stored gas is then utilized during periods of low renewable energy availability, preventing shutdowns and maintaining continuous operation. The control system anticipates power variability and prepares by accumulating gas inventory in advance.
Solution Approach 2:
A gas storage resource is introduced as an intermediary between the variable renewable energy source and the downstream process. This storage buffer decouples the intermittent power supply from the continuous process requirements, absorbing the variability and delivering stable gas flow to the downstream process regardless of instantaneous power availability.
2Productivity
If gas production rate is increased to maximize utilization of renewable energy, then energy efficiency is improved, but downstream process supply stability deteriorates
Solution Approach 1:
The control system continuously monitors the pressure in the supply feed line and uses this feedback to regulate gas flow. When pressure exceeds the set point, the system diverts excess gas to storage. When pressure drops below the set point, the system supplements flow from storage. This closed-loop feedback mechanism maintains stable downstream supply while allowing production to vary with renewable energy availability.
Solution Approach 2:
The system dynamically adjusts the flow distribution between the downstream process and gas storage based on real-time conditions. The control system modulates valve positions and flow rates continuously, enabling the production system to operate at variable rates matched to renewable energy availability while maintaining stable downstream supply through dynamic balancing.
3Reliability
If pressure regulation is maintained at set point to ensure process stability, then operational reliability is improved, but flexibility in managing variable production rates deteriorates
Solution Approach 1:
The gas storage resource serves multiple functions simultaneously: it acts as a buffer to maintain downstream pressure stability, a reservoir to store excess production during high renewable energy periods, and a supplement to ensure continuous supply during low production periods. This multi-functionality allows the system to maintain set point pressure regulation while adapting to variable production rates from renewable energy sources.
Data Source
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AI summary
An industrial gas production plant operable to produce a feedstock gas at a variable production rate for supply to the downstream process; and a gas storage resource operable to store produced feedstock gas, the method comprising: determining the pressure of feedstock gas in a supply feed line to the downstream process; selectively controlling, using a control system, a flow of feedstock gas from the supply feed line to the gas storage resource or from the gas storage resource to the supply feed line in response to the determined pressure in order to regulate the pressure of the feedstock gas in the supply feed line to the downstream process at a predetermined set point pressure; and selectively controlling, using a control system, a flow rate of feedstock gas in the supply feed line to the downstream process in dependence upon at least one operational parameter of the gas storage resource.