Power Recovery Turbine Integration for Plant Debottlenecking
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Solution Overview
Problem
Existing mechanical drives such as pumps and compressors are often oversized to minimize capital costs, leading to energy inefficiencies due to over-compression and pressure reduction, and conventional flow control methods like control valves dissipate energy, making energy conservation projects unattractive in revamped processes due to high capital costs and downtime requirements.
Innovation Solution
The integration of power-recovery turbines in parallel or series with control valves in existing processes to conserve energy and increase throughput, utilizing turbines that approximate isentropic expansion and reduce fluid exit temperatures, thereby enabling debottlenecking and improved economic justification for capital expenditure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If power recovery turbine equipment is added to existing processes, then energy efficiency is improved, but device complexity increases
Solution Approach 1:
The power recovery turbine is nested within the existing process equipment structure, with the turbine integrated into the vacuum system infrastructure. The turbine utilizes the existing vacuum pump discharge stream, nesting the energy recovery function within the existing process flow without requiring completely separate systems.
Solution Approach 2:
The power recovery turbine serves multiple functions: it generates electrical power from the vacuum pump exhaust stream, maintains the vacuum process requirements, and reduces overall energy consumption. This multi-functionality addresses both the energy efficiency improvement and limits the need for additional separate equipment.
2Productivity
If power recovery turbine equipment is added to existing processes, then productivity is improved, but device complexity increases
Solution Approach 1:
The power recovery turbine is designed to be self-contained with integrated motor-generator assembly and control systems that automatically regulate power output. The system serves itself by utilizing the existing vacuum pump exhaust stream without requiring additional external control infrastructure, thereby improving productivity while limiting complexity increases.
3Loss of energy
If power recovery turbine equipment is added to existing processes, then loss of energy is reduced, but ease of manufacture worsens
Solution Approach 1:
The turbine system is designed with pre-engineered standard components including the motor-generator assembly and coupling mechanisms that can be manufactured separately and assembled during installation. This preliminary design approach reduces manufacturing complexity while maximizing energy recovery from the vacuum pump exhaust stream.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in significant energy recovery, increased plant throughput, and improved economic justification for capital expenditure by reducing energy consumption and allowing higher hydrocarbon feed rates, while avoiding additional capital costs by leveraging existing equipment.
Implementation Method 1
a turbine coupled to a motor-generator assembly wherein the motor-generator assembly is configured to generate power in response to rotation of the turbine by the gas stream
Data Source
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AI summary
Power recovery turbines can be used debottlenecking of an existing plant, as well as recover electric power when revamping a plant. A process for recovering energy in a petroleum, petrochemical, or chemical plant is described. A fluid stream having a first control valve thereon is identified. A first power-recovery turbine is installed at the location of the first control valve, and at least a portion of the first fluid stream is directed through the first power-recovery turbine to generate electric power as direct current therefrom. The electric power is then recovered.