| 11. |
- Hackl, Roman, 1981
(författare)
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A Methodology for Identifying Transformation Pathways for Industrial Process Clusters: Toward Increased Energy Efficiency and Renewable Feedstock
- 2014
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Doktorsavhandling (övrigt vetenskapligt/konstnärligt)abstract
- The European process industry is facing major challenges. Modern, large-scale production facilities in other parts of the world are often more efficient. Furthermore, limited access to inexpensive shale gas from North America has led to an additional disadvantage for the European industry. At the same time, the European Union (EU) has implemented policy instruments aiming at increasing the costs for emitting Greenhouse Gases (GHG) in order to curb global warming.According to the International Energy Agency (IEA), the only measure that decreases GHG emissions and at the same time achieves economic, environmental and societal goals is increasing energy efficiency. Clusters of industrial production plants often offer considerable opportunities to increase efficiency at the total site level. Another option for the process industry is to tap into new markets in order to stay competitive. The interest for biomass based products has increased lately due to societal expectations for sustainable development and renewable feedstock based products. This work presents a framework methodology that can provide guidance to the process industry in order to manage this transformation in an efficient way. Process integration tools are used to identify common measures to improve energy efficiency at a site-wide scale. This targeting procedure is followed by a detailed procedure for design and evaluation of practical energy efficiency measures. This step should be performed in close collaboration with experts from the industrial cluster in order to present solutions that can overcome some of the main barriers for the implementation of common energy efficiency measures. The knowledge obtained during this targeting and design process can also be used to identify favourable ways to integrate biomass based processes that can replace fossil with biogenic feedstocks and utilise existing infrastructure. In most chemical processes, there is usually excess process heat that cannot be utilised internally. In the last stage of the framework methodology developed in this work, the opportunity to export industrial excess heat should be investigated. This includes an assessment of the quantity of available heat, the economic feasibility and the competition between internal integration and the export of heat.The framework methodology is demonstrated via a case study of a chemical cluster in Sweden.
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| 12. |
- Hackl, Roman, 1981, et al.
(författare)
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Applying exergy and total site analysis for targeting refrigeration shaft power in industrial clusters
- 2013
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Ingår i: Energy. - : Elsevier BV. - 0360-5442. ; 55, s. 5-14
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Tidskriftsartikel (refereegranskat)abstract
- Process cooling below ambient temperature is an energy demanding part of many chemical production processes. Compression refrigeration systems operating at very low temperatures consume a lot of high quality utility such as electricity or high pressure steam to drive the compressor units. In industrial process clusters with several processes operating at low temperatures, it is important to investigate opportunities for exchange of low-temperature energy between processes. This paper demonstrates how total site analysis and exergy analysis can be applied to target for shaft power and related hot utility savings for processes and utility systems operating below ambient temperature. Shaft power targeting by optimizing refrigerant use is conducted. In addition the methodology is extended for shaft power targeting in connection with site-wide heat recovery from cold process streams to generate sub-ambient utility. The methodology is illustrated through application to a case study of a chemical cluster. One chemical plant within the cluster operates two compression refrigeration systems at its steam cracker plant. The results of the case study indicate potential savings of 1.5 MW of shaft power by optimizing the use of refrigerant from the compression refrigeration system and additional 2.5 MW of shaft power by recovering refrigeration from two other sites located outside the cracker plant. In total this corresponds to 15% of the total shaft power consumption of the refrigeration systems. Economic evaluation of the proposed measures indicates a pay-back period of approximately 4 years.
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| 13. |
- Hackl, Roman, 1981, et al.
(författare)
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Applying process integration methods to target for electricity production from industrial waste heat using Organic Rankine Cycle (ORC) technology
- 2011
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Ingår i: World Renewable Energy Congress 2011 – Sweden 8-11 May 2011, Linköping, Sweden - Industrial Energy Efficiency (IEE). - : Linköping University Electronic Press.
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Konferensbidrag (refereegranskat)abstract
- This paper presents the results of an investigation of power production from low temperature excess process heat from a chemical cluster using Organic Rankine Cycle (ORC) technology. Process simulations and process integration methods including Pinch Technology and Total Site Analysis (TSA) are used to estimate the potential for electricity production from excess heat from the cluster. Results of a previous TSA study indicate that ca. 192 MWheat of waste heat are available at 84 °C to 55 °C, a suitable temperature range for ORC applications. Process streams especially suitable for ORC power production are identified. Simulation results indicate that 14 MWheat of waste heat are available from a PE-reactor, which can be used to generate ca. 1 MWel. Costs of electricity production calculated range from 70 to 147 €/MWh depending on the cost for ORC integration. Economic risk evaluation indicates that pay-back periods lower than 4.5 years should not be expected at the electricity price and RES-E support (a European support system for renewable electricity) levels considered in this study. CO2 emission reductions of up to 5900 tonnes/year were estimated for the analysed case.
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| 14. |
- Hackl, Roman, 1981, et al.
(författare)
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Cultivating Ciona intestinalis to counteract marine eutrophication: Environmental assessment of a marine biomass based bioenergy and biofertilizer production system
- 2018
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Ingår i: Renewable Energy. - : Elsevier BV. - 0960-1481 .- 1879-0682. ; 124, s. 103-113
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Tidskriftsartikel (refereegranskat)abstract
- Eutrophication in the North and Baltic Seas is a major problem to the marine environment and the communities depending on it. To counteract this, the Swedish Marine and Water Authority suggested financial support for measures that increase the uptake of nutrients from the water by e.g. marine organisms and support for the utilisation of these organisms as value added products. In Sweden the use of biogas to replace fossil transportation fuels is widely adopted. The domestic biogas production corresponded to approx. 1.95 TWh (approx. 7010 TJ) in 2015 of which approx. 63% were upgraded for use as e.g. transportation fuel. Other uses are heat and electricity generation as well as industrial applications. To expand production, the biogas industry is searching for new substrates. In this paper the utilisation of the marine evertebrate organism Ciona intestinalis (tunicata), cultivated in the North Sea and used as feedstock for biogas and biofertilizer production is suggested and assessed. The greenhouse gas (GHG) emissions performance of the concept and it's consequences on marine eutrophication are investigated applying life cycle assessment. Results show that at full scale biogas production from C. intestinalis reduces GHG emissions by more than 65% compared to fossil transportation fuels. In addition, the results show that accounting for the system consequences of other products and services such as biofertilizer replacing mineral fertilizers and decreased marine eutrophication largely increase the environmental benefits provided by the concept. Approx. 3.7 g-N eq /MJ biogas of nitrogen are removed from the marine environment during the cultivation of C. intestinalis.
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| 15. |
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| 16. |
- Hackl, Roman, 1981, et al.
(författare)
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Framework methodology for increased energy efficiency and renewable feedstock integration in industrial clusters
- 2012
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Ingår i: International Conference on Applied Energy ICEA 2012, Jul 5-8, 2012, Suzhou, China. ; , s. 11-
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Konferensbidrag (refereegranskat)abstract
- Energy intensive industries, such as the bulk chemical industry, are facing major challenges. The chemical cluster in Stenungsund on the West coast of Sweden recently adopted a common vision called “Sustainable Chemistry 2030”. The cluster consists of 5 different companies operating 6 process plants. There is a wide range of technologies and process integration opportunities available for improving the clusters overall performance, including (i) decreasing fossil fuel and electricity demand by increasing heat integration within individual processes and across the total site; (ii) replacing fossil feedstocks with renewables and biorefinery integration with the existing cluster; (iii) increased external utilization of excess process heat wherever possible. This paper presents an overview of the use of process integration methods for the holistic development of the cluster. The framework methodology is based on a Total Site Analysis (TSA) study, in which the cluster’s current energy system was analysed and measures for site-wide energy efficiency improvement were identified. TSA showed that up to 129 MW of heat can be recovered by site-wide energy efficiency measures, theoretically eliminating the cluster’s demand for external boiler fuel. Pinch analysis of a single plant showed hot utility savings potential of 38 % of the current demand. Heat integration investments with a pay-back period of 0.4 to 1.2 years could cover up to 83 % (6.5 MWheat) of the identified savings potential.A process integration study on replacing fossil based ethylene in the cluster by bio-ethylene produced via fermentation of lignocellulosic biomass and ethanol dehydration showed that the heating demand of the bio-ethylene process can be reduced by 37 % if the both process steps are integrated. TSA showed that 9 MW of excess heat from the cluster can be used to replace hot utility in the biorefinery.A total of 226 MWexcess heat above 50 °C is available from the cluster that can be used, e.g. for district heating, low temperature refrigeration/electricity generation, heat pumping or biomass drying
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| 17. |
- Hackl, Roman, 1981, et al.
(författare)
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Framework methodology for increased energy efficiency and renewable feedstock integration in industrial clusters
- 2013
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Ingår i: Applied Energy. - : Elsevier BV. - 1872-9118 .- 0306-2619. ; 112, s. 1500-1509
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Tidskriftsartikel (refereegranskat)abstract
- Energy intensive industries, such as the bulk chemical industry, are facing major challenges and adopting strategies to face these challenges. This paper investigates options for clusters of chemical process plants to decrease their energy and emission footprints. There is a wide range of technologies and process integration opportunities available for achieving these objectives, including (i) decreasing fossil fuel and electricity demand by increasing heat integration within individual processes and across the total cluster site; (ii) replacing fossil feedstocks with renewables and biorefinery integration with the existing cluster; (iii) increasing external utilization of excess process heat wherever possible. This paper presents an overview of the use of process integration methods for development of chemical clusters. Process simulation, pinch analysis, Total Site Analysis (TSA) and exergy concepts are combined in a holistic approach to identify opportunities to improve energy efficiency and integrate renewable feedstocks within such clusters. The methodology is illustrated by application to a chemical cluster in Stenungsund on the West Coast of Sweden consisting of five different companies operating six process plants. The paper emphasizes and quantifies the gains that can be made by adopting a total site approach for targeting energy efficiency measures within the cluster and when investigating integration opportunities for advanced biorefinery concepts compared to restricting the analysis to the individual constituent plants. The holistic approach applied highlights the significant potential improvement to energy and emissions footprints that can be achieved when applying a total site approach.
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| 18. |
- Hackl, Roman, 1981, et al.
(författare)
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From heat integration targets toward implementation - A TSA (total site analysis)-based design approach for heat recovery systems in industrial clusters
- 2015
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Ingår i: Energy. - : Elsevier BV. - 0360-5442. ; 90, s. 163-172
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Tidskriftsartikel (refereegranskat)abstract
- The European process industry is facing major challenges to decrease production costs. One strategy to achieve this is by increasing energy efficiency. Single chemical processes are often well-integrated and the tools to target and design such measures are well developed. Site-wide heat integration based on total site analysis tools can be used to identify opportunities to further increase energy efficiency. However, the methodology has to be developed further in order to enable identification of practical heat integration measures in a systematic way. Designing site-wide heat recovery systems across an industrial cluster is complex and involves aspects apart from thermal process and utility flows. This work presents a method for designing a roadmap of heat integration investments based on total site analysis. The method is applied to a chemical cluster in Sweden. The results of the case study show that application of the proposed method can achieve up to 42% of the previously targeted hot utility savings of 129 MW. A roadmap of heat integration systems is suggested, ranging from less complex systems that achieve a minor share of the heat recovery potential to sophisticated, strongly interdependent systems demanding large investments and a high level of collaboration. (C) 2015 Elsevier Ltd. All rights reserved.
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| 19. |
- Hackl, Roman, 1981, et al.
(författare)
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Identification, cost estimation and economic performance of common heat recovery systems for the chemical cluster in Stenungsund
- 2013
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Rapport (övrigt vetenskapligt/konstnärligt)abstract
- In previous work, the heat savings potential that can be accomplished by increased heat recovery collaboration between the constituent companies was identified at the chemical cluster in Stenungsund. Based on this work specific measures to realize the potential were determined. All heat exchangers that can be included in a common heat recovery system were identified and other measures necessary in order to construct such a system were described. Detailed systems design, cost estimation, economic evaluation and cost sensitivity analysis was not dealt with in detail. A number of different systems solutions are available In order to identify cost-efficient system configurations it is important to develop a methodology that deals with design, cost estimation, economic evaluation and cost sensitivity analysis. The present study aims the development of such a methodology in order to enable decision makers to identify and compare cost-efficient and site-wide common heat recovery system configurations.In a first step all the different cost items of the common heat recovery measures are identified. After that a short cut approach for estimating the different costs (HX, piping, pumps etc.) involved is applied. Later a methodological approach to identify the most cost efficient overall systems solutions is introduced. During this a number of promising options is identified, which then are evaluated in more detail according their economic performance.As a result five promising systems were identified saving between 20.6 MW and 53.6 MW of hot utility. The estimated Pay Back Period (PBP) of the system was between 3.2 and 4.2 years. Further evaluation showed that especially two systems showed superior economic performance. System 20 recovering 20.6 MW of heat at a PBP of 3.2 years has the best Discounted Cash Flow Rate Of Return (DCFROR) of all systems (34.2 %). The retrofit only involves Borealis and Perstorp. Perstorp only serves as a sink for excess LP steam from Borealis, while recovered excess process heat is delivered from Borealis PE to Borealis Cracker. As it only enables for utilizing a minor share of the total heat integration potential it is considered as a first step towards a larger system. The final step in the development of common heat recovery systems is System 50 recovering 50.8 MW of heat at a PBP of 3.9 years and a DCFROR of 26.6 %. This system shows the highest Net Present Value of all investigated systems and recovers a major share of the heat recovery potential. Three companies, Borealis, Perstorp and INEOS are involved in the retrofit. Borealis PE and Perstorp are mainly delivering excess process heat to Borealis Cracker, while INEOS solely servers as a sink for excess steam from Borealis Cracker. It is possible to extend System 20 towards System 50 if minor preparatory investments are taken. Sensitivity analysis showed that only in two scenarios where the price of saved fuel decrease or the total investment costs increase by 30 % the PBP of System 50 exceeds 5 years and DCFROR drops below 20 %. The systems identified can be considered robust to fluctuations in investments costs and fuel price.The methodology applied in this study was shown to enable for identifying cost efficient and economically robust heat recovery systems and even making it possible to describe staged investment paths where the simplest investments are taken first allowing for further systems extension in order to realize the a larger share of the heat recovery potential.
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| 20. |
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