Conventional and Advanced Exergetic and Exergoeconomic Analysis Applied to an Air Preheater System for Fired Heater (Case Study: Tehran Oil Refinery Company)

Document Type: Research Article

Authors

Graduate Faculty of Environment, College of Engineering, University of Tehran, PO. Box 1416853534 Tehran, I.R. IRAN

Abstract

TThe present paper evaluates the plan of combustion air pre-heater installation on the fired heater from thermodynamics and thermos-economics point of view. As a real case study, one of the fired heaters (H_101) of Distillation unit in Tehran Oil Refinery, Iran, is intended. With applying an air pre-heater in this study, flue gases temperature falls down from 430 ºC to 200ºCand combustion air temperature grows up from 25ºCto 350 ºC. By examining the energy and exergy analyses before and after the installation of air pre-heater, the increase in thermal efficiency by 20% and exergy efficiency by 37% and accordingly decreasing fuel consumption by 20% is observed. It is also indicated that the most exergy destruction is accrued in the fired heater (57.24%). In this study for the first time, based on advanced exergy analyses and concepts of endogenous/exogenous and avoidable/unavoidable parts, exergy destruction, exergy destruction cost rates and capital investment of combustion air preheater system are found which results show the endogenous and unavoidable parts in overall system are dominant. Also, the effect of flue gases temperature (T5) on the system performance is investigated through sensitivity analyses. It is seen that with rising T5, thermal efficiency and exergy efficiency in real, theory and unavoidable conditions decrease. The results demonstrate the majority parts of exergy destruction in fired heater and air preheater is endogenous, unavoidable and unavoidable endogenous. Considering the cost of air preheater and related equipment and operating and maintenance costs annually, the payback period is estimated to be less than 2 years. In this research, the EES and Excel were applied to calculate the amount.

Keywords

Main Subjects


[1] Ghodsipour N., Sadrameli M., Experimental and Sensitivity Analysis of a Rotary Air preheater for the Flue Gas Heat Recovery, Applied Thermal Engineering,,. 23(5): 571-580 (2003).

[2] Hasanuzzaman M., Nasrudin A.R., Saidur R., Energy Savings in the Combustion Based Process Heating in Industrial Sector, Renewable and Sustainable Energy Reviews, 16(7): 4527-4536 (2012).

[3] Shekarchian M., Zarifi F., Moghavvemi M., Motasemi F., Mahlia T.M., Energy, Exergy, Environmental and Economic Analysis of Industrial Fired Heaters Based on Heat Recovery and Preheating Techniques, Energy Conversion and Management, 71: 51-61 (2013).

[4] Katsuki, M. Hasegawa T., The Science and Technology of Combustion in Highly Preheated Air, Symposium (International) on Combustion, 27(2): 3135-3146 (1998).

[5] Weber R., Orsino S., Lallemant N., Verlaan A., Combustion of Natural Gas with High-Temperature Air and Large Quantities of Flue Gas, Proceedings of the Combustion Institute, 28(1): 1315-1321 (2000).

[6] Choi G.-M., Katsuki M., Advanced Low NOx Combustion Using Highly Preheated Air, Energy Conversion and Management, 42(5): 639-652 (2001).

[7] Kawai K., Yoshikawa K., Kobayashi H., Syan T.J., Matsuo M., Katsushima H., Kawai K., High Temperature Air Combustion Boiler for Low BTU Gas, Energy Conversion and Management, 43(9): 1563-1570 (2002).

[9] Boyaghchi F.A., Molaie H., Sensitivity Analysis of Exergy Destruction in a Real Combined Cycle Power Plant Based on Advanced Exergy Method, Energy Conversion and Management, 99: 374-386 (2015).

[10] Wang H.Y., Zhao L.L., Zhou Q.T., Xu Z.G., Wang H.Y., Exergy Analysis on the Irreversibility of Rotary Air Preheater in Thermal Power Plant, Energy, 33(4): 647-656 (2008).

[12] Wu S.R., Chen C.H., Chung I.L., Lee H.T., Combustion of Low-Calorific Waste Liquids in High Temperature Air, Fuel, 90(8): 2639-2644 (2011).

[13] Hasanuzzaman M., Saidur R., Rahim N., Energy, Exergy and Economic Analysis of an Annealing Furnace, International Journal of Physical Sciences, 6(6): 1257-1266 (2011).

[14] Varghese J., Bandyopadhyay S., Improved Area—Energy Targeting for Fired Heater Integrated Heat Exchanger Networks, Chemical Engineering Research and Design, 90(2): 213-219 (2012).

[15] Aisyah L., Rulianto D., Wibowo C.S., Analysis of the Effect of Preheating System to Improve Efficiency in LPG-fuelled Small Industrial Burner, Energy Procedia, 65: 180-185 (2015).

[16] Huang M., Zhang Z., Shao W., Xiong Y., Effect of Air Preheat Temperature on the MILD Combustion of Syngas, Energy Conversion and Management, 86: 356-364 (2014).

[17] Bejan A., Tsatsaronis G., "Thermal Design and Optimization" John Wiley & Sons Inc. (1996).

[18] Szargut J., Morris D.R., Steward F.R., Exergy Analysis of Thermal, Chemical, and Metallurgical Processes, Theory and Practices for Energy Education, Training, Regulation and Standards, Hemisphere; 1st ed. (1988).

[20] Morosuk T., Tsatsaronis G., Advanced Exergy Analysis for Chemically Reacting Systems–Application to a Simple Open Gas-Turbine System, International Journal of Thermodynamics, 12(3): 105-111 (2009).

[21] Kelly S., Tsatsaronis G., Morosuk T., Advanced Exergetic Analysis: Approaches for Splitting the Exergy Destruction Into Endogenous and Exogenous Parts, Energy, 34(3): 384-391 (2009).

[22] Petrakopoulou F., Tsatsaronis G., Morosuk T., Carassai A., Conventional and Advanced Exergetic Analyses Applied to a Combined Cycle Power Plant, Energy, 41(1): 146-152 (2012).

[24]. Morosuk T., Tsatsaronis G., A New Approach to the Exergy Analysis of Absorption Refrigeration Machines, Energy, 33(6): 890-907 (2008).

[25] Morosuk T., Tsatsaronis G., Comparative Evaluation of LNG–Based Cogeneration Systems Using Advanced Exergetic Analysis, Energy, 36(6): 3771-3778 (2011).

[26] Morosuk T., Tsatsaronis G., Boyano A., Gantiva C., Advanced Exergy-Based Analyses Applied to a System Including LNG Regasification and Electricity Generation, International Journal of Energy and Environmental Engineering, 3(1): 1-9 (2012).

[27] Petrakopoulou F., Tsatsaronis G., Morosuk T., Carassai A., Advanced Exergoeconomic Analysis Applied to a Complex Energy Conversion System, Journal of Engineering for Gas Turbines and Power, 134(3): 031801 (2012).

[28] Heywood,J.B., "Internal Combustion Engine Fundamentals", Vol. 930. Mcgraw-hill New York (1988).

[29] Wei-ping Y., Xi Y., Essentials of Boiler Performance Test Code ASME PTC 4-1998 [J], Journal of Power Engineering, 2: 005-017 (2007).

[31] Boyaghchi F.A., Heidarnejad P., Thermoeconomic Assessment and Multi Objective Optimization of a Solar Micro CCHP Based on Organic Rankine Cycle for Domestic Application, Energy Conversion and Management, 97: 224-234 (2015).

[32] Mohammadkhani F., Shokati N., Mahmoudi S.M.M., Yari M., Exergoeconomic Assessment and Parametric Study of a Gas Turbine-Modular Helium Reactor Combined with Two Organic Rankine Cycles, Energy, 65: 533-543 (2014). 

[33] Farshi L.G., Mahmoudi S.S., Rosen M., Exergoeconomic Comparison of Double Effect and Combined Ejector-Double Effect Absorption Refrigeration Systems, Applied Energy, 103: 700-711 (2013).

[34] Mashayekh H., Salehi G.R., Taghdiri E., Hamedi M.H., “Thermoeconomic Optimization of Absorption Chiller Cycle”, A World Renewable Energy Congress-Sweden; 8-13 May; 2011; Linköping; Sweden. Linköping University Electronic Press (2011).

[35] Oyedepo S., Fagbenle R., Adefila S.S., Alam M.,  Exergy Costing Analysis and Performance Evaluation of Selected Gas Turbine Power Plants, Cogent Engineering, 2(1): 1101048 (2015).

[36] Morosuk T., Tsatsaronis G., Advanced Exergetic Evaluation of Refrigeration Machines Using Different Working Fluids, Energy, 34(12): 2248-2258 (2009).

[37] Tsatsaronis G., Park M.-H., On Avoidable and Unavoidable Exergy Destructions and Investment Costs in Thermal Systems, Energy Conversion and Management, 43(9): 1259-1270 (2002).

[38] Kelly S., "Energy Systems Improvement Based on Endogenous and Exogenous Exergy Destruction", M.Phil. Thesis, TU Berlin (2008).

[39] Tsatsaronis G., Morosuk T., "A General Exergy-Based Method for Combining a Cost Analysis with an Environmental Impact Analysis: Part I—Theoretical Development", ASME 2008 International Mechanical Engineering Congress and Exposition, American Society of Mechanical Engineers (2008).

[40] Yang Q., Qian Y., Kraslawski A., Zhou H., Yang S., Framework for Advanced Exergoeconomic Performance Analysis and Optimization of an Oil Shale Retorting Process, Energy, 109: 62-76 (2016).

[41] Petrakopoulou F., Tsatsaronis G., Morosuk T., Evaluation of a Power Plant with Chemical Looping Combustion Using an Advanced Exergoeconomic Analysis, Sustainable Energy Technologies and Assessments, 3: 9-16 (2013).