Efficient enhancement of cryogenic processes: Extracting valuable insights with minimal effort

Mona Albatarni, Zineb Bouabidi, Mary A. Katebah, Fares Almomani, Mohamed M. Hussein and Easa I. Al-musleh

Energy, 2024, vol. 304, issue C

Abstract: Cryogenic systems are widely used in industries but are known for their high energy consumption. Designing these systems involves numerous variables, objectives, and constraints. This study introduces an optimization approach applied to three cryogenic processes: Natural Gas Liquids (NGLs) recovery, Air Separation Unit (ASU), and propane mixed refrigerant (C3MR) liquefaction, focusing on minimizing energy input to enhance efficiency and LNG output in a mega LNG plant. Exergy analyses identified energy losses in compressors (47 %), columns (37 %), heat exchangers (10 %), and valves/mixers (5 %), highlighting the need for improved compressor design. Optimization showed that inefficiencies could be reduced by adding inter-cooled compression stages and isentropic/isothermal compression routes. The ASU optimization involved five independent variables with optimized conditions demanding 30 MW of compression power while achieving 51 % separation efficiency. Heat exchangers are the main source of exergy loss in the standalone C3MR cycle, accounting for 61.82 % of 69.0 MW followed by compressors ∼29.27 %. When simulated with utilities, total exergy loss increases to 249.0 MW, with compressors accounting for 78.34 %, exergy loss from heat exchangers drops to 17.94 %. Results affirm the practicality of the proposed method for optimizing complex cryogenic systems, providing valuable engineering insights and potential for significant energy savings.

Keywords: Energy efficiency; Optimization; Operational control; Cryogenic systems; Process-specific response; Sustainable energy (search for similar items in EconPapers)
Date: 2024
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Persistent link: https://EconPapers.repec.org/RePEc:eee:energy:v:304:y:2024:i:c:s0360544224018978

DOI: 10.1016/j.energy.2024.132123

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