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PROCEEDINGS'
15th REGIONAL SYMPOSIUM ON CHEMICAL ENCINEEF-flNG (RSCE)
in conjunction with the

22nd SYMPOSIUM OF MALAYSIAN

CHEMICAL ENGINEERS (SOMChE)

I NNO V A T I O N S F O R SU ST A I NA B L E F U T U RE

VOLUME II
Irripiana KLCC Hotel & Spa, Kuala Lumpur, (Aaluysia 2-3 December 2008 Organized by: DepaAment of Chemical & Process Engineering Faculty of Engineering & Built Environment Universiti Kebangsaan Malaysia
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Regional Symposium on Chemical Engineering (RSCE) in conjunction with Symposium of Malcraian Chemiccl Engineers (SOXIChE)

Copyright Faculty of Engineering and Built Environment, Uni\ , ersiti KeLAingsaan Malaysia, 2008

All rights r?serveci. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical including photocopy, recording, or any i'nformation storage and retrieval system, without prior permission in writing from the Faculty of Engineering and Built Environment, Universal Kebangsaan Malaysia

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ISBN 978-983-2982-23-4
Kuala Lumpur, 2-3 December 2008

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UNIVERSI I KLBANCSA AN MALAYSIA

15 REGIONAL SYMPGSIUM ON CHEMICAL ENGINEERING In Conjunction With 22 SYMPOSIUM OF MALAYSIAN CHEMICAL ENGINEERS
2 - 3 December 2005 Kuala Lumpur, Malaysia

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UKM(S) 1.18.2/263/5/ ARN/PSE012-0 Date: 24 November 2008

Dear Author, We are very pleased to inform you that your ORAL PRESENTATION paper:

Corresponding Author M. Djoni Bustan'', Budi Santoso', Triana Prihatin

Paper Title Pinch Analysis fnr Minimizing Futl Co isumption in lire Furnace of Crucie

Affiliation University olSnwijaya

Country Indonesia

ARN PSE012-0

Distiller Unit in tie Oil Industry_______

has been reviewed and approved by our Board of Editors. Please note the following carefully:

1.Your oral presentation wall oe scheduled for the concurrent session under your assigned scope of the conference: PROCESS SYSTEM ENGINEERING and it will be indicated in the conference program. You will be given 10 minutes for presentation and 5 minutes for O&A session. 2.You must use this abstract reference number (ARN) in any nature correspondence. 3.Your paper will be published in the RSCE-SOMChE 2008 Conference Proceedings. We will inform you later if your paper will also be selected to be published in the special issue edition of die Asia Pacific Journal of Chemical Engineering, Wiley. 4.The hard copy of the Conference Proceedings is published in 2 volumes and you will also be receiving a CD-ROM format of the Proceedings. Please ensure that the peyment has been made or arranged for the registration fees so that you will receive both the hard ,:opy and the CD-ROM during the conference day, We endeavour to make your participation in RSCE-SOMChE 2008 a truly rewarding one. We look forward to meeting you in December.

Best regards,

A-4
Dr. Manal Ismail Secretary RSCE-SOMChE 2008

-11111-MBA NIMI711!1-11/11.-T h e Secretariat 71=1717T7817 enTriM1177? r'ocIMErerir 737 -Faculty of Engineering & Built Environment, Univaraiti Kebangsaan Malaysia, 43600 UKM Bangi, Selangor, MALAYSIA.

Tel: 480341921 0404/041

#803 8921 81 411 Email: rece_, URL: www.rece_somche08,ukm.my1 NTR0,4Asiv

11 15 th REGIONAL SYMPOSIUM ON CHEMICAL ENGINEERING

KirsANc;sAAN MAI.AYSIA
k r un w rI A I rm o . V. d or .

4. 1

In Conjunction With 22 nd SYMPOSfUM OF MALAYSIAN CHEMICAL ENGINEERS

2 - 3 December 2008 Kuala Lumpur, MalLysia

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1.18. 2/263 /5/ ARN/ PSE0 12-0 Date: 3 Dise mber 2008

Dear Dr M.Dioni Bustan

We are pleased to inform that your articles listed below has already been published in the Proceedings of RSCE-SOMCHE 2008 held at lmpiana Hotel & Spa on 2-3 December 2008. 1.M.Djoni Bustan, Budi Santoso & Triana Prihatatin (2008). Pinch Analysis for Minimizing Fuel Consumption in The Furnace of Crude Distiller Unit in the Oil Industry. Vol 2, p 1003-1008 2.M.Djoni Bustan, Yuri Dariansyah & Edina Okta'lani (2008). Effects of Air arid Steam Injection Flow to the Boiler Temperature in Package Boiler Model. Vol 2, p : 10091014 We would like to congratulate you on your pprticipatio:iof the conference, Thank you very much.

Best regards,

Dr. Manal Ismail Secretary RSCE-SOMChE 2008

9 7 = = 7 1 7 ! M l 1 7 7 7 6 7 3 , e e p a r t m e n o emica an ocess ngineering, Faculty of Engineering & Built Environment, Univa-sit! Kehangsaan Malaysia, 43600 UM Bangi, Selangor, MALAYSIA. Tel: +603-6921 6404.'64'13 Fax: +603 8921 6148 Email: rsce_sornche08eeng.ultm.my 1.1RL: www.rsce_somche08.ukm.my/
1-

RSCE-SOMCHE 2008 Edited by Daud et al.

1003

PINCH ANALYSIS FOR MINIMIZING FUEL CONSUMPTION IN THE FURNACE OF CRUDE DISTILLER UNIT IN THE OIL INDUSTRY
M. Djoni Bustan Budi Santoso , Triana Prihatin Deparurent of Chemical Engineering, Graduate Program, University of Sriwijaya, Indonesia J1. Padang Selasa No.524, Bukit Besar, Palembang 30139, Indonesia Phone: (0711) 352132 354222 Fax : (0711) 320310 - 317202 : djaiashantaAvahoo.co.id Keywords: fuel consumption; grand composite curves; oil industry; pinch analysis ABSTRACT Fuel consumption in furnace about 75 % from the total of energy consumption has created a dilemma in the oil industry to succeed the energy conservation. As a consideration, crude distiller Ina (CDU) of Indonesia's oil refinery plant has two furnaces. The objective of this study is to target the minimum of energy consumption in furnace of CDU cf oil refinery plant through the method of pinch analysis. This method irientified the process to seek the weakness and allowed the engineer to modify the process using new operation condition by varying the minimum temperature of air and adding superheated steam entranced to furnace. As results, the irinimizing of fuel consumption has reached 53 % along with the reduction of fuel consumption from 21 ton/day to 11 ton/day. INTRODUCTION The distilllation process of crude oil is a very high consume. To convert the crude oil, it needs approximately 70 % of energy from the total operation cost. Commonly, this huge energy consumption is took place for the combustion process in the fired heater/ furnace and power plant units. Some refinery plants of Indonesia's crude oil company still operate in a conventional process. It still uses the multi column distiller which consumes energy much more than the modern one. In addition, considerir.g also the limited energy resources, the fuel savings of distillation process as an energy conservation effort especially in the furnace is fully realized as the solution. Some energy conservations in refinery plant have been started for decades. The most common technique is cogeneration which

combines the heat utilization from power plant to be utilized in other unit processes. For the last three decades, there is a new method that very effectively in the waste heat recovery. It is called pinch technology. Linnhoff and Vredeveld [1979] introduced pinch technology. It represents a set of thermodynamically based methods that guarantee minimum energy levels in design of heat exchanger networks. The term 'Pinch Analysis' is often used to represent the application of the tools and algorithms of Pinch Technology for studying industrial processes. Pinch analysis presents a simple methodology for systematically analyzing chemical processes and surrounding utility systems with the help of First and Second laws of Thermodynamics. In practice a mininnu.m temperature difference (DTinin) has to be maintained between the 'hot' process streams (which have to he cooled to specified temperatures) and 'cold' process streams (which have to be heated to specified temperatures). This technique is used to compute the theoretically minimum utilities consumption for a process based on the thermal data of process streams i.e. their temperatures and heat duties in the process. The temperature level at which DTmin is observed in the process is referred to as 'Pinch Point'. The pinch defines the minimum driving force (DTmin) allowed in the exchanget unit. In case of heat recovery in crude distillation units, Half and Linnhoff [1994] have developed iterative targeting procedures for selecting the optimal airpreheat and fuel consumption (capacity fie mate of the fine gas). In the most common technique, an air-preheat temperature is assumed equal to the pinch temperature of the background process. Thus, the air is preheated to the highest possible temperature available from the process. Then, Liebmann [1998] proposed a systematic algorithm based on pinch analysis that lends to automation of the design procedure of crude oil distillation units where the column, the heat exchanger network, and their simultaneous interactions are considered together. Modifications that further increase the efficiency of the process are: installation of reboilers rather than stripping stream and the thermal coupling of column sections. They claimed that units conceived by this method can save up to 20% energy the base case. By applyi.eg pinch analysis, Plesu [2003] propose to thermally couple crude distillation units and delved coking units through the utility system. They basically proposed to send the vacuum bottoms to the delayed coking unit at a higher thermal lead and use this artifice to generate part of the steam needed in the crude distillation unit. They do not report energy saving fig,-ares. Gadalla [2006] optimized an existing crude distillation column where a gas turbine/generator is integrated with the preheat furnace. They claim energy reductions of up to 21%. The idea was then to maximize the energy generated in the gas turbine by adjusting the temperature of the feed, reflux ratio, steam flow rates, temperature difference of each pump around, and the flow rate

of the liquid through each pump around. dowever, the minimum temperature inlet to furnace also might take into account as a main parameter in the crude distillation units. Therefore, this study presents an approach how to minimize the

pressure steam was applied to create a high temperature in order to target minimum fuel consumption and minimum combustion air. The graphic methods will show the space which represents the difference of temperature and enthalpy or the difference between heating process and distillation process. Therefore, to target the energy consumption is needed by minimizing the space between those two operation conditions. The condition of the furnace GCC attaches to the process GC 0 i, obtained by adjusting the enthalpy of combustion air. After deter- _ ;ng thti adding enthalpy, the steam needs will also be identified f711rr.Tnquation bellow. Q =m.h (1) where, Q is the needed heat (kJ), rn is mass of steam added (kg), and H is the enthalpy of steam added (kJ/ kg). RESULTS AND DISCUSSION Figure 2 represents furnace GCC. The main parameters on this curve construction are temperatures and enthalpies of flame, combustion air, flue gas, and ambient. Because the temperature of air combustion, flue gas, and ambient condition vi:11 increase along with the process adjustment, their enthalpies are categorized as cold utility.
2000 1800 1600 1400 1200 1000 800 600 400 20C 0+ 100000 150000 200000 250000 300000
Ent ha lp y ( MI N)

r-,

350000

FIGURE 2: The Furnace Grand Composite Curve The furnace GCC had shown that the reaction with oxygen had caused the enthalpy became higher. The absorption or heat by crude oil at tube wall resulted in the decreasing of flue gas temperature before discharging through the stack. Figure 3 shows the plot of process GCC. The pinch temperature of crude oil heating in the crude distiiler unit of furnace was 260 C which was the flue gas

temperature from the stack. It illustrated that the utilization of flue gas temperature in the convection zone had raised the temperature of air combustion.

500 450 400 350 300 250 200 150 100 50

2000 , 1R00 1600 -1 1 4 0 0 9 1200 1000 O. 800 .1 600 -I

13

E
A
,

ti

400 200 0

100000

200000

Enthalpy (kW)

300000

400000

500000

Furnace GCC

Process GM.]

FIGURE 4: The modified Grand Composite Curve at At,th, = 20 ?C 0

-.

100000

200000 300000 Enthalpy (kW)

400000

500000

FIGURE 3: The Process Grand Composite Curve The modification of furnace and process GCC to target the minimum fuel consumption had represented by Figure 4. The determination of fuel oil consumption depends on the difference of heat duties (the enthalpy) between furnace GCC and process GCC and also the adding of numerous superheated steam. Furtheimore, the difference of air combustion temperature (Atmm) which is varied will cause the furnace GCC attach to the process GCC. The minimum fuel consumption was be identified at At,, 20 C.

CONCLUSIONS The pinch analysis could be developed to target the energy consumption in the furnace of crude distiller unit by the approach of thermodynamic variables and the adding some superheated steam. This method had reduced the fuel consumption about 53 %. REFERENCES Gadalla, M., Z., Jobson, M., and Smith R. 2006. Estimation and reduction of CO2 emission:: from crude oil distillation u. sits, Energy 31, 2398-2408. Hail, Stephen G., and Linhoff B. 1994. Targeting for Furnace System using Pinch Analysis, Industrial Engineering Chemistry and Research. Kam W. Li. 1985. Power System Designs, USA : John Wiley and Sons. Liebmann, K., Mole, V. R., and Jobson, M. 1998. Integrated design of a conventional crude oil distillation tower using pinch analysis, Trans IChemE, 76, Part A. Linhoff B., et al. 1982. A User Guide on Process Integration for the Efficient Use of Energy, England: The Institution of Chemical Engineering UMIST.

Tjoe, T. N., and Linnhoff B. 1986. Using Pinch Technology for Process Retrofit, Chem. Eng., 47-60.