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O aumento da eficiência energética dos processos industriais é uma forma eficaz de reduzir a emissão de gases de efeito de estufa. A recuperação do excesso entálpico eliminado para o meio ambiente sem qualquer aproveitamento é uma medida que melhora o uso eficiente de energia. Esta dissertação teve como objetivo a quantificação do excesso entálpico verificado na unidade de Produção de Anilina e Derivados, em todas as correntes de baixo nível térmico não aproveitadas na Bondalti S.A. Este trabalho foi efetuado com vista a reduzir estas emissões, melhorando a eficiência desta unidade de produção. Inicialmente foi realizado um levantamento através do método Bottom-up de todos os processos para identificar as fontes de excesso entálpico de baixo nível térmico. Para a quantificação foram utilizados dados do histórico processual, num período de março de 2019 a março de 2020. Quando estes dados não estavam disponíveis, recorreu-se a medições no local processual. As fontes identificadas foram a água de recirculação das torres de arrefecimento, os gases de exaustão do incinerador, o efluente líquido da fábrica, o vapor de 1 barg expandido, a água quente dos aeroarrefecedores e os gases de exaustão das caldeiras de produção de vapor de 24 barg. Após a quantificação do calor em excesso, concluiu-se que a fonte que representa o maior desperdício de calor são as torres de arrefecimento. No entanto a fonte que tem o maior potencial de recuperação de calor é o vapor de 1 barg expandido, visto que tem uma quantidade entálpica significativa e uma temperatura de cerca de 120 ºC. Uma proposta de recuperação de calor em excesso foi elaborada, baseada na instalação de três pré-aquecedores de ar de combustão, um no incinerador e dois nas caldeiras ECE e TERMEC. Escolheu-se utilizar duas fontes de calor, de forma intermitente, o vapor de 1 barg e a água quente, com o objetivo de poupar combustível (gás natural), recuperar parte de duas fontes de excesso entálpico e reduzir as emissões de GEE. O payback obtido para este projeto foi de 18 meses. Contudo uma segunda proposta foi elaborada que visa alterar o processo levando à instalação de apenas dois permutadores, o que reduz os custos de investimento de projeto e baixa o payback para 10 meses.
The energy efficiency improvement in industrial processes is an efficient way of reducing greenhouse gas emissions. The recovery of waste heat eliminated to the environment without utilization is one measure which betters the efficient use of energy. The aim of this dissertation is to quantify the waste heat present in the aniline and derivatives production unit, in all the low temperature process streams unused in Bondalti S.A. This report was done with the purpose of emissions reduction, improving this production unit efficiency. Firstly, a data survey about all the industrial processes was made, through the Bottomup method, to identify the low temperature waste heat sources. A process data base was used to do the quantification, in a period from March 2019 to March 2020. When these data base wasn’t available, local measurements were performed. The identified sources were recirculated water on the cooling towers, exhaustion gases in the incinerator, liquid effluent from the factory, 1 barg expanded steam, air coolers hot water and exhaustion gases from the boiler’s producers of 24 barg steam. Afterwards waste heat quantification, conclusions were made about the source representing the highest waste which is the water from the cooling towers. However, the source with the major heat recovery is the 1 barg expanded steam, due to its significant energy quantity and its temperature level of 120 ºC. A waste heat recovery proposal was done based on the installation of three air preheaters, one to incinerator and two to TERMEC and ECE boilers. The chosen strategy was a combined one, with 1 barg expanded steam and hot water, with the objective of fuel (natural gas) saving, excess heat recovery from two sources and reduction of greenhouse gases emissions. The payback obtained for this project was 18 months. However, a second proposal was made based on the installation of only two heat exchangers by changing the boilers’ process what resulted in costs and payback reduction to 10 months.
The energy efficiency improvement in industrial processes is an efficient way of reducing greenhouse gas emissions. The recovery of waste heat eliminated to the environment without utilization is one measure which betters the efficient use of energy. The aim of this dissertation is to quantify the waste heat present in the aniline and derivatives production unit, in all the low temperature process streams unused in Bondalti S.A. This report was done with the purpose of emissions reduction, improving this production unit efficiency. Firstly, a data survey about all the industrial processes was made, through the Bottomup method, to identify the low temperature waste heat sources. A process data base was used to do the quantification, in a period from March 2019 to March 2020. When these data base wasn’t available, local measurements were performed. The identified sources were recirculated water on the cooling towers, exhaustion gases in the incinerator, liquid effluent from the factory, 1 barg expanded steam, air coolers hot water and exhaustion gases from the boiler’s producers of 24 barg steam. Afterwards waste heat quantification, conclusions were made about the source representing the highest waste which is the water from the cooling towers. However, the source with the major heat recovery is the 1 barg expanded steam, due to its significant energy quantity and its temperature level of 120 ºC. A waste heat recovery proposal was done based on the installation of three air preheaters, one to incinerator and two to TERMEC and ECE boilers. The chosen strategy was a combined one, with 1 barg expanded steam and hot water, with the objective of fuel (natural gas) saving, excess heat recovery from two sources and reduction of greenhouse gases emissions. The payback obtained for this project was 18 months. However, a second proposal was made based on the installation of only two heat exchangers by changing the boilers’ process what resulted in costs and payback reduction to 10 months.
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Keywords
Excesso entálpico Quantificação energética Tecnologias de recuperação de calor; Eficiência energética Waste heat Energy quantification Heat recovery technologies Energy efficiency