Managing CO2 Emissions in the Chemical Industry (Green Chemistry)

Managing CO2 Emissions in the Chemical Industry......Page 2
Contents......Page 8
Preface......Page 22
List of Contributors......Page 24
1: Climate Change......Page 28
2: Overview of the Chemical Process Industry......Page 31
3.1 Energy Consumption and CO2 Emissions in General......Page 33
3.2 Energy Consumption and CO2 Emissions in the Chemical Industry......Page 38
3.3 Energy Prices......Page 40
3.4 Energy Efficiency in the Chemical Industry......Page 41
4: Political Framework and Trends......Page 43
5.2 Flexible Mechanisms......Page 44
5.3.1 Mitigation Policy......Page 46
5.3.4 Technology......Page 47
5.4.1 United States of America......Page 48
5.4.3 European Union......Page 49
6: Company Initiatives......Page 50
6.2 Roche......Page 51
6.3 Dow......Page 53
6.4 DuPont......Page 54
References......Page 55
Part One: Administrative and Cultural Aspects......Page 58
1.1.1 Measuring Impact on Global Warming......Page 60
1.1.2 A Simple CO2 Balance......Page 61
1.1.3 Carbon Footprints–A Few Examples......Page 62
1.1.4 Company Carbon Balances......Page 63
1.1.6 The CO2 Abatement Curve......Page 65
1.2 Product Carbon Footprints (PCF)......Page 67
1.2.1.1 Goal and Scope......Page 68
1.2.2 PCF from Cradle-to-Gate......Page 69
1.2.2.1 Energy Supply......Page 71
1.2.2.2 Raw Materials......Page 73
1.2.2.3 Logistics and Supply Chain......Page 74
1.2.2.4 Manufacturing and Product Allocation......Page 75
1.2.3 Cradle-to-Grave Carbon Footprints......Page 78
References......Page 81
2.1 Introduction......Page 84
2.2.2.1 Cap-and-Trade......Page 86
2.2.2.2 Command-and-Control......Page 88
2.2.2.3 Hybridization of Taxation and Trading......Page 89
2.3.1 Carbon Pricing and Industry Exposure......Page 90
2.3.2 Applying Carbon Pricing to the Chemical Production Chain......Page 91
2.3.2.1 Electricity Generation and Supply......Page 93
2.3.2.2 Feedstock Extraction, Transportation, and Preparation......Page 94
2.3.2.3 Basic Chemical Preparation......Page 95
2.3.2.4 Subsector Chemical Preparation......Page 97
2.4.1 Concept of Offsetting......Page 98
2.4.2 Flexible Mechanisms of the Kyoto Protocol......Page 99
2.4.2.1 Developing a CDM Project......Page 100
2.4.2.2 Developing a JI Project......Page 107
2.4.3.1 Scaling up the CDM via Benchmarking......Page 108
2.5 Positioning Industry for a Global Framework on Climate Change......Page 109
2.5.1 Defining Sectors within a Regulated Environment......Page 110
2.5.2 Allocating for the Chemical Industry......Page 111
2.5.3 Key Messages Moving Forward......Page 112
References......Page 113
3: Implementation of Energy Awareness in Plants......Page 116
3.1 Energy Awareness and Environmental Sustainability......Page 117
3.2 How to Raise Awareness and Change Behavior?......Page 118
3.2.2 Attitude Theory......Page 119
3.2.4 Goal-Setting Theory......Page 120
3.2.5 Theories About Feedback......Page 121
3.2.6 Combination of Methods......Page 122
3.3 Individual and Organizational Change Processes......Page 123
3.3.1.1 Prearrangements and Pre-analyses......Page 124
3.3.1.2 Energy Audit......Page 127
3.3.1.3 Methods, Measures and Goals......Page 128
3.3.1.4 Team and Resources (Budget)......Page 129
3.3.1.5 Plan and Timeframe (Schedule)......Page 131
3.3.2.1 Information Materials and Events......Page 132
3.3.2.2 Participative Workshops and Specific Techniques......Page 133
3.3.2.3 Goal-Setting Talks......Page 136
3.3.2.4 Feedback Instruments and Talks......Page 138
3.3.2.5 Energy Conservation Training......Page 140
3.3.2.6 Energy Saving Award Programs......Page 141
3.3.3.1 Monitoring and Controlling (Process Evaluation)......Page 142
3.3.3.3 Reporting of Results and Lessons Learned......Page 143
3.4 Sustain the Effort......Page 144
References......Page 145
Part Two: Energy Efficient Design and Production......Page 148
4.1 Overview......Page 150
4.2 Definition of Scope and Task......Page 151
4.3.1 Carbon Footprint......Page 153
4.3.2 Energy Distribution per Utility......Page 154
4.3.3 Main Energy Consumers......Page 157
4.3.6 Energy Baseline and Milestone 1......Page 159
4.4.2 Brainstorming Sessions......Page 160
4.4.3 Equipment Check......Page 162
4.4.4 Operational Improvements and Process Control......Page 163
4.4.5 Process Improvements......Page 164
4.4.7 Raw Materials......Page 165
4.4.8 Buildings and Facilities......Page 166
4.4.9 Energy and Utility Systems......Page 167
4.4.10 Milestone 2......Page 168
4.5.1 Technical Feasibility......Page 169
4.5.2 Profitability......Page 170
4.5.3 Savings Portfolio......Page 171
4.6.1 Implementation Plan......Page 174
4.6.2 Monitoring and Controlling......Page 176
4.6.3 Reporting and Target Setting......Page 177
4.6.4 Energy Loss Cascade......Page 179
4.6.5 Energy Management System and Benchmarking......Page 180
4.6.6 Energy Awareness in Plants......Page 181
4.7.1 Situation before the Bayer Climate Check......Page 182
4.7.3 Realization and Results......Page 183
References......Page 185
5.2.1 Process Retrofit......Page 186
5.2.3 Safety......Page 187
5.3.1.2 Step 2: Flowsheet Decomposition......Page 188
5.3.1.3 Step 3: Calculation of Indicators......Page 190
5.3.1.5 Step 5: Sensitivity Analysis of Operational Parameters......Page 194
5.3.1.6 Step 6: Generation of New Sustainable Design Alternatives......Page 195
5.3.2.2 Step 1A: Transform Equipment Flowsheet into an Operational Flow Diagram......Page 196
5.3.2.4 Step 3: Calculation of Indicators......Page 197
5.3.2.7 Step 6: Generation of New Sustainable Design Alternatives......Page 199
5.4.3 Supporting Tools......Page 200
5.5.1.1 Step 1: Collect the Steady-state Data......Page 201
5.5.1.3 Step 3: Calculate the Indicators, the Sustainability and the Safety Metrics......Page 202
5.5.1.6 Step 6: Generation of New Design Alternatives......Page 204
5.5.2 Batch Processes: Insulin Case Study......Page 206
5.5.2.4 Step 3: Calculate the Indicators, the Sustainability and the Safety Metrics......Page 207
5.5.2.6 Step 5: Process Sensitivity Analysis......Page 210
5.5.2.7 Step 6: Generation of New Design Alternatives......Page 211
References......Page 213
6.1 Introduction......Page 216
6.2.1 Why Heat-Integrate for Optimum Heat Recovery?......Page 217
6.2.2 Inter-Unit Heat Integration......Page 218
6.2.4 Pinch A nalysis......Page 219
6.3.1 The Concept of Quality of Energy......Page 220
6.3.2 Energy Targeting......Page 222
6.3.3 Composite Curves......Page 224
6.3.4 Setting the Energy Targets......Page 225
6.3.5 Setting the Area Targets......Page 226
6.3.6 Capital/Energy Trade-off......Page 227
6.4.1 Utility Costing......Page 228
6.4.2 Targeting for Multiple Utilities: The Grand Composite Curve......Page 230
6.4.3 Total Site Integration......Page 233
6.4.4 Steam and Power System and Efficient Power Generation......Page 234
6.4.5 Options for Low Grade Heat Use......Page 235
6.5.1 The Pinch Rules......Page 236
6.5.2 Network Design......Page 238
6.5.3.1 Process Modifications......Page 239
6.5.3.2 The Plus/Minus Principle......Page 240
6.6.1 Area Efficiency Method......Page 241
6.6.2 Modern Retrofit Techniques......Page 243
6.6.3 The Network Pinch......Page 244
6.7.1 Area Integration......Page 245
6.7.2 Water Pinch......Page 246
6.7.3 Hydrogen Pinch......Page 247
Further Reading......Page 248
7.1 Introduction......Page 250
7.2 Good Housekeeping......Page 251
7.3.1 Centrifugal Pumps......Page 253
7.4 Distillation......Page 256
7.4.1 Basic Principles......Page 257
7.4.2.2 Operating Pressure......Page 258
7.4.2.6 Process Control......Page 259
7.4.3.1 Column Internals......Page 261
7.4.3.2 Feed Preheating......Page 262
7.4.3.3 Vapor Recompression......Page 263
7.4.3.4 Intermediate Reboiler or Condenser......Page 265
7.4.3.5 Heat-Integrated Distillation Column (HIDiC)......Page 267
7.4.4.1 Dividing Wall Column......Page 268
7.4.4.2 Indirect Coupling of Columns......Page 270
7.4.4.3 Design of Distillation Processes......Page 272
7.5 Evaporation......Page 273
7.5.2 Multistage Evaporation......Page 274
7.5.3 Vapor Recompression......Page 276
7.6 Drying......Page 277
7.6.1 Operational Improvements for Convective Dryers......Page 278
7.6.2 Heat Recovery from Convective Dryers......Page 279
7.7 Crystallization......Page 280
7.7.1 Melt Crystallization by Cooling......Page 281
7.7.2 Evaporative Crystallization from Solutions......Page 282
7.8 Membrane Separation......Page 283
7.8.2.1 Separation of Organic Vapors......Page 284
7.8.2.2 Pervaporation......Page 285
7.9.1 Recovery of Reaction Heat......Page 286
7.9.2 Heat Integration......Page 287
7.9.3 Increased Conversion and Selectivity......Page 288
7.9.5 Optimized Process Conditions......Page 289
7.9.6 Microstructured Equipment......Page 291
7.11 Advanced Process Control and Performance Monitoring......Page 292
References......Page 295
8.2.1.1 Reciprocating Compressors......Page 298
8.2.1.2 Centrifugal Compressors......Page 299
8.2.1.3 Axial Compressors......Page 301
8.2.2.1 Centrifugal Pumps......Page 302
8.2.3.1 Centrifugal Fans......Page 305
8.2.4.1 Turbo-Expanders......Page 308
8.2.4.2 Liquid Turbines......Page 309
8.2.5.2 Single Stage Turbines......Page 310
8.2.5.3 Multistage Turbines......Page 311
8.2.6 Gas Turbines......Page 312
8.2.6.2 Aero-Derivative Engines......Page 313
8.2.7 Electric Motors......Page 314
8.2.8 Air Coolers......Page 315
8.3.1 Fired Heaters......Page 317
8.3.1.2 Fuel System......Page 318
8.3.2 Flares and Flare Systems......Page 319
8.3.3.1 Capital Cost versus Running Cost......Page 320
8.3.3.2 Design for Low Line Loss......Page 321
8.3.4.2 Mis-Use of Insulation......Page 322
8.3.5 Tank Farms......Page 323
8.3.6.1 Header Pressure and Temperature Control......Page 324
8.3.6.4 Steam Traps and Condensate Recovery......Page 325
8.3.7.1 Cooling Towers......Page 326
8.3.7.3 Circulation Pumps......Page 328
8.3.7.5 System Tuning......Page 330
9.1 Historical Evolution from Energy Conservation to Energy Efficiency in Refineries......Page 332
9.1.1 Global Scenarios and Impact on the Oil Business......Page 333
9.2 Good Practices for Energy Conservation Programs......Page 335
9.2.1 Energy and Material Balances......Page 336
9.2.1.1 Measurements and Basic Units......Page 337
9.2.1.2 Calculi and Approximation......Page 338
9.2.1.3 Analysis and Basis......Page 339
9.2.1.4 Standards, Averages and Deviations......Page 341
9.2.2 Process Units......Page 342
9.2.2.1 Transformation Units......Page 343
9.2.2.2 Separation Units......Page 346
9.2.2.3 Storage and Transport......Page 349
9.3.1.1 Target Clients......Page 352
9.3.1.3 Media......Page 353
9.3.2.1 Speeches......Page 354
9.3.2.2 Courses......Page 355
9.4 Saving Energy by Operation and Maintenance......Page 356
9.4.2 Pre-Maintenance Work......Page 357
9.4.3 Conditioning and Testing......Page 358
9.4.4.1 Combustion......Page 359
9.4.4.2 Heat Transfer......Page 361
9.4.4.4 Fluid Movement......Page 362
9.4.4.5 Energy Distribution......Page 363
9.5 Upgrading and New Projects for Better Energy Performance......Page 365
9.6.1 Initial Work......Page 366
9.6.2 Committees......Page 367
9.6.3 Task Forces......Page 368
9.6.4 Leadership......Page 369
9.6.5 Accountability......Page 370
9.6.6 Corporative Goals......Page 371
9.6.7 Evolutionary Organization......Page 373
9.7 Future and Environmental Concerns......Page 374
Further Reading......Page 375
10.1.1 Use of Utilities......Page 378
10.1.2 Quality......Page 379
10.1.3 Energy Exchange......Page 380
10.1.5 Energy Efficiency......Page 381
10.2.1 Steam......Page 382
10.2.3 Water......Page 383
10.2.3.2 Cooling Water......Page 384
10.2.3.3 Boiler Water......Page 385
10.2.3.4 Condensate......Page 387
10.2.4 Air......Page 388
10.2.4.2 Instrument Air......Page 389
10.3.1 Power Cycles......Page 390
10.3.2.1 Boilers......Page 396
10.3.2.2 Gas Turbines......Page 398
10.3.2.3 Steam Turbines......Page 399
10.3.3 Ancillary Systems......Page 400
10.4.1 Steam Generation......Page 401
10.4.2 Power Generation......Page 402
10.4.4 Cooling Units......Page 403
10.4.5 Ancillary Systems......Page 404
10.5.1.1 Steam......Page 405
10.5.1.2 Condensate......Page 407
10.5.2 Wiring......Page 408
10.5.2.3 Power Factor......Page 409
10.6 Design Aspects......Page 410
10.6.3 Integration with Process......Page 411
10.7.2 Safety......Page 412
10.7.4 Efficiency......Page 413
Further Reading......Page 414
Part Three: Future Developments......Page 416
11.1 Background......Page 418
11.2 General Description of the Technology with its Components......Page 420
11.3 Carbon Capture......Page 421
11.3.1.1 The Basic Idea of Carbon Capture......Page 422
11.3.1.2 Technological Implementation......Page 423
11.3.2.1 The Basic Idea of Carbon Capture......Page 426
11.3.2.2 Technological Implementation......Page 427
11.3.3.1 The Basic Idea of Carbon Capture......Page 429
11.3.3.2 Technological Implementation......Page 430
11.3.3.3 Importance for the Chemical Industry......Page 432
11.3.4 Technologies to Reduce Energy Consumption for Carbon Capture......Page 433
11.4 CO2 Transport......Page 434
11.4.1 Pipeline......Page 435
11.4.2 Ship......Page 436
11.5.1 Underground Storage of CO2......Page 437
11.5.2 Carbonation......Page 439
11.6.1 Efficiency Parameters of CCS......Page 440
11.6.2 Assessing the Economic Efficiency of CCS......Page 442
11.7 Upshot......Page 443
Further Reading......Page 444
12.1 Introduction......Page 446
12.2.1 Overview......Page 447
12.2.2.1 Renewable Feedstock Trends......Page 448
12.2.2.2 Sugar......Page 449
12.2.2.3 Starch......Page 450
12.2.2.4 Oils, Fats......Page 451
12.2.2.5 Biomass and Residues......Page 452
12.2.3.1 Competition between Fossil and Renewable Feedstocks......Page 453
12.2.3.2 Yields and Efficiency of Chemical Processing......Page 454
12.3.1 Market, Field of Application, and Currently Available Products......Page 456
12.3.2.2 Amino Acids......Page 457
12.3.2.3 Bioethanol and Bioethylene......Page 458
12.3.2.5 Bioacrylic Acid......Page 459
12.3.2.6 Oils for Chemicals......Page 460
12.3.2.7 Biocatalysis for the Production of Emollient Esters......Page 461
12.4.1 CO2 Saving Limitations of Single Product-based Systems......Page 462
12.4.2.1 Chemical Breakdown......Page 463
12.4.2.4 Chemical Structure Retention......Page 464
12.4.2.5 Proteins for Functionalized Chemicals......Page 465
12.5.1 Data Generation......Page 466
12.5.2 The Diversity in the Interpretation of Data......Page 467
12.6.1 Common Practice and Future Needs......Page 469
12.6.2 Fuel vs. Food and other Misbalances......Page 470
12.7 Outlook......Page 471
References......Page 472
Index......Page 476