Energy efficient heat exchage and catalysis
The UNIHEAT Project
Cav Prof. Sandro Macchietto, Imperial College London
© Copyright 2014-15Energy & Water Security Workshop, Doha (Qatar) 15-17 February 2015
Myself
• Chemical engineer
• Academic: Co-founder/director• Centre for Process Systems Engineering
• Energy Futures Lab
• Master in Sustainable Energy Futures
• UNIHEAT
• Entrepreneurship:
– Launched & managed 2 spinoffs
• Process Systems Engineering Ltd
• Hexxcell Ltd
Grand Challenge
• Important
• Urgent
• Difficult
• Few clues
• Not in neat disciplinary boxes
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Grand Challenge
• Science (data, methods …)
• Industrial feasibility (scaling up, make..)
• Process, plant, people …
• Technical and economic performance
• Introduction, Impact
Q: What set-up to promote successful, rapid research, technology transfer, uptake ?
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The Problem
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Crude oil Refined products
Oil Refineries use 5-7% of crude Oil to operate - World-wide >5m bbl/day !! (Saudi Arabia production ~10m bbl/day)
2.5% of all man-made CO2 emissions
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The Opportunity
6
current average energy used
practical minimum energy
theoretical minimum energy required
-100
0
100
200
300
400
500
600
700
CAE
PME
TME
Alkylat
ion
Ref
orm
ing
Hyd
rotre
ating
FCC
Vacuu
m
distilla
tion
Pro
ce
ss e
ne
rgy [1
01
2 B
tu/y
ea
r]
Atmos
pher
ic
distilla
tion
(b)
Overall, over 25% of refinery energy losses
could be practically recovered.
In some process units more than 50% (US DOE 2006)
54%
20%P
roce
ss e
ne
rgy
-p
er
year
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The UNIHEAT Project
An international partnership between leading research institutions and industry
A well funded applied research programme with industrial engagement built-in
The largest interdisciplinary team anywhere in the world in this area
Innovation by design7
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The UNIHEAT Project
8© Copyright 2014-15
Project partners
Imperial College London is a science & engineering based institutionconsistently rated amongst the world's best universities.
Boreskov Institute of Catalysis is the world’s largest research anddevelopment institution in the field of catalysis.
Novosibirsk State University is one of the best research andteaching institution organisation based in Novosibirsk, Russia.
UNICAT Ltd is a spin-off company that focuses on R&D activities inthe fields of catalysis, engineering and energy efficient technologies.
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BP is one of the world’s largest oil companies serving customersevery day in more than 90 countries across six continents.
Skolkovo Foundation is a Russian non-profit organization founded in2010 to create a new science and technology development centre
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The UNIHEAT research team
Name Affiliation Area of Expertise/Role
Prof. G.F. Hewitt Imperial College London Heat transfer, multiphase flow, nuclear power
Prof. G. Jackson Imperial College London Thermodynamics
Prof. S. Kazarian Imperial College London Advanced spectroscopic imaging, supercritical fluids processing
Prof. V.A. Kirillov Boreskov Institute of Catalysis Chemical engineering, heat and mass transfer, catalytic combustion
Prof. O.K. Matar Imperial College London Interfacial fluid mechanics, multiphase flow, first principle modelling
Prof. S. Macchietto Imperial College London Process Systems Engineering, UNIHEAT project co-director
Dr. C.N. Markides Imperial College London Heat transfer, thermodynamic cycles, energy conversion
Prof. O.N. Martyanov Boreskov Institute of Catalysis Catalysts and nanostructured materials physicochemical characterization, supercritical fluids , UNIHEAT project co-director
Dr. M. Millan-Agorio Imperial College London Catalytic upgrading of heavy oil, analytic characterization techniques
Prof. E. Müller Boreskov Institute of Catalysis Thermodynamics, Molecular simulation
Dr. A.V. Porsin Boreskov Institute of Catalysis Catalysts for air purification and fuel combustion, design of catalytic reactors, development of methods for testing catalysts and reactors
Dr. V.N. Snytnikov Boreskov Institute of Catalysis Catalysis, mathematical modelling, parallel algorithms, spectroscopy, chemical evolution, computational mathematics
Dr. V.A. Yakovlev Boreskov Institute of Catalysis Biofuels, hydrotreatment catalyst, combustion in FCB
10+ PHd and MSc Students, Research Associates, Technicians© Copyright 2014-15
From molecular to plant scale
11Pilot PlantMolecular
Chemical
Characterisation
of oil and deposits
Thermodynamics
& molecular
modelling Experimental
Measurements
Kinetics
modelling and
validation Rheological
and transfer
processes
Integration
Plant data analysis
Energy recovery
networks
Efficiency Optimisation
Equipment Unit Plant
Physical
Characterisation
of oil and
deposits
Fouling Mitigation
Heat
Enhancement
Heat exchange
and pipeline
equipment design
Waste Heat
Recovery and
conversion
Heat & Reaction
manangement
Reactor design
Catalytic
processes
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6 UNIHEAT Research themes
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Theme 1 – Multi-scale modellingproperties, flow, equipment, efficiency
Experimental data
Equation of state
Parameters intermolecular
potential
Molecular simulation
Interfacial & transportproperties
Properties ofbulk fluids
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Chemical reaction & equilibrium
Momentum balance
Heat balance
Shear stress & pressure
drops
Fouling deposition &
removal
Heat transfer coefficient
Shell-side coupled to multi-pass
tube-side model
Optimal design
Costing and impact model
Improved operations
L
SD
Economical retrofit
Thermo & Molecular modellingProf. E. Müller and Prof. G. Jackson
Fundamental transport phenomenaProf. O. K. Matar
Industrial scale modellingProf. S. Macchietto
© Copyright 2014Image courtesy of Hexxcell ltd.
State-of-the-art facilities
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HIPOR rig - Crude oil fouling measurement in industrial conditions
High Performance computing and
modelling
Catalytic reactions: partial oxidation of hydrocarbons ; thermocatalytic oxydation
Residue
Lower
P/A
Upper
P/AKerosine GO
Crude
E-01 E-02 E-04
HGO
E-07E-06E-05E-03
Fired heater
Desalter
E-07x
Residue
E-07x
Lower
P/A
Upper
P/AKerosine GO
Crude
E-01 E-02 E-04
HGO
E-07E-06E-05E-03
Fired heater
Desalter
Lower
P/A
E-05
Residue
E-07x
Upper
P/AKerosine GO
Crude
E-01 E-02 E-04
HGO
E-07E-06E-03
Fired heater
Desalter
Residue
Lower
P/A
Upper
P/AKerosine GO
Crude
E-01 E-02 E-04
HGO
E-07E-06E-05E-03
Fired heater
Desalter
1675-1620 cm-1
x
1500-1350 cm-1
x
(d)
1170-1080 cm-1
x
(a)
x
2940-2880 cm-1
(b)
(c)
Imaging - FTIR spectrometer with Infrared Microscope and Macro Chamber (128 x 128 infrared array detector)
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ATR-FTIR Spectroscopic Imaging (Chemical Imaging)
530 µm
610 µm
Wavenumber / cm-1
FPA
Detector
Low
Abs
High
Absorb
ance
IR Source
ATR Crystal
Sample
0 min 10 min 35 min 135 min
+ heptane time
Crude Oil E
Crude Oil C
0 min 10 min 40 min 90 min
Less stable
UNIHEAT Project - Industry engagement
Paul DocxManaging Director
Imperial Consultants
Dr. Francesco Coletti Industry Engagement Manager
Ivette TrinidadAssist. Project Manager
3 Steps to InnovationTM – with industry
• Advanced Research Engagement
methods, data, software focus, trust, relevance
• Lab Demonstration Data, materials
small/medium scale proof of concept
• Industrial feasibility Plant, people
full scale, real performance, benefit, ... steps for use
Industry partnersUNIHEAT
Greater probability of Technology Transfer success17
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Technologies pipeline
7 patents filed (5 + in preparation) , demonstrators, spinoffs …18
• Fouling in oil refineries (measurement, modelling
and mitigation)
• Crude oil characterisation
• Catalytic heating for pipelines and industrial heaters
• Catalytic combustion of heavy oils
• Heat recovery through catalytic Stirling engine
• Laser induced pyrolysis of light hydrocarbons
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Research to uptake
Fast track fundamentals served!19
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www.uniheat-project.com
Contact
Project:Cav Prof Sandro Macchietto [email protected]
Industry engagement:Dr. Francesco Coletti: [email protected]
© Copyright 2014-15
Utilities infrastructure for Dubai Waterfront Project
New urban development for 1.5m people with ARUP
Financial data:•CAPEX ($/kW)•OPEX ($/kWh)
•Revenues ($/kWh)
Technology options and
specifications
Identify which technologies are to
be invested in
Demand profiles (MW(t))
What capacity of each will be installed (MW)
Their operation schedules: when and how much (t,
MW)NPV ($)
Environmental impact (?)
GAMS
Parameters
Variables
Equations
Objective -function
Technology carbon
intensities (tCO2/kWh)
Input data
Weather data
Output data
Financial data:•CAPEX ($/kW)•OPEX ($/kWh)
•Revenues ($/kWh)
Technology options and
specifications
Identify which technologies are to
be invested in
Demand profiles (MW(t))
What capacity of each will be installed (MW)
Their operation schedules: when and how much (t,
MW)NPV ($)
Environmental impact (?)
GAMS
Parameters
Variables
Equations
Objective -function
Technology carbon
intensities (tCO2/kWh)
Input data
Weather data
Output data
Daily electricity generation mix for min emissions
Model
0
200
400
600
800
1000
1200
1400
1600
1 3 5 7 9 11 13 15 17 19 21 23
Hour of day
MW
Electric
demand
Wind
PV
CCGT
AD
INC
A new petrochemical complex for Vietnam
Ethylene
0.5 % of global energy consumption
35 MMTA of CO2 emission
• Greenfield site• Primary energy + sourcing• Infrastructure (port, storage, ..)• Several plants• Energy, utility integration• 30 yr plan• Max NPV Min CO2
© Sandro Macchietto 2010
Profit or environment?
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
-4000 -3000 -2000 -1000 0 1000 2000
Perc
en
tag
e o
f T
ota
l C
O2 e
mis
sio
n
NPV in 2010MUSD
Solution group
1
Solution group
3
Solution group
4
Solution group
2
Mainly coal
(domestic + regional +interregional)
Biomass + electricity
Coal, Gas + electricity
Gas, electricity, biomass
Max NPV and Min TCO2
9.7 M t CO2
$351M
A CO2 price of 36$/t would give max NPV with 70% reduction of CO2
Postgraduate training – MSc in Sustainable Energy Futures
MSc in Sustainable Energy Futures
Uniquely structured one year masters course for
students from varying backgrounds
Highly interdisciplinary
Innovative format
“MBA for engineers”
Conclusions
• Important ?
• Urgent ?
• Difficult ?
• Few clues ?
• Not in neat disciplinary boxes ?
LET’S START!
25© Copyright 2014-15
