1 “Intensified Heat Transfer Technologies for Enchanced Heat Recovery” INTHEAT (Grant Agreement ) Jiří J KLEMEŠ, Petar S VARBANOV EC Marie Currie Chair (EXC) “INEMAGLOW” Research Institute of Chemical Technology and Process Engineering – CPI 2, Faculty of Information Technology University of Pannonia, Veszprém, Hungary

2 Outline CPI 2 at the University of Pannonia Research Background P-graph for Process Synthesis Books and Other Publications Involvement of CPI 2 -UOP in INTHEAT

3 CPI 2 at the University of Pannonia

4 University of Pannonia

5 Location: Veszprem – The Town of Queens

6 Professor Ferenc Friedler, Dean Faculty of Information Technology Development of P-graph and S-graph frameworks (Co-founder) –Process Network Synthesis –Batch Process Scheduling –Energy Saving and Pollution Reduction –Reaction Pathway Identification Knight's Cross Order of Merit of the Republic of Hungary, Budapest, Hungary, 2003 László Kalmár Prize (John von Neumann Computer Science Society), Budapest, Hungary, 2003 Neumann Prize (John von Neumann Computer Science Society), Budapest, Hungary, 2007 Széchenyi Prize, Budapest, Hungary, 2010

7 CPI 2 Centre for Process Integration and Intensification Prof Jiří J Klemeš Chair Holder Assoc. Prof. Dr Petar Varbanov PhD Students Dr László Sikos CUM LAUDE Graduate Hon Loong Lam Luca De Benedetto Zsófia Fodor Prof Zdravko Kravanja, University of Maribor Lidija Čuček Andreja Nemet

8 Research background

9 UMIST: History 1824 Created by industrialists as the Manchester Mechanics Institution 1905 Faculty of Technology, University of Manchester 1956 Royal Charter granted to Manchester College of Science and Technology 1965 University of Manchester Institute of Science and Technology 2004 Merged with University of Manchester

10 Centre for Process Integration World Leaders in Process Design Technology

11 Research directions

12 Most Resent Research Cell-based dynamic heat exchanger models – direct determination of the cell number and size Petar Sabev Varbanov, Jiří Jaromir Klemeš, Ferenc Friedler

13 Heat exchange cell m H h HI m H h HO m C h CI m C h CO Cell model: detailed picture Cell model: icon representation Q CELL Definition  Two perfectly stirred tanks, exchanging heat only with each other through a dividing wall  H=”Hot”, C=”Cold”;  HI=”Hot Inlet”, HO=”Hot Outlet”  CI=”Cold Inlet”, CO=”Cold Outlet” Assumptions  Perfect mixing in the fluid cells  Constant fluid densities  The tanks are completely full  Constant specific heat capacities  The thermal resistance of the wall is neglected  The wall heat capacity is taken into account

14 Cell model of a heat exchanger A complete heat exchanger can be modelled by a number of cells The cells are combined to reflect the internal flow arrangement in the exchanger m HOT, h IN,HOT m COLD, h IN,COLD m HOT, h OUT,HOT m COLD, h OUT,COLD Single-pass (1-1) heat exchanger

15 Cell model of a heat exchanger 1-2 shell-and-tube heat exchanger (no baffles)

16 Cell model of a heat exchanger 1-2 shell-and-tube heat exchanger (with baffles)

17 Minimum number of cells Heat exchange Temperature Derivation

18 Summary on the cell model Distributed models become inefficient for complex heat exchangers From the lumped– mostly cell models are employed The cell parameters need to be carefully estimated accounting for the underestimation of the temperature differences A method for direct identification of the number of cells has been developed Mostly applicable to shell-and-tube heat exchangers A useful visualisation of the cell number identification procedure is provided The method can be further extended to the other kinds of heat exchangers

19 P-graph for Process Synthesis Friedler, F., J.B. Varga, and L.T Fan. (1995), Decision-Mapping A Tool for Consistent and Complete Decisions in Process Synthesis, Chem. Eng. Sci., 50(11):

20 P-graph: a Rigorous Mathematical Tool Axioms for feasible networks Algorithm MSG Algorithm SSG Suite of tools Search space 10 3 –10 6 x Exploit the problem structure Much faster Superior to direct Mathematical Programming

21 P-graph algorithms: Maximal Structure Generation (MSG) Problem Formulation set of raw materials set of products set of candidate operating units Reduction part Composition part Problem Formulation Consistent sets O & M Maximal Structure Superstructure (Maximal) Union of all combinatorially feasible structures Rigorous super-structure Legend: O: set of operating units; M: set of materials

22 ABB Algorithm – Even Faster Search Employs the “branch-and-bound” strategy Combines this with the P-graph logic (SSG algorithm) Ensures combinatorial feasibility Non-optimal decisions are eliminated from the search

23 PNS Paradigms: A Comparison Conventional MP (MILP, MINLP) P-graph (MSG, SSG, ABB) Network Model Formulation Mostly MANUAL ALGORITHMIC Automation allowing user interaction Complexity (Solution Speed) 6 orders of magnitude (10 6 ) faster Example: separation sequence synthesis 34 Billion possible combinations 3,465 combinatorially feasible structures Interpretation of results Flowsheets (only) Flowsheets Easier to spot structural patterns

24 Applying P-graph: Combined Heat and Power using FCCC

25 Configuration and Setup Demands: 10 MW power and 15 MW heat Power:100 €/MWh Heat: 30 €/MWh Natural gas: 30 €/MWh Fertiliser from biogas digestion: 50 €/t Plant life: 10 y Case studies Limit the availability of the biomass to 30 MW

26 Fuel Preparation Options Biomass Gasifier Syngas Filter Biogas digester Streams / Materials AR:Agricultural residuesPR:Particulates BR:Biomass residuesSG:Syngas RSG:Raw syngasBG:Biogas CO2:Carbon dioxideFRT:Fertiliser RSG, kW/kW0.65 BR, (kg/h)/kW CO 2, (kg/h)/kW0.025 SG, kW/kW0.99 PR, (kg/h)/AR BG, kW/kW0.58 FRT, (kg/h)/AR CO 2, (kg/h)/kW0.025 Performance per unit input

27 Energy Conversion Options {F}: Fuels{FCCC}{Q}: steamSteam details{Q}: steamSteam details NG: Natural gasMCFC-GTQ1P = 1 barQ20P = 20 bar BG: BiogasMCFC-STQ2P = 2 barQ40P = 40 bar SG: SyngasSOFC-GTQ5P = 5 bar SOFC-STQ10P = 10 bar Fuel Cell Combined Cycle Biogas Boiler Natural Gas Boiler W, kW/kW0.58 – Q, (kg/h)/kW0 – 0.25 CO 2, (kg/h)/kW)NG: SG/BG: 0 Q40, kW/kW0.85 Q40, kW/kW0.88 CO 2, (kg/h)/kW Performance per unit input

28 Results Cases 1, 2, 3; Biomass < 18 €/MWh Profit: / 6.48 / 6.23 MM€/y Case 4; Biomass at 10 €/MWh Profit: 5.51 MM€/y Biomass MAX 30 MW

29 Results Summary Biomass is profitable over a wide price range Topologies relatively robust until tipping point Fertiliser – marginal significance The trade-off between the Agricultural Residues – Natural Gas prices dominates the designs

30 P-graph for FCCC Summary Biomass viable for FC High efficiency  lower resource demand Energy supply and conversion: complex systems Synthesising : combinatorially difficult P-Graph: appropriate tool effectively solving the task Successfully applied to choosing FCCC - based system design

31 Books and other publications

32 Recent Publication IF 2008 = IF 2009 = Citations: 10

33 Recent Publication IF 2009 = Citations: 4

34 Citations

35 Handbook of Water and Energy Management in Food Processing Edited by J Klemeš, University of Pannonia R Smith and J-K Kim, University of Manchester, UK

36 Coming Book

37 EMINENT 2 Workshop

38 Involvement of CPI 2 -UOP in INTHEAT

39 Contribution to Work Packages WP 1 (Months 1-12): Analysis of intensified heat transfer under fouling, 6 person-months, Task 1.1 WP 2 (Months 1-18): Combined tube-side and shell- side heat exchanger enhancement, 1 person-month, Task 2.2 WP 4 (Months 1-24): Design, retrofit and control of intensified heat recovery networks, 9.5 person- months, Tasks 4.1 and 4.3. This will be a development of the P-graph methodology using the ABB algorithm WP 5 (Months 12-24): Putting into practice, 5 person- months, Tasks 5.2 and 5.3

40 Leader of WP 6 “Technology transfer” Aim: Effective technology transfer to the wide range academic and industrial communities Validation of the developed novel methodology with the SME partners. Dissemination of the project results, aiming to achieve the best possible project recognition over a broad audience Develop suitable training and support materials for SME partners Establish an active community involving the INTHEAT partners and other users/experts for continuous knowledge management and improvement

41 WP 6 “Technology Transfer” Runs during months 6 – 24 Tasks: –6.1. Technology transfer to SME consortium members –6.2. Dissemination events –6.3. Publications –6.4. Training

42 Task 6.1. Technology transfer to SME consortium members Streamlined transfer of the developed and acquired technologies, licenses and know-how among the consortium all members A special emphasis will be put on the technology transfer to the industrial partners Principles All outputs/deliverables from WPs 1 to 5 will be checked for documentation in such a way, as to enable technology users to obtain reproducible results Additional application procedures may be needed

43 Task 6.2. Dissemination events Intensified heat exchangers – Novel developments Information day for major stakeholders Organisers: UNIPAN, PIL, UNIMAN Has to be delivered by Month 8 Suggested: PRES’11, 8-11 May 2011, Florence, Italy

May 2011, Florence, Italy

45 14 th Conference Process Integration, Modelling and Optimisation for Energy Saving and Pollution Reduction 8-11 May 2011, Florence, Italy Raffaella DAMERIO The Italian Association of Chemical Engineering Via Giuseppe Colombo 81A Milano (Italy) Phone: Fax: Hon Loong LAM (Scientific Programme Secretary) Phone: Fax: Website: Organiser & Secretariat

46 Chemical Engineering Transactions (CET)

47 Task 6.2. Dissemination events Enhanced heat transfer Workshop/session at a recognised international conference Organisers: UNIPAN, CALGAVIN, EMBAFFLE, SODRU Has to be delivered by Month 12 Suggested: 6-th Dubrovnik Conference on Sustainable Development of Energy, Water and Environment Systems, September , 2011, Dubrovnik, Croatia

48 Task 6.2. Dissemination events Software Demonstration Workshop Workshop/session at a recognised international conference Organisers: UNIPAN, PIL, UNIMAN Has to be delivered by Month 18 Suggested: A dedicated workshop to be held in the summer of 2012, at PRES 2012

49 Task 6.2. Dissemination events Joint Hub for Intensified Heat Exchangers Workshop held by all academic partners with the support of the industrial partners Has to be delivered by Month 22 Suggested: A dedicated workshop to be held in Veszprém in September-October 2012

50 Task 6.3. Publications Three major conferences will be held during the project execution: PRES’11 (May 2011), SDEWES 2011 (September 2011), PRES It is expected that at least 9 conference publications will be delivered Scientific articles in refereed journals: minimum 4 papers are planned Wider dissemination to the public, authorities, environmentalists and decision-making bodies

51 Task 6.4. Training The major training will be carried out in form of workshop at UNIPAN, scheduled for delivery by Month 23 (October 2012). Suggested venue: To be organised as a follow-up event after the workshop “Joint Hub for Intensified Heat Exchangers” from Task 6.2, Veszprém in September-October 2012 The relevant training materials have to be available before the workshops. Suggested delivery – by June- July 2012, to allow for testing and fine-tuning

52 Deliverables for WP 6 DeliverableTasksNatureDissemination Level Due by D6.2Report on the performed marketing activities and commercialisation outcomes RPUMonth 24 D6.3Four dissemination events 6.2OPU Month 8, 12, 18, 22 D6.4At least 4 conference publications and 2 journal publications 6.3OPUMonth 24 D6.5Training materials for the methods and tools developed 6.4OPUMonth 24

53 Thank you for your attention! Veszprém, Castle