1. Introduction - Firenze University Press

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sufficient diversity of the ideas in terms of disciplines and also meant that the less likely ideas could be filtered out before rating all the ideas. Given the 7 technical experts, the longest possible list was 49 options. Because some solutions were selected twice or more, this resulted in a shorter list of 39 ideas. These ideas were rated on a number of ranking criteria. The chosen ranking criteria were: magnitude of the (expected) energy saving exergy level of the energy saving a qualitative estimate of the required investment the influence on the operation of the production process the extent of modifications needed within the process the timeframe in which the solution is expected to be technically feasible. Rating based on the ranking criteria was done by discussing the merits of the solutions within the entire project team. The scoring possibilities and criteria are given in Table 1. Note that the quantitative units need to be different for each study, as these savings are clearly not possible for a smaller plant. Table. 1. Schematic overview of the ranking criteria Magnitude (expected) energy saving 2MW Exergy level (expected) energy saving 0 3 6 9 Heat (100°C) Electricity and gas Required investment (e stimate) 3 6 9 2.000 k€ 10 7 4 1 Influence on operation of production process Positive (more stable) No influence Slightly more complex Loss of robustness 13 10 7 4 Extent of modifications needed within the process Easy modifications Slight modifications Significant modifications Major modifications 10 7 4 1 Time horizon within which the solution can be implemented Direct (10 years 10 7 4 1 Each ranking criterion had a weight factor accompanying it. In this way the ranking criteria can be matched to the company’s strategy. The magnitude of the expected energy saving for example had a higher weight factor than the timeframe in which the solution is expected to be technically feasible, i.e. long-term solutions with big energy savings would be rated higher than short-term solutions with mediocre energy savings. The weight factors varied from 1 to 5. The score for each criterion was multiplied by the weight factor. All scores were added up to find the best scoring solutions. Based on available capacity and similarity of solutions, the twelve highest ranking ideas were elaborated into business case. 291
3. Case study 3.1. Plant and process The plant under consideration is the Budel Plant of Nyrstar. The main products of the plant are high-purity zinc (SHG-zinc), zinc alloys and sulphuric acid. A side product is Budel Leach Product; a product containing silver and lead, that was present in the zinc ore, which is used for the production of silver. The plant uses the so-called Roasting, Leaching, Electrolysis process. The scheme is given below. Fig 2. Roasting-Leaching Electrolysis Zinc production process at Budel plant. Reproduced with permission from [11] The zinc ore is roasted in an air-blown furnace, thereby converting ZnS into ZnO and SOx. The zinc-oxide is cooled and subsequently leached in sulphuric acid, thereby forming ZnSO4 (solute) and water. Other metals are removed from the liquor of H2SO4 and Zn. The main metals are contained in the Budel Leach Product, but also pure cadmium, and copper and cobalt containing cakes are removed from the process. Very pure zinc is formed on electrodes in the electrolysis process, where ZnSO4 (solute) and water are converted into Zn, O2 and H2SO4. The heat in the SOx-containing roast gas is first used to produce steam. Solids and other impurities are removed, and subsequently sulphuric acid is produced. Additional process units are a water purification plant and the melting and casting process. The majority of the consumed energy is electricity. The majority of the electricity is consumed in the electrolysis section. The primary energy use of the entire plant is about 8000 TJ per year. 292
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Proceedings e report 90
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ECOS 2012 : the 25 th International
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Advisory Committee (Track Organizer
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The 25 th ECOS Conference 1987-2012
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VOLUME VI CONTENT VI. 1 CARBON CAPT
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-----------------------------------
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» Personal transportation energy c
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» Excess enthalpies of second gene
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VOLUME IV IV . 1 - FLUID DYNAMICS A
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» Exergy analysis and genetic algo
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» Optimal lighting control strateg
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» Stability and limit cycles in an
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PROCEEDINGS OF ECOS 2012 - THE 25 T
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Fig. 2. The exergy destruction of M
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ineffectiveness of the catalyst, in
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[ P EXmth EX SNG] ESR F where EXm
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Fuel inputkW 728221 203771 237719 3
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Not only at desined Rc (the ratio o
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4. DISCUSSION The graphic exergy an
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Figure 9(a) illustrates the energy
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Engineering Technical Conferences &
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generally there are four kinds of m
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However, even under the off-design
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Fig. 3. 600MW supercritical coal-fi
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CO2 rich loading(molCO2/molMEA) 0.4
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Net efficiency (%) 40.28 30.29 26.4
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Fig. 11. Schematic diagram of heat
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28.67%. In addition, through heat i
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Applied Thermal Engineering 2010;30
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Abstract: PROCEEDINGS OF ECOS 2012
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Fig. 1. Solution diagram of „four
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K ~ K 1 eK 1a p K 1a iK mK
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Oxygen recovery rate, % 105 95 85 7
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Calculated optimal compressor press
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The net amount of the flue gas leav
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Figure 3. Idea for lignite drying b
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Energy efficiency, % 34,00 33,00 32
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points efficiency increase related
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Figure A1b. Thermoflex flow sheet o
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Figure A3a. Thermoflex flow sheet o
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Figure A4. Thermoflex flow sheet of
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2.1. Life Cycle Assessment 2.1.1. G
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these factors. A sensitivity analys
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methane slip contributes to 13% of
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As can be seen in Fig. 5 the impact
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References [1] Eurobserv’er, The
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in which CO2 is separated from H2,
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dimensions of water droplets and wa
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Temperature (°C) 8 7 6 5 4 3 2 1 0
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4. Conclusions In the present paper
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penalty, but without separate captu
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0.5 - 0.7 kg/kg, resulting typicall
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3.3 - Utilising waste heat All exis
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4.5 - Suomusjärvi olivine deposits
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material will change from a few % t
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Fig. 5 Schematic diagram of the PFB
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8. Combined SO2 capture and CO2 min
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Fig. 10 Carbonate- (left) and sulph
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[13] Ekdahl, E., Idman, H. Statemen
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HEAT Fig. 1. Scheme and main reacti
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(raw) materials pre-heating and AS
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Fig 3- Aspen Plus® model 110
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Table 4. Elemental and XRD analysis
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the ÅA CSM route. The content of M
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moisture - 0,2237 ash - 0,0876 LHV
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2.2 CFB plant For the current momen
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The CO2 emission factor which indic
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The CO2 emission factor calculated
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Appendix A Fig A.1. Simulation mode
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(b) Fig. A.2. Simulation model of C
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Table A.1. Calculated parameters at
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References [1] Pfaff I., Oexmann J.
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with a CC installation could be avo
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2.3. Basic CHP plant indices. The b
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3. Off-design calculations The main
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Fig. 6. CHP plant efficiency Fig. 7
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amount of steam delivered to the he
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[5] Lukowicz H., Mroncz M.: Analysi
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water removal is feasible by coolin
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Figure 2. Sketch of the suggested P
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a b Figure 5. a) Exergy balance of
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The basis of comparison of each met
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Figure 7a. Impact of S/CATR on PCU
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However, more energy duty is requir
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3.1. JACOBIAN-ASPEN Interface ASPEN
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Fig. 3. Triple Pressure Bottoming S
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As seen from Table 1, the mass flow
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4. Conclusion Fig. 5. Partial Emiss
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[19] Yantovski E., Shokotov M., Sho
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investigation and the developing of
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University of L’Aquila and German
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hydrogen combustion technology at d
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eversibility of a pre-treated synth
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Fig. 1. TG curves collected for spe
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(see Fig 5). Carbon dioxide uptake
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period is reduced to the first 15 c
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CO2 capture capacity up to 150 th c
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the way for biogas utilisation is t
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projectand is described in the foll
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4. Pilot plant tests In order to de
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Concerning the absorption reaction,
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with Regeneration (AwR), consists i
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[25] Aspen Plus 2004.1. Cambridge,
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systems for fuel drying waste strea
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heated in a heat exchanger placed i
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Fig. 2. Lower heating value of fuel
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Acknowledgements The results presen
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large amount of CO2 [1,5-7]. APCr a
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N 1 i ( x x i n 1 m ) 2.3. Carbon
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DTA analysis of the untreated APCrs
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Table 4. Relative Error (%) of the
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CaO HCl CaCl H O 193kJ / mol (
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[1] M. Fernández Bertos, S.J.R. Si
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2. Process development 2.1. Backgro
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to dissolve the chloride salts prec
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The remaining 25% (5 ml/min) of the
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Table 6. Experimental conversions o
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p p 1 1. 5 p H 1 1. 5 2O p mi
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Calculating from the Aspen Plus mod
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[11] Mattila, H.-P., Experimental s
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Mg2SiO4(s) + 2CO2(g) →2MgCO3(s) +
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(Mg/Fe) of the mineral rock, Mg-sil
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Figure 2. Effect of Mg/Fe ratio of
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Page 275 and 276: Table A2. Extraction equations and
Page 277 and 278: [13] Teir S, Kuusik R, Fogelholm CJ
Page 279 and 280: In the area of coal technologies al
Page 281 and 282: Tabel 1. Characteristics quantities
Page 283 and 284: N m eT 4a ~ T cp T4a 1 ( K
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Page 291 and 292: 2. Numerical model The purpose of t
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Page 305 and 306: Table 5. Key data for the four ener
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Page 337 and 338: In the presented paper a framework
Page 339 and 340: [5] Erdil E, Ilkan M, Egelioglu F.
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Page 343 and 344: district energy network simulation
Page 345 and 346: were decreased by 10°C.All scenari
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Page 349 and 350: 3.2.2. Input data and assumptions A
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Page 353 and 354: [13] TERMIS Operation User Guide, 7
Page 355 and 356: Polygeneration is a term used to de
Page 357 and 358: The increase in energy utilization
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Page 361 and 362: 6. Extensions to core methodology 6
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Page 367 and 368: Abstract: PROCEEDINGS OF ECOS 2012
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gasification [15], hybrid biomass g
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the second reactor. In this unit, s
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The variables effect was evaluated
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atio, as well as the shift-syngas f
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Fig. 4. Effect of operating tempera
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SDG has slight effect on the syngas
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[26.] Castle WF. Air separation and
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1. Introduction - Firenze University Press

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