Heat integration of an Olefins Plant: Pinch Analysis and mathematical optimization working together

Abstract

This work explores a two-step, complexity reducing methodology, to analyze heat integration opportunities of an existing Olefins Plant, identify and quantify reduction of energy consumption, and propose changes of the existing heat exchanger network to achieve these goals. Besides the analysis of plant design conditions, multiple operational scenarios were considered to propose modifications for handling real plant operation (flexibility). On the strength of plant complexity and large dimension, work methodology was split into two parts: initially, the whole plant was evaluated with traditional Pinch Analysis tools. Several opportunities were identified and modifications proposed. Modifications were segregated to represent small and independent portions of the original process. One of them was selected to be re-analyzed, considering two scenarios. Reduction of problem dimension allowed mathematical methodologies (formulation with decomposition, applying LP, MILP and NLP optimization methods) to synthesize flexible networks to be applied, generating a feasible modification capable of fulfilling the proposed operational scenarios.