Methods and systems for electrifying, decarbonizing, and reducing energy demand and process carbon intensity in industrial processes via integrated vapor compression
This disclosure provides systems and methods that utilize integrated mechanical vapor or thermal vapor compression to upgrade process vapors and condense them to recover the heat of condensation across multiple processes, wherein the total process energy is reduced. Existing processes that are unable to recover the heat of condensation in vapors are integrated with mechanical or thermal compressors that raise vapor pressures and temperatures sufficient to permit reuse. Integrating multiple processes permits vapor upgrading that can selectively optimize energy efficiency, environmental sustainability, process economics, or a prioritized blend of such goals. Mechanical or thermal vapor compression also alters the type of energy required in industrial processes, favoring electro-mechanical energy which can be supplied from low-carbon, renewable sources rather than combustion of carbonaceous fuels.
1. A method for electrifying, decarbonizing, and reducing energy requirements in a refinery, wherein said method comprises introducing multiple vapor compression sub-systems within said refinery, wherein said multiple vapor compression sub-systems comprise multiple mechanical compressors, thermal compressors, and/or vapor jets, and wherein said refinery comprises multiple vapor-processing units that are energy-integrated with said multiple vapor compression sub-systems such that (a) a first vapor stream from a first vapor-processing unit is compressed using a first vapor compression sub-system to generate a compressed first vapor stream; (b) said compressed first vapor stream is condensed to generate a first amount of condensation heat (c) said first amount of condensation heat is heat-exchanged with a second vapor-processing unit within said refinery; (d) a second vapor stream from a second vapor-processing unit is compressed using a second vapor compression sub-system to generate a compressed second vapor stream; (e) said compressed second vapor stream is condensed to generate a second amount of condensation heat and (f) said second amount of condensation heat is heat-exchanged with said first vapor-processing unit and/or with at least one distinct unit, within said refinery, that is not said first vapor-processing unit or said second vapor-processing unit.
2. The method of claim 1 , wherein said multiple vapor compression sub-systems include at least three vapor compression sub-systems.
3. The method of claim 1 , wherein said multiple vapor compression sub-systems include a mechanical vapor recompression unit.
4. The method of claim 1 , wherein said multiple vapor compression sub-systems include a thermal vapor recompression unit.
5. The method of claim 1 , wherein at least one of said vapor-processing units is a distillation unit.
6. The method of claim 1 , wherein at least one of said vapor-processing units is a stripping unit.
7. The method of claim 1 , wherein at least one of said vapor-processing units is an evaporator.
8. The method of claim 1 , wherein at least one of said vapor-processing units is a multiple-effect evaporator.
9. The method of claim 1 , wherein at least one of said vapor-processing units is a molecular-sieve unit.
10. The method of claim 1 , wherein at least one of said vapor-processing units is a chemical reactor.
11. The method of claim 10 , wherein said chemical reactor is configured for a chemical reaction selected from the group consisting of oxidation, reduction, hydrolysis, condensation, transesterification, oligomerization, polymerization, crystallization, isomerization, reforming, cracking, dehydrosulfurization, hydrotreating, alkylation, hydrogenation, dehydrogenation, dehydration (olefin formation), cyclicization, coking, catalyst regeneration, and combinations thereof.
12. The method of claim 1 , wherein cascaded heat to or from said multiple vapor-processing units is integrated with at least one distinct unit within said refinery, and wherein compressed process vapors and optionally generated steam are returned to said first vapor-processing unit.
13. The method of claim 1 , wherein at least one of said multiple compressors, thermal compressors, and/or vapor jets is configured to cascade heat to or from a refinery unit that carries out a chemical reaction.
14. The method of claim 13 , wherein said chemical reaction is selected from the group consisting of oxidation, reduction, hydrolysis, condensation, transesterification, oligomerization, polymerization, crystallization, isomerization, reforming, cracking, dehydrosulfurization, hydrotreating, alkylation, hydrogenation, dehydrogenation, dehydration (olefin formation), cyclicization, coking, catalyst regeneration, and combinations thereof.
15. The method of claim 1 , wherein at least one of said multiple mechanical compressors, thermal compressors, and/or vapor jets is configured to cascade heat to or from a refinery unit that carries out a thermal separation.
16. The method of claim 1 , wherein at least one of said multiple mechanical compressors, thermal compressors, and/or vapor jets is configured to cascade heat to or from a refinery unit that carries out a fuel or chemical storage operation.
17. The method of claim 1 , wherein at least one of said vapor-processing units is configured to process a vapor comprising a refinery intermediate or product, and wherein at least one of said vapor compression sub-systems is configured to compress a heat-exchange medium that is out-of-contact with said vapor.
18. The method of claim 1 , wherein said refinery is selected from the group consisting of biorefineries, petroleum refineries, petrochemical plants, natural gas refineries, shale oil refineries, coal-derived product refineries, and syngas-derived product plants.