Energy costs impact the profitability of virtually all industrial processes. Stressing how plants use power, and how that power is actually generated, this book provides a clear and simple way to understand the energy usage in various processes, as well as methods for optimizing these processes using practical hands-on simulations and a unique approach that details solved problems utilizing actual plant data. Invaluable information offers a complete energy-saving approach essential for both the chemical and mechanical engineering curricula, as well as for practicing engineers.

Preface xiiiConversion Factors xviiList of Symbols xix1. Introduction to Energy Usage, Cost, and Efficiency 11.1 Energy Utilization in the United States 11.2 The Cost of Energy 11.3 Energy Efficiency 41.4 The Cost of Self-Generated versus Purchased Electricity 101.5 The Cost of Fuel and Fuel Heating Value 111.6 Text Organization 121.7 Getting Started 151.8 Closing Comments 16References 16Problems 172. Engineering Economics with VBA Procedures 192.1 Introduction to Engineering Economics 192.2 The Time Value of Money: Present Value (PV) and Future Value (FV) 192.3 Annuities 222.4 Comparing Process Alternatives 292.5 Plant Design Economics 332.6 Formulating Economics-Based Energy Optimization Problems 342.7 Economic Analysis with Uncertainty: Monte Carlo Simulation 362.8 Closing Comments 38References 39Problems 393. Computer-Aided Solutions of Process Material Balances: The Sequential Modular Solution Approach 423.1 Elementary Material Balance Modules 423.2 Sequential Modular Approach: Material Balances with Recycle 463.3 Understanding Tear Stream Iteration Methods 493.4 Material Balance Problems with Alternative Specifications 583.5 Single-Variable Optimization Problems 613.6 Material Balance Problems with Local Nonlinear Specifications 663.7 Closing Comments 68References 69Problems 704. Computer-Aided Solutions of Process Material Balances: The Simultaneous Solution Approach 764.1 Solution of Linear Equation Sets: The Simultaneous Approach 764.2 Solution of Nonlinear Equation Sets: The Newton-Raphson Method 82References 92Problems 935. Process Energy Balances 985.1 Introduction 985.2 Separator: Equilibrium Flash 1015.3 Equilibrium Flash with Recycle: Simultaneous Approach 1095.4 Adiabatic Plug Flow Reactor (PFR) Material and Energy Balances Including Rate Expressions: Euler's First-Order Method 1125.5 Styrene Process: Material and Energy Balances with Reaction Rate 1175.6 Euler's Method versus Fourth-Order Runge-Kutta Method for Numerical Integration 1215.7 Closing Comments 124References 125Problems 1256. Introduction to Data Reconciliation and Gross Error Detection 1326.1 Standard Deviation and Probability Density Functions 1336.2 Data Reconciliation: Excel Solver 1366.3 Data Reconciliation: Redundancy and Variable Types 1386.4 Data Reconciliation: Linear and Nonlinear Material and Energy Balances 1436.5 Data Reconciliation: Lagrange Multipliers 1496.6 Gross Error Detection and Identification 1546.7 Closing Remarks 158References 158Problems 1587. Gas Turbine Cogeneration System Performance, Design, and Off-Design Calculations: Ideal Gas Fluid Properties 1647.1 Equilibrium State of a Simple Compressible Fluid: Development of the T ds Equations 1657.2 General Energy Balance Equation for an Open System 1677.3 Cogeneration Turbine System Performance Calculations: Ideal Gas Working Fluid 1677.4 Air Basic Gas Turbine Performance Calculations 1697.5 Energy Balance for the Combustion Chamber 1727.6 The HRSG: Design Performance Calculations 1737.7 Gas Turbine Cogeneration System Performance with Design HRSG 1777.8 HRSG Off-Design Calculations: Supplemental Firing 1807.9 Gas Turbine Design and Off-Design Performance 1857.10 Closing Remarks 193References 194Problems 1948. Development of a Physical Properties Program for Cogeneration Calculations 1988.1 Available Function Calls for Cogeneration Calculations 1988.2 Pure Species Thermodynamic Properties 2028.3 Derivation of Working Equations for Pure Species Thermodynamic Properties 2078.4 Ideal Mixture Thermodynamic Properties: General Development and Combustion Reaction Considerations 2098.5 Ideal Mixture Thermodynamic Properties: Apparent Difficulties 2118.6 Mixing Rules for EOS 2138.7 Closing Remarks 215References 216Problems 2169. Gas Turbine Cogeneration System Performance, Design, and Off-Design Calculations: Real Fluid Properties 2229.1 Cogeneration Gas Turbine System Performance Calculations: Real Physical Properties 2239.2 HRSG: Design Performance Calculations 2309.3 HRSG Off-Design Calculations: Supplemental Firing 2329.4 Gas Turbine Design and Off-Design Performance 2359.5 Closing Remarks 237References 238Problems 23810. Gas Turbine Cogeneration System Economic Design Optimization and Heat Recovery Steam Generator Numerical Analysis 24310.1 Cogeneration System: Economy of Scale 24410.2 Cogeneration System Confi guration: Site Power-to-Heat Ratio 24410.3 Economic Optimization of a Cogeneration System: The CGAM Problem 24510.4 Economic Design Optimization of the CGAM Problem: Ideal Gas 24910.5 The CGAM Cogeneration Design Problem: Real Physical Properties 25010.6 Comparing CogenD and General Electric's GateCycle(TM) 25310.7 Numerical Solution of HRSG Heat Transfer Problems 25410.8 Closing Remarks 266References 267Problems 26711. Data Reconciliation and Gross Error Detection in a Cogeneration System 27211.1 Cogeneration System Data Reconciliation 27211.2 Cogeneration System Gross Error Detection and Identification 27811.3 Visual Display of Results 28111.4 Closing Comments 281References 282Problems 28312. Optimal Power Dispatch in a Cogeneration Facility 28412.1 Developing the Optimal Dispatch Model 28412.2 Overview of the Cogeneration System 28612.3 General Operating Strategy Considerations 28712.4 Equipment Energy Efficiency 28712.5 Predicting the Cost of Natural Gas and Purchased Electricity 29812.6 Development of a Multiperiod Dispatch Model for the Cogeneration Facility 30212.7 Closing Comments 309References 310Problems 31013. Process Energy Integration 31413.1 Introduction to Process Energy Integration/Minimum Utilities 31413.2 Temperature Interval/Problem Table Analysis with 0° Approach Temperature 31613.3 The Grand Composite Curve (GCC) 31713.4 Temperature Interval/Problem Table Analysis with "Real" Approach Temperature 31813.5 Determining Hot and Cold Stream from the Process Flow Sheet 31913.6 Heat Exchanger Network Design with Maximum Energy Recovery (MER) 32413.7 Heat Exchanger Network Design with Stream Splitting 32813.8 Heat Exchanger Network Design with Minimum Number of Units (MNU) 32913.9 Software for Teaching the Basics of Heat Exchanger Network Design (Teaching Heat Exchanger Networks (THEN)) 33113.10 Heat Exchanger Network Design: Distillation Columns 33113.11 Closing Remarks 336References 336Problems 33714. Process and Site Utility Integration 34314.1 Gas Turbine-Based Cogeneration Utility System for a Processing Plant 34314.2 Steam Turbine-Based Utility System for a Processing Plant 35314.3 Site-Wide Utility System Considerations 35614.4 Closing Remarks 362References 363Problems 36315. Site Utility Emissions 36815.1 Emissions from Stoichiometric Considerations 36915.2 Emissions from Combustion Equilibrium Calculations 37015.3 Emission Prediction Using Elementary Kinetics Rate Expressions 38015.4 Models for Predicting Emissions from Gas Turbine Combustors 38215.5 Closing Remarks 393References 393CVODE Tutorial 393Problems 39416. Coal-Fired Conventional Utility Plants with CO2 Capture (Design and Off-Design Steam Turbine Performance) 39716.1 Power Plant Design Performance (Using Operational Data for Full-Load Operation) 39816.2 Power Plant Off-Design Performance (Part Load with Throttling Control Operation) 40616.3 Levelized Economics for Utility Pricing 40916.4 CO2 Capture and Its Impact on a Conventional Utility Power Plant 41316.5 Closing Comments 414References 417Problems 41717. Alternative Energy Systems 41917.1 Levelized Costs for Alternative Energy Systems 41917.2 Organic Rankine Cycle (ORC): Determination of Levelized Cost 42017.3 Nuclear Power Cycle 425References 427Problems 427Appendix. Bridging Excel and C Codes 429A.1 Introduction 429A.2 Working with Functions 431A.3 Working with Vectors 434A.4 Working with Matrices 442A.5 Closing Comments 446References 448Tutorial 448Microsoft C++ 2008 Express: Creating C Programs and DLLs 448Index 458