Search Results (108)

The increasing demand for hydrogen has made it a promising alternative for decarbonizing industries and reducing CO₂ emissions. Although mainly produced through the gray pathway, the integration of carbon capture and storage (CCS) reduces the CO₂ emissions. This study presents a sustainability method that uses flare gas for hydrogen production through steam methane reforming (SMR) with CCS, supported by a techno-economic analysis. Data Envelopment Analysis (DEA) was used to evaluate the oil company’s efficiency, and inverse DEA/sensitivity analysis identified maximum flare gas reduction, which was modeled in Aspen HYSYS V14. Subsequently, an economic evaluation was performed to determine the levelized cost of hydrogen (LCOH) and the cost–benefit ratio (CBR) for Nigeria. The CBR results were 2.15 (payback of 4.11 years with carbon credit) and 1.96 (payback of 4.55 years without carbon credit), indicating strong economic feasibility. These findings promote a practical approach for waste reduction, aiding Nigeria’s transition to a circular, low-carbon economy, and demonstrate a positive relationship between lean and green strategies in the petroleum sector. Full article

Based on the medium-pressure natural gas ethane recovery and helium extraction process, this paper proposes three different refrigerant Schemes. Thermodynamic analysis and adaptability evaluation of the three Schemes were conducted using Aspen HYSYS V12 software. The ethylene–propane cascade refrigeration Scheme demonstrated superior energy efficiency in terms of comprehensive energy consumption, heat exchange performance in the cryogenic cold box, and exergy analysis. Adaptability analysis indicated that this Scheme exhibits strong tolerance to variations in feed gas temperature as well as N₂ and CO₂ content. The ethylene–propane cascade refrigeration process demonstrates significant energy-saving advantages and exhibits robust operational performance. Full article

Blue hydrogen is a key pathway for reducing greenhouse gas emissions while utilizing natural gas with carbon capture and storage (CCS). This study conducts a techno-economic and environmental analysis of a greenfield blue hydrogen plant in Saskatchewan, Canada, integrating both SMR and ATR technologies. Unlike previous studies that focus mainly on production units, this research includes all process and utility systems such as H₂ and CO₂ compression, air separation, refrigeration, co-generation, and gas dehydration. Aspen HYSYS simulations revealed ATR’s energy demand is 10% lower than that of SMR. The hydrogen production cost was USD 3.28/kg for ATR and USD 3.33/kg for SMR, while a separate study estimated a USD 2.2/kg cost for design without utilities, highlighting the impact of indirect costs. Environmental analysis showed ATR’s lower Global Warming Potential (GWP) compared to SMR, reducing its carbon footprint. The results signified the role of utility integration, site conditions, and process selection in optimizing energy efficiency, costs, and sustainability. Full article

Gas turbines are widely used in power generation due to their reliability, flexibility, and high efficiency. As the energy sector transitions towards low-carbon alternatives, hydrogen and ammonia are emerging as promising fuels. This study investigates the thermodynamic and combustion performance of a GE LM6000 gas turbine fueled by methane/hydrogen and methane/ammonia fuel blends under varying levels of oxygen enrichment (21%, 30%, and 40% $O_2$ by volume). Steady-state thermodynamic simulations were conducted using Aspen HYSYS, and combustion modeling was performed using ANSYS Chemkin-Pro, assuming a constant thermal input of 102 MW. Results show that increasing hydrogen content significantly raises flame temperature and burning velocity, whereas ammonia reduces both due to its lower reactivity. Net power output and thermal efficiency improved with higher fuel substitution, peaking at 43.46 MW and 42.7% for 100% $N{H}_3$. However, $N{O}_{\mathrm{x}}$ emissions increased with higher hydrogen content and oxygen enrichment, while $N{H}_3$ blends exhibit more complex emission trends. The findings highlight the trade-offs between efficiency and emissions in future low-carbon gas turbine systems. Full article

This paper presents an exergy analysis of a 500 MW unit based on actual measurement data. The mathematical model of the system was built in the Aspen HYSYS 2.4 software. The analysis was carried out for two operating states of the unit, at nominal load and at minimum technical load, based on data from two measurement campaigns carried out specifically for this study. The use of measurement data allows an accurate representation of the unit’s current operating conditions, which is crucial for the accuracy of the analysis and the practical implementation of the results obtained. The results show that the dominant sources of exergy losses are the irreversibilities associated with combustion and boiler heat transfer, which account for more than 60% of total exergy losses. The article makes an important contribution to sustainability by identifying opportunities to increase the operating efficiency of the power unit and reduce CO₂ emissions. Proposed technical modifications, such as the modernisation of air heaters, the use of inverters in ventilation systems, or the optimisation of heat exchangers in the turbine system, can significantly improve energy efficiency and reduce the unit’s environmental impact. The analysis provides a valuable resource for the development of energy technologies that promote efficiency and sustainable resource use. Full article

The increasing global demand for clean energy and sustainable industrial processes necessitates innovative approaches to energy production and chemical synthesis. This study proposed and simulated an innovative integrated system for the co-production of power, hydrogen, and dimethyl ether (DME), combining the high-efficiency Allam–Fetvedt cycle with co-electrolysis and indirect DME synthesis. The Allam–Fetvedt cycle generated electricity while capturing CO₂, which, along with water, was used in solid oxide electrolyzers (SOEs) to produce syngas via co-electrolysis. The resulting syngas was converted to methanol and subsequently to DME. Aspen HYSYS was used to model and simulate the process, and heat/mass integration strategies were implemented to reduce energy demand and optimize resource utilization. The proposed integrated process enabled an annual production of 980,021 metric tons of DME, 189,435 metric tons of hydrogen, and 7698.27 metric tons of methanol. The energy efficiency of the Allam–Fetvedt cycle reached 55%, and heat integration reduced the system’s net energy demand by 14.22%. Despite the high energy needs of the electrolyzer system (81.28% of net energy), the overall energy requirement remained competitive with conventional methods. Carbon emissions per kilogram of DME were reduced from 1.16 to 0.77 kg CO₂ through heat integration and can be further minimized to 0.0308 kg CO₂/kg DME (near zero) with renewable electrification. Results demonstrated that 96% of CO₂ was recycled within the Allam–Fetvedt cycle, and the rest (the 4% of CO₂) was captured and converted to syngas, achieving net-zero carbon emissions. This work presents a scalable and sustainable pathway for integrated clean energy and chemical production, advancing toward industrial net-zero targets. Full article

Hydrogen (H₂) liquefaction is an energy-intensive process, and improving its efficiency is critical for large-scale deployment in H₂ infrastructure. Industrial waste heat recovery contributes to energy savings and environmental improvements in liquid H₂ processes. This study proposes a comparative framework for industrial waste heat recovery in H₂ liquefaction systems by examining three recovery cycles, including an ammonia–water absorption refrigeration (ABR) unit, a diffusion absorption refrigeration (DAR) process, and a combined organic Rankine/Kalina plant. All scenarios incorporate 2 MW of industrial waste heat to improve precooling and reduce the external power demand. The simulations were conducted using Aspen HYSYS (V10) in combination with an m-file code in MATLAB (R2022b) programming to model each configuration under consistent operating conditions. Detailed energy and exergy analyses are performed to assess performance. Among the three scenarios, the ORC/Kalina-based system achieves the lowest specific power consumption (4.306 kWh/kg LH₂) and the highest exergy efficiency in the precooling unit (70.84%), making it the most energy-efficient solution. Although the DAR-based system shows slightly lower performance, the ABR-based system achieves the highest exergy efficiency of 52.47%, despite its reduced energy efficiency. By comparing three innovative configurations using the same industrial waste heat input, this work provides a valuable tool for selecting the most suitable design based on either energy performance or thermodynamic efficiency. The proposed methodology can serve as a foundation for future system optimization and scale-up. Full article

The cryogenic supercritical hydrogen storage system offers notable advantages including heightened hydrogen storage density and operation under relatively moderate conditions compared to conventional hydrogen storage methodologies. In this study, a cryogenic supercritical hydrogen storage system based on the multi-stage Joule–Brayton refrigeration cycle is presented, analyzed, and optimized. The proposed system employs a five-stage cascade cycle, each stage utilizes a distinct refrigerant, including propane, ethylene, methane, and hydrogen, facilitated by Joule–Brayton cycles, with expanders employed for mechanical work recovery, which is capable of effectively cooling hydrogen from ambient temperature and atmospheric pressure to a cryogenic supercritical state of −223.15 °C (50 K), 18,000 kPa, exhibiting a density of 73.46 kg/m³ and a hydrogen processing capacity of 2 kg_H2/s. The genetic algorithm is applied to optimize 25 key parameters in the system, encompassing temperature, pressure, and flow rate, with the objective function is specific energy consumption. Consequently, the specific energy consumption of the system is 5.71 kWh/kg_H2 with an exergy efficiency of 56.2%. Comprehensive energy analysis, heat transfer analysis, and exergy analysis are conducted based on the optimized system parameters, yielding insights crucial for the development of medium- and large-scale supercritical hydrogen storage systems. Full article

In coal chemical industries, the optimal allocation of gas and steam is crucial for enhancing production efficiency and maximizing economic returns. This paper proposes an optimal scheduling method using operating zone models and entropy weights for an energy system in a gas-to-methanol process. The first step is to develop mechanistic models for the main facilities in methanol production, namely desulfurization, air separation, syngas compressors, and steam boilers. A genetic algorithm is employed to estimate the unknown parameters of the models. These models are grounded in physical mechanisms such as energy conservation, mass conservation, and thermodynamic laws. A multi-objective optimization problem is formulated, with the objectives of minimizing gas loss, steam loss, and operating costs. The required operating constraints include equipment capacities, energy balance, and energy coupling relationships. The entropy weights are then employed to convert this problem into a single-objective optimization problem. The second step is to solve the optimization problem based on an operating zone model, which describes a high-dimensional geometric space consisting of all steady-state data points that satisfy the operation constraints. By projecting the operating zone model on the decision variable plane, an optimal scheduling solution is obtained in a visual manner with contour lines and auxiliary lines. Case studies based on Aspen Hysys are used to support and validate the effectiveness of the proposed method. Full article

The Indonesian government has established an energy transition policy for decarbonization, including the target of utilizing hydrogen for power generation through a co-firing scheme. Several studies indicate that hydrogen co-firing in gas-fired power plants can reduce CO₂ emissions while improving efficiency. This study develops a simulation model for hydrogen co-firing in an M701F gas turbine at the Cilegon power plant using Aspen HYSYS. The impact of different hydrogen volume fractions (5–30%) on thermal efficiency and CO₂ emissions is analyzed under varying operational loads (100%, 75%, and 50%). The simulation results show an increase in thermal efficiency with each 5% increment in the hydrogen fraction, averaging 0.32% at 100% load, 0.34% at 75% load, and 0.37% at 50% load. The hourly CO₂ emission rate decreased by an average of 2.16% across all operational load variations for every 5% increase in the hydrogen fraction. Meanwhile, the average reduction in CO₂ emission intensity at the 100%, 75%, and 50% operational loads was 0.017, 0.019, and 0.023 kg CO₂/kWh, respectively. Full article

The vaporization of liquefied natural gas (LNG) liberates a substantial quantity of cold energy. If left unutilized, this cold energy would cause significant energy waste. Currently, both domestic and international cold energy utilization strategies are rather simplistic and unable to fully capitalize on the wide temperature range feature inherent in LNG cold energy. This study presents a three-tiered cold energy utilization system that integrates liquid air energy storage (LAES), cold energy power generation, and cold energy air conditioning. Moreover, during the LNG vaporization process, the thermal discharge from the power plant is utilized as a heat source to boost energy utilization efficiency and environmental performance. This research develops thermodynamic and economic evaluation models for the coupled system. It uses Aspen HYSYS V14 software to conduct process simulation, analyze cycle efficiency and exergy efficiency, and assesses the system’s economic feasibility by applying the net present value (NPV) method, which is based on the regional electricity prices of an LNG receiving station in Tangshan. The results show that the system attains a cycle efficiency of 105.83% and an exergy efficiency of 55.89%, representing a 6.18% improvement over traditional LAES systems. The system yields an annual revenue of CNY 77.06 million, with a net present value (NPV) of CNY 566.41 million and a capital payback period of merely 2.53 years, demonstrating excellent economic feasibility. This study offers crucial references and a foundation for the engineering application of LNG cold energy in energy storage and power plant peak regulation. Full article

With the global shift to sustainability, the energy sector faces pressure to adopt low-carbon solutions. Blue ammonia (BA), derived from natural gas (NG) with carbon capture, presents significant opportunities but requires a holistic sustainability assessment. This study conducts a novel life cycle sustainability assessment (LCSA) of BA, evaluating environmental, economic, and social impact performance from feedstock processing to maritime transport for a 1.2 MMTPA production capacity. Process simulations in Aspen HYSYS V12 and the ammonia maritime transport operations’ sustainability assessment model provide critical insights. The ammonia converter unit contributes the highest emissions (17.9 million tons CO₂-eq), energy use (963.2 TJ), and operational costs (USD 189.2 million). CO₂ removal has the most considerable land use (141.7 km²), and purification records the highest water withdrawal (14.8 million m³). Carbon capture eliminates 6.5 million tons of CO₂ annually. Economically, ammonia shipping dominates gross surplus (USD 653.9 million, 72%) and tax revenue (USD 65.3 million) despite employing just 43 workers. Socially, the ammonia converter unit has the highest human health impact (16,621 DALY, 54%). Sensitivity analysis reveals transport distance (46.5% CO₂ emissions) and LNG fuel prices (63.8% costs) as key uncertainties. Findings underscore the need for optimized logistics and alternative fuels to enhance BA sustainability. Full article

To address the challenges and risks associated with the declining crude yield, an optimization project for the surface production facilities at ZY Oilfield is underway. Upon the completion of this project, the oilfield’s export pipelines will transport water-containing live crude oil. To ensure pipeline transportation safety, it is essential to clarify the phase behaviors and flow state of water-containing live oil. For this purpose, the VLLE characteristics of water-containing live oil were analyzed with Aspen HYSYS V12 software and validated through PVT tests. Additionally, the pressure variations in multiphase flow pipelines under different operating conditions were calculated using the Beggs and Brill–Moody–Eaton method with Pipephase 9.6 software. The results indicated that the bubble point pressure and vapor fraction of water-containing live oil were higher than those of dehydrated dead crude within the operating temperature range. Liquid–gas flow was likely to occur in the presence of low soil temperatures, low oil output, low outlet pressure, high outlet temperatures, or small water fractions, particularly at the pipeline ends. Moreover, the optimized technological processes for stations and pipeline operations were proposed. The findings offer a new approach for the safe transportation of low-output live oil and provide valuable insights for optimizing surface production in aging oilfields. Full article

A challenge for the oil refinement industry is the production of high-octane gasoline with a low benzene content. This work reports the calculation of the atmospheric benzene emissions generated from gasoline storage, transfer, and transport operations in Mexico, estimating 1.48 KBPD of environmental release. The aim was to estimate the minimum benzene emissions through operative improvements in refineries, initially by performing simulations of the Naphtha Catalytic Reforming (NCR) process using ASPEN HYSYS^® ver. 8.8 (34.0.08909) and then by optimizing the operative conditions to improve the reformate quality while reducing the benzene content. The operative ranges comprised hydrogen/hydrocarbon (H₂/HC) feedstock molar ratios from 2.0 to 6.0 and reaction temperatures from 450 to 525 °C, which were used as independent variables to assess the benzene content and the Research Octane Number (RON) of the produced gasoline. The Surface Response Method (SRM) and multi-objective optimization analysis were applied. The improved operative conditions were 491 °C and a H₂/HC ratio of 2.0, which allowed us to obtain a RON value of 89.87, an aromatics value of 37.39% (v/v), and a benzene value of 1.48% (v/v), with an estimated 16.44% drop in atmospheric benzene emissions, meaning a reduction in greenhouse gas emissions and climate change, thus favorably impacting public health by improving refinery operations. The simulation outcomes were compared with industrial-scale data and the experimental results, with significant similitudes being observed. Full article

As an important part of industrial production, the optimization of circulating water systems is of great significance for improving energy efficiency and reducing operating costs. However, traditional optimization methods lack real-time and dynamic adjustment capabilities and often cannot fully cope with the complex and changeable industrial environment and energy demands. Advances in computer technology can enable people to use machine learning models to process information and data and ultimately help simplify simulation and optimization. In this paper, the circulating water system of a Fluid Catalytic Cracking (FCC) unit is optimized and evaluated based on process simulation and machine learning, adopting 284 sets of industrial operating data. The cooler network of the system is modified from a parallel structure to a series mode, and the effect is clarified using the ASPEN HYSYS software V12. Meanwhile, the fan power of the cooling tower is predicted by employing an optimized Gradient Boosting Regression (GBR) model, and the influence of the parallel-to-series transformation on the fan power is discussed. It is shown that the computer modeling results are in coincidence with the industrial data. Converting the parallel design to a series arrangement of the cooler network can significantly decrease the water consumption, with a reduction of 11%. The fan power of the cooling tower is also reduced by 8% after the optimization. Considering the changes in both water consumption and fan power, the saved total economic cost is 8.65%, and the decreased gas emission is 2142.06 kg/h. By building the optimization prediction system, the real-time sequencing and monitoring of equipment parameters are realized, which saves costs and improves process safety. Full article