Modeling and Performance Evaluation of Branch and Looped Steam Pipeline Networks

• Published in: Process integration and optimization for sustainability 2024-05, Vol.8 (2), p.423-438
• Main Authors: Ong, Chong Wei, Chen, Shao-Chiu, Cheng, Hsiang-Hsuan, Tsai, Meng-Lin, Chen, Cheng-Liang
• Format: Article
• Language: English
• Subjects: Algorithms; Boilers; Case studies; Design; Economics and Management; Energy consumption; Energy efficiency; Energy loss; Energy Policy; Engineering; Environmental impact; Flow rates; Industrial and Production Engineering; Industrial Chemistry/Chemical Engineering; Maintenance; Mathematical models; Methods; Network topologies; Networks; Optimization; Original Research Paper; Performance evaluation; Pipelines; Pipes; Pressure; Pressure distribution; Pressure drop; Refineries; Simulation; Steam pipes; Sustainable Development; Sustainable energy; Temperature distribution; Waste Management/Waste Technology
• ISSN: 2509-4238; 2509-4246
• DOI: 10.1007/s41660-023-00354-7

The increasing energy consumption of the industrial sector necessitates the adoption of sustainable energy practices, and steam pipeline networks provide an opportunity to improve energy efficiency while reducing environmental impact. This study evaluates the performance of branch and looped steam pipeline networks and investigates the impact of adding pipelines to branch networks, forming looped networks. A practical branch medium-pressure steam pipeline network in an operating oil refinery plant is examined, considering 16 steam users (U1–U16) and 3 boilers (S1–S3). The modified Hardy Cross model accurately simulates temperature and pressure distribution, and condensate rate and flow rate within the network. This research considers both normal and boiler maintenance conditions, enhancing the system’s robustness. Considering the limitations of modifying the existing onsite system, this research proposes various feasible design scenarios that do not rely on typical optimization algorithms. Four loop designs are proposed to mitigate temperature and pressure drops during boiler 1 (S1) maintenance, with the extended U8+50 m loop design proving the most effective in controlling the pressure and temperature distribution without condensation. Similarly, for the boiler 3 (S3) maintenance case, three loop designs are proposed, with the U12+U16 loop design identified as optimal for maintaining pressure and temperature without condensation. The findings demonstrate that loop designs reduce pressure drop, minimizing energy loss and promoting optimal and sustainable steam transport practices.