"The FURNAC initiative optimises heat recovery and power generation in the chemical industry"
The FURNAC initiative optimises heat recovery and energy generation in the chemical industry to foster progress towards decarbonisation
FURNAC is developing a smart strategy for the global optimisation of the process in order to maximise the economic value of the heat generated. The solution enables process behaviour and its interactions to be understood and predicted, facilitating real-time decision-making to optimise operating conditions, maximise heat recovery and power generation, whilst ensuring compliance with environmental emissions limits.
The chemical industry generates large amounts of heat which can be used through the production of high-pressure steam and its subsequent conversion into electricity.
However, maximising this power generation poses a challenge due to the complex interdependence between the plant’s various stages, where even small variations can affect overall performance and make it difficult to predict and optimise energy efficiency by means of local control systems.
A more accurate insight into industrial processes
TECNALIA has developed a Decision Support System which integrates advanced models capable of jointly analysing the plant’s operational and contextual information, anticipating its behaviour and converting the data into useful recommendations for operators in order to maximise heat recovery and power generation without compromising emissions or process stability.
- Sulphuric acid production requires maintaining a delicate balance between energy efficiency, process stability and environmental compliance. The complex interaction between the various stages of the process, from sulphur combustion and catalytic conversion to heat recovery and the generation of steam and electricity, means that even small variations in operating conditions may affect the plant’s overall performance.
- External factors, such as temperature and humidity, and internal factors, such as the progressive ageing of the catalysts, which alter the behaviour of the process and make it difficult to identify the optimum operating conditions, can be added to this complexity.
A virtual environment to anticipate and optimise plant performance
The virtual environment incorporates specialised models that represent the plant’s main processes, ranging from sulphur combustion and heat recovery to catalytic oxidation, air drying and emissions estimation. This overview enables the interactions between the various processes to be analysed and how changes in operating conditions may affect the plant’s overall performance may be anticipated.
- One of the most significant developments is the ability to predict the behaviour and degradation of catalysts, a key factor to maintain process efficiency over time. This predictive capability anticipates deviations, enables maintenance work to be planned in advance and reduces operational risks.
- Based on this overview, the tool dynamically identifies and recommends the optimum operating conditions, adjusting critical variables such as the combustion air flow rate to favour increased steam generation, maximise energy efficiency and keep emissions within the established limits.
Increased competitiveness and more reliable recommendations
The progress made improves the profitability of chemical plants without compromising safety or compliance with environmental requirements.
- On the one hand, optimising heat recovery and use, along with advanced emissions control, contributes directly to the decarbonisation of the sector.
- On the other hand, the ability to anticipate performance losses and plan maintenance work reduces operating costs, prevents unscheduled downtime and extends the service life of equipment.
- Furthermore, the integration of physical knowledge of the processes into the models developed increases the reliability of the recommendations generated, thereby increasing safety and confidence in decision-making.
Towards a more proactive industry
FURNAC exemplifies the vision set out in The Proactive Factory, promoted by TECNALIA: industrial environments capable of understanding what is happening in their processes, anticipating deviations and facilitating smarter decision-making.
By combining advanced modelling, process knowledge and data analysis, the solution optimises power generation, reduces emissions and increases industrial competitiveness. Another step towards more environmentally friendly, connected and proactive factories, where technology becomes an ally to accelerate the transition towards a sustainable industry.