Process integration and intensification : saving energy and resources

"The authors have provided all the elements required for complete understanding of the basic concepts in heat recovery and water minimization in chemical and related processes, and followed these with carefully selected and developed problems and solutions in order to ensure that the concepts delivered can be applied." Simon Perry, The University of Manchester.

This graduate textbook covers fundamentals of the key areas of Process Integration and Intensification for intra-process heat recovery (Heat Integration), inter-process heat recovery and cogeneration (Total Site) as well as water conservation. Step by step working sessions are illustrated for deeper understanding of the taught materials.

The textbook also provides a wealth of pointers as well as further information for readers to acquire more extensive materials on the diverse industrial applications and the latest development trends in Process Integration and Intensification. It is addressed to graduate students as well as professionals to help the effectively application of Process Integration and Intensification in plant design and operation.

Author Notes

Prof. J. J. Kleme University of Pannonia, Hungary. He has a long-term research record in Process Integration, energy saving, pollution reduction, integration of renewable sources, waste to energy and sustainability issues
Prof. S. R. Wan Alwi Director of Process Systems Engineering Centre (PROSPECT), Universiti Teknologi Malaysia. Her research focuses on Process integration, Pinch Analysis and resource minimisation
Prof. P. S. Varbanov University of Pannonia, Hungary. His main focus is on energy efficiency, waste-to-energy and renewables, energy supply networks.
Prof. Z. A. Manan Faculty of Chemical Engineering and Process Systems Engineering Centre, Universiti Teknologi Malaysia. His research focuses on sustainable systems as well as process planning and engineering.

Preface	p. v
Acronyms, abbreviations and symbols	p. xi
1 Process Integration and Intensification: an introduction	p. 1
1.1 Process Intensification	p. 1
1.2 Process Systems Engineering and Process Integration	p. 3
1.3 Contributions to PIs and PI to energy and water saving	p. 4
1.4 What is Process Integration?	p. 4
1.5 A brief history of the development of Process Integration	p. 5
1.6 The aim and scope of this textbook	p. 8
References	p. 9
2 Setting energy targets and Heat Integration	p. 13
2.1 Introduction	p. 13
2.1.1 Initial development of Heat Integration	p. 14
2.1.2 Pinch Technology and targeting Heat Recovery: the thermodynamic roots	p. 14
2.1.3 Supertargeting: full-fledged HEN targeting	p. 15
2.1.4 Modifying the Pinch Idea for HEN retrofit	p. 16
2.1.5 Benefits of Process Integration	p. 16
2.2 Pinch Analysis for maximising energy efficiency	p. 17
2.2.1 Introduction to Heat Exchange and Heat Recovery	p. 17
2.2.2 Basic principles	p. 19
2.2.3 Basic Pinch Technology	p. 28
2.3 Summary	p. 63
References	p. 64
3 Synthesis of Heat Exchanger Networks	p. 67
3.1 Introduction	p. 67
3.2 HEN synthesis	p. 67
3.2.1 The Pinch Design Method	p. 68
3.2.2 Methods using mathematical programming	p. 89
3.3 Grassroots and retrofits, impact of economic criteria	p. 93
3.3.1 Network optimisation	p. 93
3.3.2 The Network Pinch	p. 94
3.4 Summary	p. 96
References	p. 96
4 Total Site Integration	p. 99
4.1 Introduction	p. 99
4.2 What is a Total Site and what are the benefits?	p. 100
4.2.1 Total Site definition	p. 101
4.2.2 Total Site Analysis interfaces	p. 102
4.3 HI extension for Total Sites: data extraction for Total Sites	p. 103
4.3.1 The algorithm	p. 103
4.3.2 Step-by-step guidance	p. 105
4.3.3 Working session	p. 109
4.4 Total Site Profiles and Total Site Composite Curves	p. 110
4.5 Site Utility Grand Composite Curve (SUGCC)	p. 118
4.6 Combined Heat and Power Generation (CHP, Cogeneration) targeting	p. 120
4.6.1 A simple cogeneration model	p. 121
4.6.2 Targeting CHP using the SUGCC	p. 122
4.6.3 Choice of optimal steam pressure levels	p. 124
4.7 Advanced Total Site developments	p. 126
4.7.1 Introduction of process-specific minimum allowed temperature differences	p. 126
4.7.2 Numerical tools for Total Site Heat Integration	p. 127
4.7.3 Power Integration	p. 128
4.8 Summary	p. 133
References	p. 134
5 Introduction to Water Pinch Analysis	p. 137
5.1 Water management and minimisation	p. 137
5.2 History and definition of Water Pinch Analysis	p. 139
5.3 Applications of Water Pinch Analysis	p. 139
5.4 Water Pinch Analysis steps	p. 140
5.5 Analysis of water networks and data extraction	p. 141
5.5.1 Analysis of water networks	p. 141
5.5.2 Data extraction	p. 143
5.5.3 Example	p. 144
References	p. 148
6 Setting the maximum water recovery targets	p. 151
6.1 Introduction	p. 151
6.2 Maximum water recovery target for single pure freshwater	p. 155
6.2.1 Water Cascade Analysis technique	p. 155
6.2.2 Source/Sink Composite Curves (SSCC)	p. 158
6.2.3 Significance of the Pinch region	p. 159
6.3 Maximum water recovery target for a single impure freshwater source	p. 160
6.3.1 Pinched problems	p. 160
6.3.2 Threshold problems	p. 166
6.4 Maximum water recovery targets for multiple freshwater sources	p. 168
6.5 Working session	p. 170
6.6 Solution	p. 170
References	p. 174
7 Water network design/retrofit	p. 177
7.1 Introduction	p. 177
7.2 Source/Sink Mapping Diagram (SSMD)	p. 177
7.3 Source and Sink Allocation Curves (SSAC)	p. 179
7.3.1 Example of network design using SSCC for utility purity superior to all other streams	p. 183
7.3.2 Freshwater purity not superior to all other streams	p. 186
7.3.3 Simplification of a water network or constructing other network possibilities	p. 189
7.4 Working session	p. 192
7.5 Solution	p. 193
7.6 Water MATRIX software	p. 195
References	p. 196
8 Design of Cost-Effective Minimum Water Network (CEMWN)	p. 197
8.1 Introduction	p. 197
8.2 Water Management Hierarchy	p. 197
8.3 Cost-Effective Minimum Water Network (CEMWN)	p. 199
8.4 Industrial case study - a semiconductor plant	p. 209
8.4.1 Using CEMWN targets as reference benchmarks	p. 227
References	p. 227
9 Conclusions and sources of further information	p. 229
9.1 HEN targeting and synthesis	p. 229
9.2 Total Site Integration	p. 229
9.3 Total Site methodology addressing variable energy supply and demand	p. 231
9.4 Utility system optimisation accounting for cogeneration	p. 231
9.5 Maximum water recovery targeting and design	p. 232
9.5.1 Recommended books for further reading	p. 233
9.5.2 State of-the-art review	p. 234
9.6 Analysing the designs of isolated energy systems	p. 235
9.7 PI contribution to supply chain development	p. 236
9.8 Hydrogen networks design and management	p. 236
9.9 Oxygen Pinch Analysis	p. 237
9.10 Pressure drop considerations and heat transfer enhancement in Process Integration	p. 238
9.11 Computational and modelling tools suitable for applying PI	p. 240
9.11.1 Heat and power PI applications	p. 241
9.11.2 Water Pinch software	p. 242
9.12 Challenges and recent developments in Pinch-based PI	p. 243
References	p. 244
Index	p. 249

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