Sustainability in the Process Industry: Integration and Optimization

Home >
Browse >
Sustainability in the Process Industry: Integration and Optimization

Sustainability in the Process Industry: Integration and Optimization

Authors: Jiri Klemes, Ferenc Friedler, Igor Bulatov and Petar Varbanov

Published: August 2010

eISBN: 9780071605557 007160555X | ISBN: 9780071605540

Contents

Preface

Acknowledgments

1 Introduction and Defi nition of the Field

1.1 Introduction

1.2 Energy Efficiency

1.3 Screening and Scoping: Auditing, Benchmarking, and Good Housekeeping

1.4 Balancing and Flowsheeting Simulation as a Basis for Optimization

1.5 Integrated Approach: Process Integration

1.6 Optimal Process Synthesis and Combinatorial Graphs

1.7 How to Apply the Process Integration and Optimization Technology

2 Process Integration

2.1 Introduction: The Need for Process Integration

2.2 What Is Process Integration?

2.3 History and Development of Process Integration

2.4 Pinch Technology and Targeting Heat Recovery: The Thermodynamic Roots

2.5 Supertargeting: Full-Fledged HEN Targeting

2.6 Modifying the Pinch Idea for HEN Retrofit

2.7 Mass Exchange and Water Networks

2.8 Benefits of Process Integration

2.9 The Role of PI in Making Industry Sustainable

2.10 Examples of Applied Process Integration

2.11 Summary

3 Process Optimization

3.1 Introduction

3.2 Model Building and Optimization: General Framework and Workflow

3.3 Optimization: Definition and Mathematical Formulation

3.3.1 What Is Optimization?

3.3.2 Mathematical Formulation of Optimization Problems

3.4 Main Classes of Optimization Problems

3.5 Conditions for Optimality

3.5.1 Conditions for Local Optimality

3.5.2 Conditions for Global Optimality

3.6 Deterministic Algorithms for Solving Continuous Linear Optimization Problems

3.7 Deterministic Algorithms for Solving Continuous Nonlinear Optimization Problems

3.7.1 Search Algorithms for Nonlinear Unconstrained Problems

3.7.2 Algorithms for Solving Constrained Nonlinear Problems

3.8 Deterministic Methods for Solving Discrete Problems

3.9 Stochastic Search Methods for Solving Optimization Problems

3.10 Creating Models

3.10.1 Conceptual Modeling

3.10.2 Mathematical Modeling of Processes: Constructing the Equations

3.10.3 Choosing an Objective Function

3.10.4 Handling Process Complexity

3.10.5 Applying Process Insight

3.10.6 Handling Model Nonlinearity

3.10.7 Evaluating Model Adequacy and Precision

4 Process Integration for Improving Energy Efficiency

4.1 Introduction to Heat Exchange and Heat Recovery

4.1.1 Heat Exchange Matches

4.1.2 Implementing Heat Exchange Matches

4.2 Basics of Process Integration

4.2.1 Process Integration and Heat Integration

4.2.2 Hierarchy of Process Design

4.2.3 Performance Targets

4.2.4 Heat Recovery Problem Identification

4.3 Basic Pinch Technology

4.3.1 Setting Energy Targets

4.3.2 The Heat Recovery Pinch

4.3.3 Numerical Targeting: The Problem Table Algorithm

4.3.4 Threshold Problems

4.3.5 Multiple Utilities Targeting

4.4 Extended Pinch Technology

4.4.1 Heat Transfer Area, Capital Cost, and Total Cost Targeting

4.4.2 Heat Integration of Energy-Intensive Processes

4.4.3 Process Modification

4.5 HEN Synthesis

4.5.1 The Pinch Design Method

4.5.2 Superstructure Approach

4.5.3 A Hybrid Approach

4.5.4 Key Features of the Resulting Networks

4.6 Total Site Energy Integration

4.6.1 Total Site Data Extraction

4.6.2 Total Site Profiles

4.6.3 Heat Recovery via the Steam System

4.6.4 Power Cogeneration

4.6.5 Advanced Total Site Optimization and Analysis

5 Mass Integration

5.1 Water Integration

5.2 Minimizing Water Use and Maximizing Water Reuse

5.2.1 Legislation

5.2.2 Best Available Techniques

5.2.3 Water Footprint

5.2.4 Minimizing Water Usage and Wastewater

5.3 Introduction to Water Pinch Analysis

5.4 Flow-Rate Targeting with the Material Recovery Pinch Diagram

5.5 MRPD Applied to Fruit Juice Case Study

5.6 Water Minimization via Mathematical Optimization

5.6.1 Introduction to Mathematical Optimization

5.6.2 Illustrative Example: A Brewery Plant

5.7 Summary

6 Further Applications of Process Integration

6.1 Design and Management of Hydrogen Networks

6.2 Oxygen Pinch Analysis

6.3 Combined Analyses, I: Energy-Water, Oxygen-Water, and Pinch-Emergy

6.3.1 Simultaneous Minimization of Energy and Water Use

6.3.2 Oxygen-Water Pinch Analysis

6.3.3 Emergy-Pinch Analysis

6.4 Combined Analysis, II: Budget-Income-Time, Materials Reuse-Recycling, Supply Chains, and CO[sub(2)] Emissions Targeting

6.4.1 Budget-Income-Time Pinch Analysis

6.4.2 Materials Reuse-Recycle and Property Pinch Analysis

6.4.3 Pinch Analysis of Supply Chains

6.4.4 Using the Pinch to Target CO[sub(2)] Emissions

6.4.5 Regional Resource Management

6.5 Heat-Integrated Power Systems: Decarbonization and Low-Temperature Energy

6.5.1 Decarbonization

6.5.2 Low-Temperature Energy

6.6 Integrating Reliability, Availability, and Maintainability into Process Design

6.6.1 Integration

6.6.2 Optimization

6.7 Pressure Drop and Heat Transfer Enhancement in Process Integration

6.8 Locally Integrated Energy Sectors and Extended Total Sites

6.9 Summary

7 Process Optimization Frameworks

7.1 Classic Approach: Mathematical Programming

7.2 Structural Process Optimization: P-Graphs

7.2.1 Process Representation via P-Graphs

7.2.2 The P-Graph’s Significance for Structural Optimization

7.2.3 The P-Graph’s Mathematical Engine: MSG, SSG, and ABB

7.3 Scheduling of Batch Processes: S-Graphs

7.3.1 Scheduling Frameworks: Suitability and Limitations

7.3.2 S-Graph Framework for Scheduling

8 Combined Process Integration and Optimization

8.1 The Role of Optimization in Process Synthesis

8.2 Optimization Tools for Efficient Implementation of PI

8.3 Optimal Process Synthesis

8.3.1 Reaction Network Synthesis

8.3.2 Optimal Synthesis of Heterogeneous Flowsheets

8.3.3 Synthesis of Green Biorefineries

8.3.4 Azeotropic Distillation Systems

8.4 Optimal Synthesis of Energy Systems

8.4.1 Simple Heat Integration

8.4.2 Optimal Retrofit Design

8.5 Optimal Scheduling for Increased Throughput, Profit, and Security

8.5.1 Maximizing Throughput and Revenue

8.5.2 Heat-Integrated Production Schedules

8.6 Minimizing Emissions and Effluents

8.7 Availability and Reliability

8.8 Summary

9 Software Tools

9.1 Overview of Available Tools

9.2 Graph-Based Process Optimization Tools

9.2.1 PNS Solutions

9.2.2 S-Graph Studio

9.3 Heat Integration Tools

9.3.1 SPRINT

9.3.2 HEAT-int

9.3.3 STAR

9.3.4 SITE-int

9.3.5 WORK

9.3.6 HEXTRAN

9.3.7 SuperTarget

9.3.8 Spreadsheet-Based Tools

9.4 Mass Integration Software: WATER

9.5 Flowsheeting Simulation Packages

9.5.1 ASPEN

9.5.2 HYSYS and UniSim Design

9.5.3 gPROMS

9.5.4 CHEMCAD

9.5.5 PRO/II

9.6 General-Purpose Optimization Packages

9.6.1 GAMS

9.6.2 MIPSYN

9.6.3 LINDO

9.6.4 Frontline Systems

9.6.5 ILOG ODM

9.7 Mathematical Modeling Suites

9.7.1 MATLAB

9.7.2 Alternatives to MATLAB

9.8 Other Tools

9.8.1 Modelica

9.8.2 Emerging Trends

9.8.3 Balancing and Flowsheeting Simulation for Energy-Saving Analysis

9.8.4 Integrating Renewable Energy into Other Energy Systems

10 Examples and Case Studies

10.1 Heat Pinch Technology

10.1.1 Heat Pinch Technology: First Problem

10.1.2 Heat Pinch Technology: Second Problem

10.2 Total Sites

10.2.1 Total Sites: First Problem

10.2.2 Total Sites: Second Problem

10.3 Integrated Placement of Processing Units and Data Extraction

10.4 Utility Placement

10.4.1 Utility Placement: First Problem

10.4.2 Utility Placement: Second Problem

10.5 Water Pinch Technology

10.5.1 Water Pinch Technology: First Problem

10.5.2 Water Pinch Technology: Second Problem

11 Industrial Applications and Case Studies

11.1 Energy Recovery from an FCC Unit

11.2 De-bottlenecking a Heat-Integrated Crude-Oil Distillation System

11.3 Minimizing Water and Wastewater in a Citrus Juice Plant

11.4 Efficient Energy Use in Other Food and Drink Industries

11.5 Synthesis of Industrial Utility Systems

11.6 Heat and Power Integration in Buildings and Building Complexes

11.7 Optimal Design of a Supply Chain

11.8 Scheduling a Large-Scale Paint Production System

12 Typical Pitfalls and How to Avoid Them

12.1 Data Extraction

12.1.1 When Is a Stream a Stream?

12.1.2 How Precise Must the Data Be at Each Step?

12.1.3 How Can Considerable Changes in Specific Heat Capacities Be Handled?

12.1.4 What Rules and Guidelines Must Be Followed to Extract Data Properly?

12.1.5 How Can the Heat Loads, Heat Capacities, and Temperatures of an Extracted Stream Be Calculated?

12.1.6 How “Soft” Are the Data in a Plant or Process Flowsheet?

12.1.7 How Can Capital Costs and Operating Costs Be Estimated?

12.2 Integration of Renewables: Fluctuating Demand and Supply

12.3 Steady-State and Dynamic Performance

12.4 Interpreting Results

12.5 Making It Happen

13 Information Sources and Further Reading

13.1 General Sources of Information

13.1.1 Conferences

13.1.2 Journals

13.1.3 Service Providers

13.1.4 Projects

13.2 Heat Integration

13.2.1 Conferences

13.2.2 Journals

13.2.3 Service Providers

13.2.4 Projects

13.3 Mass Integration

13.3.1 Conference

13.3.2 Journals

13.3.3 Service Providers

13.3.4 Projects

13.4 Combined Analysis

13.4.1 Conferences

13.4.2 Journals

13.4.3 Service Providers

13.4.4 Projects

13.5 Optimization for Sustainable Industry

13.5.1 Conferences

13.5.2 Journals

13.5.3 Service Providers

13.5.4 Projects

14 Conclusions and Further Information

14.1 Further Reading

14.1.1 Books and Key Articles

14.1.2 Lecture Notes and Online Teaching Resources

14.2 Development Trends

14.2.1 Top-Level Analysis

14.2.2 Maintenance Scheduling, Maintainability, and Reliability

14.2.3 Hybrid Energy Conversion Systems

14.2.4 Integration of Renewables and Waste

14.2.5 Better Utilization of Low-Grade Heat

14.2.6 Energy Planning That Accounts for Carbon Footprint

14.3 Conclusions

Bibliography

Index