Process Integration and Intensification (eBook)

Preface 5
Acronyms, abbreviations and symbols 11
1 Process Integration and Intensification: an introduction 15
1.1 Process Intensification 15
1.2 Process Systems Engineering and Process Integration 17
1.3 Contributions to PIs and PI to energy and water saving 18
1.4 What is Process Integration? 18
1.5 A brief history of the development of Process Integration 19
1.6 The aim and scope of this textbook 22
References 23
2 Setting energy targets and Heat Integration 27
2.1 Introduction 27
2.1.1 Initial development of Heat Integration 28
2.1.2 Pinch Technology and targeting Heat Recovery: the thermodynamic roots 28
2.1.3 Supertargeting: full-fledged HEN targeting 29
2.1.4 Modifying the Pinch Idea for HEN retrofit 30
2.1.5 Benefits of Process Integration 30
2.2 Pinch Analysis for maximising energy efficiency 31
2.2.1 Introduction to Heat Exchange and Heat Recovery 31
2.2.2 Basic principles 33
2.2.3 Basic Pinch Technology 42
2.3 Summary 77
References 78
3 Synthesis of Heat Exchanger Networks 81
3.1 Introduction 81
3.2 HEN synthesis 81
3.2.1 The Pinch Design Method 82
3.2.2 Methods using mathematical programming 103
3.3 Grassroots and retrofits, impact of economic criteria 107
3.3.1 Network optimisation 107
3.3.2 The Network Pinch 108
3.4 Summary 110
References 110
4 Total Site Integration 113
4.1 Introduction 113
4.2 What is a Total Site and what are the benefits? 114
4.2.1 Total Site definition 115
4.2.2 Total Site Analysis interfaces 116
4.3 HI extension for Total Sites: data extraction for Total Sites 117
4.3.1 The algorithm 117
4.3.2 Step-by-step guidance 119
4.3.3 Working session 123
4.4 Total Site Profiles and Total Site Composite Curves 124
4.5 Site Utility Grand Composite Curve (SUGCC) 132
4.6 Combined Heat and Power Generation (CHP, Cogeneration) targeting 134
4.6.1 A simple cogeneration model 135
4.6.2 Targeting CHP using the SUGCC 136
4.6.3 Choice of optimal steam pressure levels 138
4.7 Advanced Total Site developments 140
4.7.1 Introduction of process-specific minimum allowed temperature differences 140
4.7.2 Numerical tools for Total Site Heat Integration 141
4.7.3 Power Integration 142
4.8 Summary 147
References 148
5 Introduction to Water Pinch Analysis 151
5.1 Water management and minimisation 151
5.2 History and definition of Water Pinch Analysis 152
5.3 Applications of Water Pinch Analysis 153
5.4 Water Pinch Analysis steps 154
5.5 Analysis of water networks and data extraction 155
5.5.1 Analysis of water networks 155
5.5.2 Data extraction 157
5.5.3 Example 158
References 162
6 Setting the maximum water recovery targets 165
6.1 Introduction 165
6.2 Maximum water recovery target for single pure freshwater 169
6.2.1 Water Cascade Analysis technique 169
6.2.2 Source/Sink Composite Curves (SSCC) 172
6.2.3 Significance of the Pinch region 173
6.3 Maximum water recovery target for a single impure freshwater source 174
6.3.1 Pinched problems 174
6.3.2 Threshold problems 180
6.4 Maximum water recovery targets for multiple freshwater sources 182
6.5 Working session 184
6.6 Solution 184
References 188
7 Water network design/retrofit 191
7.1 Introduction 191
7.2 Source/Sink Mapping Diagram (SSMD) 191
7.3 Source and Sink Allocation Curves (SSAC) 193
7.3.1 Example of network design using SSCC for utility purity superior to all other streams 197
7.3.2 Freshwater purity not superior to all other streams 200
7.3.3 Simplification of a water network or constructing other network possibilities 203
7.4 Working session 206
7.5 Solution 207
7.6 Water MATRIX software 209
References 210
8 Design of Cost-Effective Minimum Water Network (CEMWN) 211
8.1 Introduction 211
8.2 Water Management Hierarchy 211
8.3 Cost-Effective Minimum Water Network (CEMWN) 213
8.4 Industrial case study – a semiconductor plant 223
8.4.1 Using CEMWN targets as reference benchmarks 241
References 241
9 Conclusions and sources of further information 243
9.1 HEN targeting and synthesis 243
9.2 Total Site Integration 243
9.3 Total Site methodology addressing variable energy supply and demand 245
9.4 Utility system optimisation accounting for cogeneration 245
9.5 Maximum water recovery targeting and design 246
9.5.1 Recommended books for further reading 247
9.5.2 State of-the-art review 248
9.6 Analysing the designs of isolated energy systems 249
9.7 PI contribution to supply chain development 250
9.8 Hydrogen networks design and management 250
9.9 Oxygen Pinch Analysis 251
9.10 Pressure drop considerations and heat transfer enhancement in Process Integration 252
9.11 Computational and modelling tools suitable for applying PI 254
9.11.1 Heat and power PI applications 255
9.11.2 Water Pinch software 256
9.12 Challenges and recent developments in Pinch-based PI 257
References 258
Index 263