Method to incorporate energy integration considerations in multiproduct batch processes

Water and energy integration: A comprehensive literature review of non-isothermal water network synthesis

The integration of energy and mass processes is one of the most powerful tools for creating sustainable and energy efficient production systems. Process integration covers a wide range of system-oriented methods and approaches that are used in the design and reconstruction of industrial processes to obtain optimal use of resources. Traditionally, methods have focused on energy efficiency, but more recently they have also covered other areas, such as the integration of mass processes for the efficient use of water and other resources.In production systems with batch processes, the task of energy integration is significantly more complex due to the presence of predominantly low-potential heat, which until recently was considered not to be recoverable. In addition, the periodic and discrete nature of heat sources and recipients imposes additional constraints that require process coordination. Two main approaches for thermal integration of periodic processes are defined, direct and indirect: Direct heat integration determines the existence of heat exchange between technological flows that occur simultaneously over time. This approach to heat recovery requires adherence to a strict production schedule to ensure energy efficiency and product quality. In the chapter different variants for direct heat integration are considered, with recirculation of the main fluids, or with the use of intermediate heating and cooling agents. The corresponding mathematical models are derived. Indirect heat integration determines the existence of heat exchange between flows that do not occur simultaneously in the system. This approach uses intermediate fluids and a heat storage system (heat tanks) so that the heat can be stored, transferred, and utilized in a future period of time. It allows the heat exchange process to be less limited and less sensitive than schedules and provides some operational flexibility. The possibilities for heat integration with the use of one common cold/hot heat tank and two separate ones, but with a common heating/cooling agent are considered. The respective mathematical models are also presented. Key wordsDirect heat integrationRecirculation main fluidsIntermediate heating and cooling agentsIndirect heat integrationTwo heat storageOne heat storage

New completion time algorithms for sequence based scheduling in multiproduct batch processes using matrix

Better solutions for process sustainability through better insight in process energy integration

Optimal assignment of multiple utilities in heat exchange networks

This paper deals with a campaign planning problem typical for multi-product batch plants. Here the campaign size (production amount of one continuous production run) is often constrained by the multiples of a batch size, which is limited by a lower and upper bound according to the volume of reactor and safe operations. A new and applicable Mixed Integer Linear Programming (MILP) model formulation is presented that is based on the standard capacitated lot-sizing model with some adaptive innovations, such as adding the value of un-utilized capacity to objective function, non-uniform time division, capacity variations, non-continuous limitation of production quantity, limitation of raw materials etc. In order to solve large-scale problems and lower computational time, some valid inequalities are adopted. The problem size of the proposed formulation is acceptable, and can be solved using commerce optimization software ILOG CPLEX within tolerable CPU time. The performance of the approach is illustrated by one real case study.

A conceptual efficient design of energy recovery systems using a new energy-area key parameter

Process integration is a holistic approach to process design and operation which emphasizes the unity of the process. Process integration design tools have been developed over the past two decades to achieve process improvement, productivity enhancement, conservation in mass and energy resources, and reductions in the operating and capital costs of chemical processes. The primary applications of these integrated tools have focused on resource conservation, pollution prevention and energy management. Specifically, the past two decades have seen the development and/or application of process integration design tools for heat exchange networks (HENs), wastewater reduction and water conservation networks, mass exchange networks (MENs), heat‐ and energy‐induced separation networks (HISENs and EISENs), waste interception networks (WINs) and heat‐ and energy‐induced waste minimization networks (HIWAMINs and EIWAMINs), to name a few. This paper provides an overview of some of these developments and outlines major driving forces and hurdles. The fundamental aspects of this approach along with their incorporation in an overall design methodology will be discussed. The paper also highlights several recent applications of process integration to industrial processes. Copyright © 2003 Society of Chemical Industry

Assessing the CO2 Emissions Reduction from Cement Industry by Carbon Capture Technologies: Conceptual Design, Process Integration and Techno-economic and Environmental Analysis

Energy Reduction Potential in Natural Gas Processing through Heat and Process Integration

Chapter 22 - Macroscopic Approaches of Process Integration

This paper presents a framework for the system integration and optimization of a molten carbonate fuel cell (MCFC) working under stationary conditions using process integration. Here, the analysis is focused on two systems in terms of the efficiency and process requirements: (i) an MCFC system alone and (ii) an MCFC system integrated with the steam turbine cycle, now onwards referred to as fuel cell combined cycle system for electric power generation. In the first system, a steady state direct internal reforming MCFC system is being simulated using desulphurized natural gas. A heat exchanger network is developed using process integration so that a minimum amount of external thermal energy is provided to the fuel cell system for electric power generation. In the second analysis, a steam turbine system is added to the first (fuel cell) one to form a fuel cell combined cycle system. The procedure for developing a network of heat exchangers and proper integration of the steam turbine system with an optimized minimum temperature difference is discussed. The results of the study elucidate the advantages of properly designed fuel cell combined cycle system to reach power demand with 17% higher efficiency as compared with the system without a combined cycle.

In the situation of high prices and depletion of the world energy, one way for energy management is process heat integration. In Specific, pinch technology has demonstrated that good process integration pays off through simplicity of plant design and good use of energy and capital. The principle is to predict what should be achieved (targeting), and then to set out how to achieve it (design). For modification of existing plants, retrofitting is used with the same thermodynamic principles that area of an aromatics plant, retrofitting the heat exchanger network to obtain the best design which results in high degree of energy recovery. In this area of plant, nine heat exchangers can be found. The streams that involve in this pinch analysis can be grouped into two types; hot and cold streams, which are thirty and twenty on for hot and cold streams respectively. First of all, the target of energy savings will be conducted for the specified payback period. In this step the problem table analysis and composite curves have been done in order to find the area and energy target. The result of these targets shows the very low payback period. The retrofit procedure then can be done by constructing the grid diagram and finding the heat exchangers crossing pinch point. Eliminating these exchangers plus adding some area of heat exchangers result in energy saving about 10-20%.

This article provides an introduction to the current Special Issue of the journal of Applied Thermal Engineering, which contains eight carefully selected articles from the 12th Conference Process Integration, Modelling and Optimisation for Energy Saving and Pollution Reduction – PRES’09. This issue builds upon the multi-year co-operation between the PRES conference planners and the journal. The articles cover important subjects of increased energy and resource efficiency in industrial production and emission reduction. The first paper is based on the conference plenary presentation and is providing an overview of the historical developments in the Process Integration (PI) area and the apparently significant contribution of the PRES series of conferences. This is followed by a second group of two papers dedicated to important PI topics – retrofit of Heat Exchanger Networks and simultaneous minimisation of water and energy consumption. The third group contains three contributions dedicated to energy savings via the application of PI in specific industrial sectors. The final fourth group of two papers is dedicated to the implementation of energy conversion technologies. Those papers are discussing environmental impact of waste-to-energy processes and heat exchanger improvements.

Heat Exchanger Networks Targeting and Design with Unequal Heat Transfer Coefficient Regarding Allowable Pressure Drop of Streams