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Introduction To Process Integration

Process integration refers to system-oriented, thermodynamics-based approaches to analyzing, designing, and retrofitting process plants to minimize energy and emissions. The goals are to integrate material and energy usage and minimize waste generation. Integration combines opposing needs to create savings. Examples include heat, power, chemical, and equipment integration. Process integration considers whole processes as interconnected systems and applies engineering principles to establish performance targets for resource usage and emissions. Design is then finalized to meet targets. Pinch analysis is a key tool that uses the pinch concept to optimize energy and mass integration. It can reduce utility usage by 15-45% compared to traditional design.

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Gamme Abdataa
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62 views

Introduction To Process Integration

Process integration refers to system-oriented, thermodynamics-based approaches to analyzing, designing, and retrofitting process plants to minimize energy and emissions. The goals are to integrate material and energy usage and minimize waste generation. Integration combines opposing needs to create savings. Examples include heat, power, chemical, and equipment integration. Process integration considers whole processes as interconnected systems and applies engineering principles to establish performance targets for resource usage and emissions. Design is then finalized to meet targets. Pinch analysis is a key tool that uses the pinch concept to optimize energy and mass integration. It can reduce utility usage by 15-45% compared to traditional design.

Uploaded by

Gamme Abdataa
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Introduction to Process

Integration
INTRODUCTION

What is Process Integration?

This Question can be decomposed into

What do we mean by a Process?


and
What do we mean by Integration?
Process Integration
 Process integration refers to the system-oriented,
thermodynamics-based, integrated approaches
to the analysis, synthesis and retrofit of process
plants.

 The goals of process integration are


1. To integrate the use of materials and energy,
2. To minimize the generation of emissions and
wastes.
Meaning of Integration

 Integration means combining Needs/Tasks of


“opposite” kinds so that Savings can be obtained
 Examples of such Integration in the Process
Industries:
 Heat Integration
 Power Integration
 Chemical Integration
 Equipment Integration → Process Intensification
Concept of Process Integration
• Process integration is built on three basic concepts:
1. Consider the whole manufacturing process as an integrated
system of interconnected processing units as well as process,
utility and waste streams.
2. Apply process-engineering principles, such as thermodynamics
and mass and energy balances, to key process steps to establish
the performance targets on the use of materials and energy and
the generation of emissions and wastes (e.g., the minimum utility
consumptions, the minimum CO2 and NOx emission levels, the
minimum freshwater requirement, etc.).
3. Finalize the details of process design and retrofit later to realize
the established performance targets.
Onion diagram for process synthesis
• The overall design process is effectively
represented by the onion diagram.
• The four tasks in the layers of the onion are,
namely reaction, separation, heat exchange
and external heating/cooling.
• The core of the process is the chemical
reaction step, and the reactor product
composition and feed requirements dictate
the separation tasks (including recycles). Onion diagram
• Then, and only then, can the design engineer
determine the various heating and cooling
duties for the streams, the heat exchanger
network and the requirements for heating
and cooling.
The Tools of Process Integration

In general, we select from two approaches to an integrated process design. We apply


the pinch concept for integrating energy (e.g., targeting heating- and cooling-utility
consumptions) and mass (e.g., analyzing solvent-recovery systems or water-using
operations), or use a mathematical optimization approach (e.g., minimizing effluent-
treatment flow rates in a wastewater-treatment system).
Benefit of Pinch Analysis
Figure 1.1(a) is a traditional design
for the front end of a specialty
chemicals process. Six heat transfer
“units” (i.e. heaters, coolers and
exchangers) are used and the
energy requirements are 1,722 kW
for heating and 654 kW for cooling.
Figure 1.1(b) shows an alternative
design which was generated by
using pinch analysis techniques for
energy targeting and network
integration. The alternative flow
sheet uses only four heat transfer
“units” and the utility heating load
is reduced by about 40% with
cooling no longer required. The Figure 1.1 Outline flow sheets for the front end
design is as safe and as operable as of a specialty chemicals process
the traditional one. It is simply
better.
Heat Integration

 Typical energy saving 15 – 45 %


 Very general – easily applicable in Power generation, Oil refining,
Petrochemicals, Food and Drink Industry, Pulp & Paper, hospitals
etc.
Simple Heat Exchange Network (HEN)
cooling water

steam

water steam water steam

As ∆Tmin becomes less, utility demands become less. However, there is a


reasonable minimum ∆Tmin to provide a driving force for heat exchange (e.g. 10°C).
Synthesis of HENs
A possible two-stage method to the synthesis
of HEN
Example: 2 Hot Streams, 2 Cold Streams
Minimize Utilities For 4 Streams
C1 235 120
C2 240 180
H1 235 120
H2 240 180

Total: 470

Total: 480

Note that total cooling demand is 10×104 Btu/hr more than total heating demand.
A possible Heat Exchange Network (HEN)
to Achieve Required Heating and Cooling

Required cold utilities


(cooling water): 67.5 Required hot utilities
(steam): 57.5

• Note that QCW – Qsteam = 10, which is required difference

Required cold utilities (cooling water): 67.5 X 104 BTU/hr


Required hot utilities (steam): 57.5 X 104 BTU/hr

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