Handbook of Process Integration (PI)
1st Edition
Minimisation of Energy and Water Use, Waste and Emissions
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Table of Contents
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Woodhead Publishing Series in Energy
Foreword
Part I: Overview of Process Integration and Analysis
Chapter 1: Process Integration (PI): An Introduction
Abstract:
1.1 Introduction
1.2 A Short History of Process Integration (PI)
1.3 Current Centres of Expertise in PI
1.4 Sources of Further Information
Chapter 2: Basic Process Integration Terminology
Abstract:
2.1 Introduction
2.2 Process Integration Terms: The Importance of Context
2.3 Fundamental Process Integration Terms
2.4 Conventions: Symbols for Heaters and Coolers
2.6 Appendix: Nomenclature
Chapter 3: Process Design, Integration and Optimisation: Advantages, Challenges and Drivers
Abstract:
3.1 Introduction
3.2 Grassroots Design versus Retrofit Design
3.3 Process Integration
3.4 Integration versus Intensification
3.5 Process Integration Techniques
3.6 Optimisation of Integrated Processes
3.7 Controllability of Integrated Processes
3.8 Process Integration under Disturbances
Part II: Heat Integration
Chapter 4: Heat Integration: Targets and Heat Exchanger Network Design
Abstract:
4.1 Introduction
4.2 Stages in the Design of Heat Recovery Systems
4.3 Data Extraction
4.4 Performance Targets
4.5 Process Modifications
4.6 Network Design
4.7 Design Evolution
4.8 Conclusion
4.9 Sources of Further Information
Chapter 5: Application of Process Integration to the Synthesis of Heat and Power Utility Systems Including Combined Heat and Power (CHP) and Industrial Heat Pumps
Abstract:
5.1 Introduction
5.2 Targeting Utility Loads and Temperature Levels
5.3 Integration of Advanced Energy Conversion Cycles as Process Utilities: Basic Concepts
5.4 Process Integration of Heat Engines
5.5 Process Integration of Heat Pumps
5.6 Sources of Further Information and Advice
Chapter 6: Total Site Methodology
Abstract:
6.1 Introduction
6.2 Data Extraction for Total Sites
6.3 Total Site Profiles and Total Site Composite Curves
6.4 Site Utility Grand Composite Curve (SUGCC)
6.5 Conclusion
6.6 Sources of Further Information
Chapter 7: Extending Total Site Methodology to Address Varying Energy Supply and Demand
Abstract:
7.1 Introduction
7.2 Characteristics of Energy Supply and Demand
7.3 Thermal Energy Storage and Integrated Architecture
7.4 Terminology for Process Streams and Utilities
7.5 Identification of Time Slices
7.6 Heat Cascades for the Evaluation of Total Site Targets When There Is Variation in Supply and Demand
7.7 Case Study: Integration of Solar Thermal Energy into a Locally Integrated Energy Sector (LIES)
7.8 Conclusion
7.9 Sources of Further Information
7.11 Appendix: Nomenclature
Chapter 8: Analysis and Design of Heat Recovery Systems for Grassroots and Retrofit Situations
Abstract:
8.1 Introduction
8.2 Extended Procedures for Grassroots Analysis
8.3 Extended Procedures for Grassroots Design
8.4 Retrofit Analysis and Design
8.5 Use of Optimisation for Heat Exchanger Network Synthesis
8.6 Conclusion
8.7 Sources of Further Information
Chapter 9: Heat Integration in Batch Processes
Abstract:
9.1 Introduction
9.2 Graphical Technique for Heat Integration in Batch Process
9.3 Mathematical Technique for Heat Integration of Batch Plants
9.4 Case Study of a Multipurpose Batch Facility
9.5 Industrial Case Study
9.6 Conclusion
9.7 Sources of Further Information
9.9 Appendix: Glover Transformation (Glover, 1975)
Part III: Mass Integration
Chapter 10: Water Pinch Analysis for Water Management and Minimisation: An Introduction
Abstract:
10.1 Approaches for Water Management and Minimisation
10.2 Water Integration and Water Pinch Analysis
10.3 Water Pinch Analysis Steps
10.4 Examples of Successful Case Studies
10.7 Appendix: Nomenclature
Chapter 11: Using Systematic Design Methods to Minimise Water Use in Process Industries
Abstract:
11.1 Introduction
11.2 Water Use in Process Industries
11.3 Process Integration for Water Systems
11.4 Conclusions and Future Trends
11.5 Sources of Further Information
Chapter 12: Synthesis of Water Networks with Water Loss and Gain via an Extended Pinch Analysis Technique
Abstract:
12.1 Introduction
12.2 Targeting a Single Water-Using Process
12.3 Process-based Graphical Approach (PGA) for Synthesis of Direct Reuse Water Networks
12.4 Conclusion
12.5 Sources of Further Information and Advice
12.6 Acknowledgements
12.8 Appendix: Nomenclature
Chapter 13: Conserving Material Resources through Process Integration: Material Conservation Networks
Abstract:
13.1 Introduction
13.2 Overall Targeting of Material Conservation Networks
13.3 Mass Exchange Networks
13.4 Water-Pinch Analysis
13.5 Direct Recycle and Material Recycle Pinch Diagram
13.6 Property-Based Material Recycle Pinch Diagram
13.8 Appendix: Nomenclature
Part IV: Extended Process Integration
Chapter 14: Process Integration for Cleaner Process Design
Abstract:
14.1 Introduction
14.2 A Revised ‘Onion Diagram’
14.3 Different Models for Total Material Network (TMN)
14.4 Case Study: Water Minimisation in a Water Fabrication Plant
14.5 Conclusion
14.6 Sources of Further Information
14.8 Appendix: Nomenclature
Chapter 15: Process Integration Concepts for Combined Energy and Water Integration
Abstract:
15.1 Introduction
15.2 Water–Energy Specifics and Challenges
15.3 Water Path Concept
15.4 State-of-the-Art Methodology for Combined Energy and Water Integration
15.5 Sequential, Simultaneous, Mathematical Programming
15.6 Conclusion
15.7 Sources of Further Information
Chapter 16: Process Integration Techniques for Cogeneration and Trigeneration Systems
Abstract:
16.1 Introduction
16.2 Combined Heat and Power
16.3 Heat Integration of Trigeneration Systems
16.4 Conclusions
16.5 Sources of Further Information
16.7 Appendix: Nomenclature
Chapter 17: Pinch Analysis for Sustainable Energy Planning Using Diverse Quality Measures
Abstract:
17.1 Introduction
17.2 Generalised Problem Statement
17.3 Graphical Targeting Procedure
17.4 Case Studies
17.5 Conclusion
17.6 Sources of Further Information
17.8 Appendix
Chapter 18: A Unified Targeting Algorithm for Diverse Process Integration Problems
Abstract:
18.1 Introduction to Targeting Algorithms
18.2 Unified Approach to Diverse Resource Optimisation Problems
18.3 Basis for Unification
18.4 Unified Targeting Algorithm (UTA)
18.5 Heat Exchange Networks (HENs) and Mass Exchange Networks (MENs)
18.6 Water Networks: Case Study of a Specialty Chemical Plant
18.7 Hydrogen and Other Gas Networks
18.8 Property-Based Material Reuse Networks
18.9 Alternative Approaches to Targeting
18.10 Conclusion
18.11 Sources of Further Information
18.13 Appendix: Nomenclature
Chapter 19: A Process Integration Approach for Supply Chain Development
Abstract:
19.1 Introduction
19.2 Supply Chain Characteristics and Performance Measurement
19.3 Supply Chain Development with Process Integration
19.4 Case Studies
19.5 Future Trends
19.6 Sources of Further Information
Chapter 20: Application of Heat Recovery Loops to Semi-continuous Processes for Process Integration
Abstract:
20.1 Introduction
20.2 Indirect Heat Recovery Systems
20.3 Application of Heat Recovery Loops to Semi-continuous Plants
20.4 A More Complex Example of a Heat Recovery Loop (HRL)
20.5 Case Study: Semi-continuous Multi-plant Dairy Factory
20.6 Conclusions and Future Trends
20.7 Sources of Further Information
Part V: Applications and Case Studies
Chapter 21: Applications of Energy and Water Process Integration Methodologies in Oil Refineries and Petrochemical Complexes
Abstract:
21.1 Introduction
21.2 Heat and Power Integration
21.3 Water and Wastewater Minimisation
Results and Discussion
Results and Discussion
21.4 Effluent Treatment and Regeneration
Results and Discussion
Results and Discussion
21.5 Conclusion
Chapter 22: Process Integration of an Oil Refinery Hydrogen Network
Abstract:
22.1 Introduction
22.2 Technology Review
22.3 An Industrial Case Study
22.4 Hydrogen Management in the Wider Context of Process Integration: Future Trends
22.5 Conclusion
22.6 Sources of Further Information
Chapter 23: Retrofit Mass Integration of Acid Gas Removal Systems in Petrochemical Plants
Abstract:
23.1 Introduction
23.2 Review of Previous Work on Mass Exchanger Network Synthesis (MENS) and Retrofit of Existing Systems
23.3 Systems Studied: Venturi Scrubber System and Ethanolamine Absorber System
23.4 Pinch Approach
23.5 Hybrid Approach
23.6 Solution Equilibria
23.7 Results and Discussion
23.8 Conclusions and Sources of Further Information
Chapter 24: Applications of Pinch Technology to Total Sites: A Heavy Chemical Industrial Complex and a Steel Plant
Abstract:
24.1 Introduction
24.2 Case Study of a Heavy Chemical Complex
24.3 Case Study of a Steel Plant
24.4 Conclusion
24.5 Sources of Further Information
24.6 Acknowledgements
Chapter 25: Applications of Process Integration Methodologies in the Pulp and Paper Industry
Abstract:
25.1 Introduction
25.2 Energy Demands and Sources in the Kraft Pulping Process
25.3 Relations between the Heat Exchanger and Water Networks
25.4 Increasing Energy Efficiency in Existing Mills
25.5 Methodological Developments for Heat Integration in Existing Mills
25.6 Evolution of Pulp and Paper Mills
25.7 Conclusion
25.8 Sources of Further Information
Chapter 26: Application of Process Integration Methodologies to the Thermal Processing of Waste
Abstract:
26.1 Introduction
26.2 Types of Waste Thermal Processing Plants
26.3 Analysis of Energy Efficiency in the TERMIZO Plant
26.4 Application of Heat Integration Technology
26.5 Conclusion
26.6 Sources of Further Information and Advice
Chapter 27: Application of Process Integration Methodologies in the Brewing Industry
Abstract:
27.1 Introduction
27.2 Process Flowsheet Analysis
27.3 Calculating Maximum Heat Recovery in the System
27.4 Defining the Energy Conversion System
27.5 Conclusion
27.6 Sources of Further Information
27.8 Appendix A: Complementary Tables
27.9 Appendix B: Nomenclature
Chapter 28: Applications of Process Integration Methodologies in Dairy and Cheese Production
Abstract:
28.1 Introduction
28.2 Application of Process Integration Methodologies
28.3 Selected Case Studies
28.4 Future Trends
28.5 Sources of Further Information
Chapter 29: Applications of Process Integration Methodologies in Beet Sugar Plants
Abstract:
29.1 Introduction
29.2 Sugar Production from Sugar Beet
29.3 Identification of Opportunities to Improve Energy and Water Use in Sugar Plants
29.4 Reduction of Energy Consumption
29.5 Reduction of Water Consumption
29.6 Energy and Water Use in Sugar Production Directly from Raw Beet Juice
29.7 Future Trends
29.8 Sources of Further Information and Advice
Chapter 30: Application of Process Integration Techniques for the Efficient Use of Energy in a Urea Fertiliser Plant: A Case Study
Abstract:
30.1 Introduction
30.2 Process Description
30.3 Opportunities for the Reduction of Energy Consumption
30.4 Conclusion
30.5 Sources of Further Information
30.7 Appendix: Nomenclature
Chapter 31: Process Integration for Energy Saving in Buildings and Building Complexes
Abstract:
31.1 Introduction
31.2 Buildings as Consumers and Producers of Energy
31.3 Commercial and Public Buildings and Building Complexes
31.4 District Energy (DE) Systems and Total Site Analysis (TSA)
31.5 The Use of Industrial Waste Heat
31.6 Renewable Energy for Buildings
31.7 Conclusion
31.8 Sources of Further Information and Advice
Chapter 32: Heat Transfer Enhancement in Heat Exchanger Networks
Abstract:
32.1 Introduction to Shell-and-Tube Heat Exchangers
32.2 Heat Transfer Enhancement Techniques
32.3 Heat Transfer Enhancement in Heat Exchanger Network Retrofit
32.4 Heat Transfer Enhancement in Heat Exchanger Network Retrofit with Fouling Consideration
32.5 Sources of Further Information
32.6 Nomenclature
Chapter 33: Applications of Pinch Analysis in the Design of Isolated Energy Systems
Abstract:
33.1 Introduction
33.2 Isolated Energy Systems: Descriptions and Models
33.3 Grand Composite Curve and Storage Sizing
33.4 Design Space
33.5 Illustrative Applications
33.6 Sources of Further Information and Advice
Part VI: Software Tools and Epilogue
Chapter 34: Software Tools for Heat Integration
Abstract:
34.1 Heat Integration Software Tools
34.2 Sources of Further Information and Advice
Chapter 35: Mass and Water Integration Software Tools
Abstract:
35.1 Mass and Water Integration Software Tools
35.2 Sources of Further Information and Advice
Chapter 36: Epilogue: The Importance of Problem Formulation and Data Extraction in Process Integration
Abstract:
36.1 Introduction: Process Integration – from its Roots to its Present Strong Position
36.2 Successful Applications of Process Integration
36.3 Methods of Obtaining Credible High Integration HI Solutions
36.4 Data Extraction
36.5 Integration of Renewables – Fluctuating Demand and Supply
36.6 Results Interpretation
36.7 Conclusion: Making It Happen
36.8 Sources of Further Information
36.9 Acknowledgements
Index
Description
Since its first development in the 1970s, Process Integration (PI) has become an important methodology in achieving more energy efficient processes. This pioneering handbook brings together the leading scientists and researchers currently contributing to PI development, pooling their expertise and specialist knowledge to provide readers with a comprehensive and up-to-date guide to the latest PI research and applications.
After an introduction to the principles of PI, the book reviews a wide range of process design and integration topics ranging from heat and utility systems to water, recycling, waste and hydrogen systems. The book considers Heat Integration, Mass Integration and Extended PI as well as a series of applications and case studies. Chapters address not just operating and capital costs but also equipment design and operability issues, through to buildings and supply chains.
With its distinguished editor and international team of expert contributors, Handbook of Process Integration (PI) is a standard reference work for managers and researchers in all energy-intensive industries, as well as academics with an interest in them, including those designing and managing oil refineries, petrochemical and power plants, as well as paper/pulp, steel, waste, food and drink processors.
Key Features
- This pioneering handbook provides a comprehensive and up-to-date guide to the latest process integration research and applications
- Reviews a wide range of process design and integration topics ranging from heat and utility systems to water, recycling, waste and hydrogen systems
- Chapters also address equipment design and operability issues, through to buildings and supply chains
Readership
Chemical and industrial process engineers and manufacturers; Energy and environmental consultants and managers
Details
- No. of pages:
- 1184
- Language:
- English
- Copyright:
- © Woodhead Publishing 2013
- Published:
- 31st July 2013
- Imprint:
- Woodhead Publishing
- Hardcover ISBN:
- 9780857095930
- eBook ISBN:
- 9780857097255
Reviews
"The 34 chapters solicited for this dense volume describe the basic steps of pinch analysis for heat recovery that started the process integration movement, and review current methods for combining operations within several processes to reduce consumption of resources and harmful emissions...Topics include total site targeting, total material network, trigeneration systems, targeting algorithms, supply chain development, heat recovery loops, and software tools."--ProtoView.com, February 2014
Ratings and Reviews
About the Editor
Jiri Klemes
Prof Dr-Hab Jiří Jaromír KLEMEŠ, DSc, Dr h c (mult) George Pólya Professor Head of a Centre of Excellence “Sustainable Process Integration Laboratory – SPIL”, NETME Centre, FME, Brno University of Technology - VUT Brno, Czech Republic and Emeritus Professor at “Centre for Process Systems Engineering and Sustainability”, Pázmány Péter Catholic University, Budapest, Hungary. Previously the Project Director, Senior Project Officer and Hon Reader at Department of Process Integration at UMIST, The University of Manchester and the University of Edinburgh, UK. Founder and a long-term Head of the Centre for Process Integration and Intensification – CPI2, University of Pannonia, Veszprém, Hungary. Awarded by the EC with Marie Curie Chair of Excellence (EXC). Track record of managing and coordinating 94 major EC, NATO, bilateral and UK Know-How projects. Research funding attracted over 43 M€. Co-Editor-in-Chief of Journal of Cleaner Production (IF 6.315) and Chemical Engineering Transactions, Editor in Chief of Cleaner Engineering and Technology - CLET (Elsevier Golden Access), Subject Editor of Energy and Emeritus Executive Editor of Applied Thermal Engineering. The founder and President for 23 y of PRES (Process Integration for Energy Saving and Pollution Reduction) conferences. Seven years Chairperson of CAPE Working Party of EFCE (European Federation of Chemical Engineering), a member of WP on Process Intensification and of the EFCE Sustainability platform. A Member of the IChemE Sargent Medal International Committee on CAPE. He has been awarded by the Web of Science and Publons a Highly Cited Researcher, Top Peer Reviewer and Top Handling Editor. He authored and co-authored 556 papers, 13,789 citations, h-index in Google Scholar 60, in Scopus 53 His Publons profile (Web of Science) shows 1,832 reviews for 121 scientific journals and 7,960 Editors Merits for 21 Editorial boards. A number of books published by Elsevier, De Gruyter, Woodhead, McGraw-Hill; Ashgate Pub. Cambridge; Springer; WILEY-VCH; Taylor & Francis). Invited lecturer at 56 universities and Distinquished Visiting Professor world-wide including Cornell, Ithaca, New York and North-West University Chicago, Fudan University and SINOPEC Shanghai Research Institute of Petrochemical Technology, Shanghai; Tsinghua and Chinese Academy of Sciences, Beijing, China University of Petrochemistry Beijing, Xi'an Jiaotong University, China; Hong-Kong Polytechnic University; National Chengchi University, National University of Taiwan., National University Singapore. Hanyang University, and Korea Universities, Seoul, Republic of Korea; Institute of Food Research, Norwich Research Park, Colney, Norwich, Imperial College, London, UK; Norwegian University of Science and Technology – NTNU, Trondheim, Norway; Tomsk Technological University, Tomsk, Russian Federation; S. Amanzholov East Kazakhstan State University, Ust-Kamenogorsk, Kazakhstan; University of Paderborn and Bayer Technology Services GmbH, Leverkusen and BASF Board of Directors Forum on Process Technology, Ludwigshafen, Germany; VTT Energy, Finland; VITO MOL, Belgium; MOL Hungarian Oil Company, DUSLO Šala, Slovakia, TNO Leiden, Groningen, Zeist and Eindhoven; Utrecht and Delft University, the Netherlands; University Politechnica Leonardo da Vinci, Milano, Università degli studi di Genova and Sapienza, Rome, Italy; Universidad Industrial de Santander, Colombia; King Mongkut’s University of Technology Thonburi, Bangkok, Thailand, Faculdade de Engenharia da Universidade do Porto, Oporto, Portugal, CEA Grenoble, France; Charmers and Stockholm University, Sweden, Taiwan Association of Environmental and Resource Economics (TAERE), Taiwan Chemical Industry Forum, Technical University Cracow, Poland, University of Tennessee, Knoxville, USA. Several times Distinguished Visiting Professor at Universiti Teknologi Malaysia and University Technology Petronas, Malaysia; Xi’an Jiaotong University; the South China University of Technology, Guangzhou and Tianjin University in China; University of Maribor, Slovenia; the Brno University of Technology, the Russian Mendeleev University of Chemical Technology, Moscow and Cracow University of Technology, Poland. Doctor Honoris Causa of Kharkiv National University “Kharkiv Polytechnic Institute” in Ukraine, the University of Maribor in Slovenia, University POLITEHNICA Bucharest, Romania “Honorary Doctor of Engineering Universiti Teknologi Malaysia”. Awarded with “Honorary Membership of Czech Society of Chemical Engineering", "European Federation of Chemical Engineering (EFCE) Life-Time Achievements Award" and "Pro Universitaire Pannonica" Gold Medal. He has been a supervisor and co-supervisor of 27 PhD students at UMIST; The University of Manchester, UK; Prague University of Chemical Technology, Universiti Technologi Malaysia, Universiti Technologi Petronas, Malaysia, South China University of Technology, Guangzhou, China, University of Pannonia, Hungary, University of Maribor, Slovenia; D. Serikbayev East Kazakhstan State Technical University, Ust-Kamenogorsk, Kazakhstan, and Brno University of Technology, VUT Brno. Most PhD graduated as “Suma Cum laude” and “Cum laude”. He has many years of research and industrial experience, including research in process integration, sustainable technologies and renewable energy, which has resulted in extensive successful industrial case studies and applications. He consulted on energy saving and pollution reduction 37 major clients. Research results have been applied by world-leading industrial companies and universities as ICI (Imperial Chemical Industries) Plc, Runcorn, UK; Dow Chemical Canada Inc, Sarnia, Ontario; BASF Aktiengesellschaft, Ludwigshafen, Germany; COPENE – Petroquimica Do Nordeste S.A., Camacari/Bajia, Brazil, SLOVNAFT Bratislava, Slovakia; CHEMOPROJEKT Praha, Czechoslovakia; DUSLO Sala, Slovakia; NORSK HYDRO, Porsgrunn, Norway; ZVU Hradec Kralova; Czechoslovakia, Critical Fluid Systems Inc, Cambridge, MA, USA; United States Environmental Protection Agency, Washington, DC, USA; SHELL Global Solution, Amsterdam and ECOPETROL Colombia; MOL Group The Duna Refinery at Százhalombatta; PETROBRAS Brazil, ALDARIS Brewery Riga, Latvia; KREMENCHUG REFINERY and SODRUGESTVO-T Kharkiv, Ukraine; Sumy Khimprom TiO2 plant, Ukraine, EVECO Brno; CHEMOPETROL Litvínov, ACHEMA JONAVA Lithuania, PPRI Bratislava and Chemical Works NOVAKY Slovakia; BUTiH Poland, MARCH Consulting Group UK, LINNHOFF MARCH UK, Firth Executive Ltd Wales, UK, PETROM Romania; Libyan Petroleum Institute, Tripoli, Libya. A very high profile application was an invited FPD Course for a prestigious von Karman Institute for Fluid Dynamics in Brussels and CSIR - Council for Scientific and Industrial Research Pretoria, South Africa.
Affiliations and Expertise
University of Pannonia, Hungary
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