Handbook of Process Integration (PI)

Prof Dr-Hab Jiří Jaromír KLEMEŠ, DSc, Dr h c (mult) and George Pólya Professor. Head of a Centre of Excellence “Sustainable Process Integration Laboratory – SPIL”, NETME Centre, Faculty of Mechanical Engineering, Brno University of Technology - VUT Brno, Czech Republic. 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 97 major EC, NATO, bilateral and UK Know-How projects. Research funding attracted over 46 M€. Co-Editor-in-Chief of Journal of Cleaner Production (IF 2020 = 9.297) and Chemical Engineering Transactions, Editor in Chief Cleaner Technologies and Engineering and Cleaner Chemical Engineering (Elsevier); Subject Editor of Energy (IF 2020 = 7.147) Managing Guest Editor of Renewable and Sustainable Energy Reviews (IF 2020 = 14.982). The founder and President of 25 y of PRES (Process Integration for Energy Saving and Pollution Reduction) conferences. Seven years Chairperson of CAPE Working Party of European Federation of Chemical Engineering, a member of WP on Process Intensification. A Member of the IChemE, UK, Sargent Medal International Committee on CAPE. Awarded by the Web of Science and Publons as a Highly Cited Researcher, Top Peer Reviewer and Top Handling Editor. He authored and co-authored 792 papers (WoS) in 106 scientific journals, h-index in Google Scholar 78, Scopus 67, PUBLONS (WoS) 61. His Publons profile (Web of Science) has 2,552 reviews for 186 scientific journals and 17,020 Editor Merits for 24 Editorial boards. Invited lecturer at 68 universities, 14 Distinguished Visiting Professor, 6 Doctor Honoris causa, 36 PhD students, 44 Expert Evaluator. Several times Distinguished Visiting Professor incl Universiti Teknologi Malaysia and University Technology Petronas, Malaysia; Xi’an Jiaotong University; the South China University of Technology, Guangzhou, Xi’an Jiaotong-Liverpool University Suzhou, JiangSu, 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”, Ukraine, the University of Maribor, Slovenia, University POLITEHNICA Bucharest, Romania, Széchenyi István University Györ, Hungary and “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.

"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

• Contributor contact detailsWoodhead Publishing Series in EnergyForewordPart I: Overview of Process Integration and AnalysisChapter 1: Process Integration (PI): An IntroductionAbstract:1.1 Introduction1.2 A Short History of Process Integration (PI)1.3 Current Centres of Expertise in PI1.4 Sources of Further InformationChapter 2: Basic Process Integration TerminologyAbstract:2.1 Introduction2.2 Process Integration Terms: The Importance of Context2.3 Fundamental Process Integration Terms2.4 Conventions: Symbols for Heaters and Coolers2.6 Appendix: NomenclatureChapter 3: Process Design, Integration and Optimisation: Advantages, Challenges and DriversAbstract:3.1 Introduction3.2 Grassroots Design versus Retrofit Design3.3 Process Integration3.4 Integration versus Intensification3.5 Process Integration Techniques3.6 Optimisation of Integrated Processes3.7 Controllability of Integrated Processes3.8 Process Integration under DisturbancesPart II: Heat IntegrationChapter 4: Heat Integration: Targets and Heat Exchanger Network DesignAbstract:4.1 Introduction4.2 Stages in the Design of Heat Recovery Systems4.3 Data Extraction4.4 Performance Targets4.5 Process Modifications4.6 Network Design4.7 Design Evolution4.8 Conclusion4.9 Sources of Further InformationChapter 5: Application of Process Integration to the Synthesis of Heat and Power Utility Systems Including Combined Heat and Power (CHP) and Industrial Heat PumpsAbstract:5.1 Introduction5.2 Targeting Utility Loads and Temperature Levels5.3 Integration of Advanced Energy Conversion Cycles as Process Utilities: Basic Concepts5.4 Process Integration of Heat Engines5.5 Process Integration of Heat Pumps5.6 Sources of Further Information and AdviceChapter 6: Total Site MethodologyAbstract:6.1 Introduction6.2 Data Extraction for Total Sites6.3 Total Site Profiles and Total Site Composite Curves6.4 Site Utility Grand Composite Curve (SUGCC)6.5 Conclusion6.6 Sources of Further InformationChapter 7: Extending Total Site Methodology to Address Varying Energy Supply and DemandAbstract:7.1 Introduction7.2 Characteristics of Energy Supply and Demand7.3 Thermal Energy Storage and Integrated Architecture7.4 Terminology for Process Streams and Utilities7.5 Identification of Time Slices7.6 Heat Cascades for the Evaluation of Total Site Targets When There Is Variation in Supply and Demand7.7 Case Study: Integration of Solar Thermal Energy into a Locally Integrated Energy Sector (LIES)7.8 Conclusion7.9 Sources of Further Information7.11 Appendix: NomenclatureChapter 8: Analysis and Design of Heat Recovery Systems for Grassroots and Retrofit SituationsAbstract:8.1 Introduction8.2 Extended Procedures for Grassroots Analysis8.3 Extended Procedures for Grassroots Design8.4 Retrofit Analysis and Design8.5 Use of Optimisation for Heat Exchanger Network Synthesis8.6 Conclusion8.7 Sources of Further InformationChapter 9: Heat Integration in Batch ProcessesAbstract:9.1 Introduction9.2 Graphical Technique for Heat Integration in Batch Process9.3 Mathematical Technique for Heat Integration of Batch Plants9.4 Case Study of a Multipurpose Batch Facility9.5 Industrial Case Study9.6 Conclusion9.7 Sources of Further Information9.9 Appendix: Glover Transformation (Glover, 1975)Part III: Mass IntegrationChapter 10: Water Pinch Analysis for Water Management and Minimisation: An IntroductionAbstract:10.1 Approaches for Water Management and Minimisation10.2 Water Integration and Water Pinch Analysis10.3 Water Pinch Analysis Steps10.4 Examples of Successful Case Studies10.7 Appendix: NomenclatureChapter 11: Using Systematic Design Methods to Minimise Water Use in Process IndustriesAbstract:11.1 Introduction11.2 Water Use in Process Industries11.3 Process Integration for Water Systems11.4 Conclusions and Future Trends11.5 Sources of Further InformationChapter 12: Synthesis of Water Networks with Water Loss and Gain via an Extended Pinch Analysis TechniqueAbstract:12.1 Introduction12.2 Targeting a Single Water-Using Process12.3 Process-based Graphical Approach (PGA) for Synthesis of Direct Reuse Water Networks12.4 Conclusion12.5 Sources of Further Information and Advice12.6 Acknowledgements12.8 Appendix: NomenclatureChapter 13: Conserving Material Resources through Process Integration: Material Conservation NetworksAbstract:13.1 Introduction13.2 Overall Targeting of Material Conservation Networks13.3 Mass Exchange Networks13.4 Water-Pinch Analysis13.5 Direct Recycle and Material Recycle Pinch Diagram13.6 Property-Based Material Recycle Pinch Diagram13.8 Appendix: NomenclaturePart IV: Extended Process IntegrationChapter 14: Process Integration for Cleaner Process DesignAbstract:14.1 Introduction14.2 A Revised ‘Onion Diagram’14.3 Different Models for Total Material Network (TMN)14.4 Case Study: Water Minimisation in a Water Fabrication Plant14.5 Conclusion14.6 Sources of Further Information14.8 Appendix: NomenclatureChapter 15: Process Integration Concepts for Combined Energy and Water IntegrationAbstract:15.1 Introduction15.2 Water–Energy Specifics and Challenges15.3 Water Path Concept15.4 State-of-the-Art Methodology for Combined Energy and Water Integration15.5 Sequential, Simultaneous, Mathematical Programming15.6 Conclusion15.7 Sources of Further InformationChapter 16: Process Integration Techniques for Cogeneration and Trigeneration SystemsAbstract:16.1 Introduction16.2 Combined Heat and Power16.3 Heat Integration of Trigeneration Systems16.4 Conclusions16.5 Sources of Further Information16.7 Appendix: NomenclatureChapter 17: Pinch Analysis for Sustainable Energy Planning Using Diverse Quality MeasuresAbstract:17.1 Introduction17.2 Generalised Problem Statement17.3 Graphical Targeting Procedure17.4 Case Studies17.5 Conclusion17.6 Sources of Further Information17.8 AppendixChapter 18: A Unified Targeting Algorithm for Diverse Process Integration ProblemsAbstract:18.1 Introduction to Targeting Algorithms18.2 Unified Approach to Diverse Resource Optimisation Problems18.3 Basis for Unification18.4 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 Plant18.7 Hydrogen and Other Gas Networks18.8 Property-Based Material Reuse Networks18.9 Alternative Approaches to Targeting18.10 Conclusion18.11 Sources of Further Information18.13 Appendix: NomenclatureChapter 19: A Process Integration Approach for Supply Chain DevelopmentAbstract:19.1 Introduction19.2 Supply Chain Characteristics and Performance Measurement19.3 Supply Chain Development with Process Integration19.4 Case Studies19.5 Future Trends19.6 Sources of Further InformationChapter 20: Application of Heat Recovery Loops to Semi-continuous Processes for Process IntegrationAbstract:20.1 Introduction20.2 Indirect Heat Recovery Systems20.3 Application of Heat Recovery Loops to Semi-continuous Plants20.4 A More Complex Example of a Heat Recovery Loop (HRL)20.5 Case Study: Semi-continuous Multi-plant Dairy Factory20.6 Conclusions and Future Trends20.7 Sources of Further InformationPart V: Applications and Case StudiesChapter 21: Applications of Energy and Water Process Integration Methodologies in Oil Refineries and Petrochemical ComplexesAbstract:21.1 Introduction21.2 Heat and Power Integration21.3 Water and Wastewater MinimisationResults and DiscussionResults and Discussion21.4 Effluent Treatment and RegenerationResults and DiscussionResults and Discussion21.5 ConclusionChapter 22: Process Integration of an Oil Refinery Hydrogen NetworkAbstract:22.1 Introduction22.2 Technology Review22.3 An Industrial Case Study22.4 Hydrogen Management in the Wider Context of Process Integration: Future Trends22.5 Conclusion22.6 Sources of Further InformationChapter 23: Retrofit Mass Integration of Acid Gas Removal Systems in Petrochemical PlantsAbstract:23.1 Introduction23.2 Review of Previous Work on Mass Exchanger Network Synthesis (MENS) and Retrofit of Existing Systems23.3 Systems Studied: Venturi Scrubber System and Ethanolamine Absorber System23.4 Pinch Approach23.5 Hybrid Approach23.6 Solution Equilibria23.7 Results and Discussion23.8 Conclusions and Sources of Further InformationChapter 24: Applications of Pinch Technology to Total Sites: A Heavy Chemical Industrial Complex and a Steel PlantAbstract:24.1 Introduction24.2 Case Study of a Heavy Chemical Complex24.3 Case Study of a Steel Plant24.4 Conclusion24.5 Sources of Further Information24.6 AcknowledgementsChapter 25: Applications of Process Integration Methodologies in the Pulp and Paper IndustryAbstract:25.1 Introduction25.2 Energy Demands and Sources in the Kraft Pulping Process25.3 Relations between the Heat Exchanger and Water Networks25.4 Increasing Energy Efficiency in Existing Mills25.5 Methodological Developments for Heat Integration in Existing Mills25.6 Evolution of Pulp and Paper Mills25.7 Conclusion25.8 Sources of Further InformationChapter 26: Application of Process Integration Methodologies to the Thermal Processing of WasteAbstract:26.1 Introduction26.2 Types of Waste Thermal Processing Plants26.3 Analysis of Energy Efficiency in the TERMIZO Plant26.4 Application of Heat Integration Technology26.5 Conclusion26.6 Sources of Further Information and AdviceChapter 27: Application of Process Integration Methodologies in the Brewing IndustryAbstract:27.1 Introduction27.2 Process Flowsheet Analysis27.3 Calculating Maximum Heat Recovery in the System27.4 Defining the Energy Conversion System27.5 Conclusion27.6 Sources of Further Information27.8 Appendix A: Complementary Tables27.9 Appendix B: NomenclatureChapter 28: Applications of Process Integration Methodologies in Dairy and Cheese ProductionAbstract:28.1 Introduction28.2 Application of Process Integration Methodologies28.3 Selected Case Studies28.4 Future Trends28.5 Sources of Further InformationChapter 29: Applications of Process Integration Methodologies in Beet Sugar PlantsAbstract:29.1 Introduction29.2 Sugar Production from Sugar Beet29.3 Identification of Opportunities to Improve Energy and Water Use in Sugar Plants29.4 Reduction of Energy Consumption29.5 Reduction of Water Consumption29.6 Energy and Water Use in Sugar Production Directly from Raw Beet Juice29.7 Future Trends29.8 Sources of Further Information and AdviceChapter 30: Application of Process Integration Techniques for the Efficient Use of Energy in a Urea Fertiliser Plant: A Case StudyAbstract:30.1 Introduction30.2 Process Description30.3 Opportunities for the Reduction of Energy Consumption30.4 Conclusion30.5 Sources of Further Information30.7 Appendix: NomenclatureChapter 31: Process Integration for Energy Saving in Buildings and Building ComplexesAbstract:31.1 Introduction31.2 Buildings as Consumers and Producers of Energy31.3 Commercial and Public Buildings and Building Complexes31.4 District Energy (DE) Systems and Total Site Analysis (TSA)31.5 The Use of Industrial Waste Heat31.6 Renewable Energy for Buildings31.7 Conclusion31.8 Sources of Further Information and AdviceChapter 32: Heat Transfer Enhancement in Heat Exchanger NetworksAbstract:32.1 Introduction to Shell-and-Tube Heat Exchangers32.2 Heat Transfer Enhancement Techniques32.3 Heat Transfer Enhancement in Heat Exchanger Network Retrofit32.4 Heat Transfer Enhancement in Heat Exchanger Network Retrofit with Fouling Consideration32.5 Sources of Further Information32.6 NomenclatureChapter 33: Applications of Pinch Analysis in the Design of Isolated Energy SystemsAbstract:33.1 Introduction33.2 Isolated Energy Systems: Descriptions and Models33.3 Grand Composite Curve and Storage Sizing33.4 Design Space33.5 Illustrative Applications33.6 Sources of Further Information and AdvicePart VI: Software Tools and EpilogueChapter 34: Software Tools for Heat IntegrationAbstract:34.1 Heat Integration Software Tools34.2 Sources of Further Information and AdviceChapter 35: Mass and Water Integration Software ToolsAbstract:35.1 Mass and Water Integration Software Tools35.2 Sources of Further Information and AdviceChapter 36: Epilogue: The Importance of Problem Formulation and Data Extraction in Process IntegrationAbstract:36.1 Introduction: Process Integration – from its Roots to its Present Strong Position36.2 Successful Applications of Process Integration36.3 Methods of Obtaining Credible High Integration HI Solutions36.4 Data Extraction36.5 Integration of Renewables – Fluctuating Demand and Supply36.6 Results Interpretation36.7 Conclusion: Making It Happen36.8 Sources of Further Information36.9 AcknowledgementsIndex