Smith: Chemical Process Design and Integration (Chapters 16,18)

Kemp: Pinch Analysis and Process Integration (Chapter 9)

Process Integration
for Efficient Use of Energy

Cheng-Liang Chen

PSE

LABORATORY

Department of Chemical Engineering

National TAIWAN University

Chen CL

Important Global Crises

Ten Most Important Global Crises:
Energy
Water
Food
Environment Poverty
Terrorism Disease Education Democracy
Population

Chen CL

Chen CL

Chen CL

Outline
Systematic Approach for Chemical Process Design
How do we go about the design of a chemical process?
What Is Process Integration?
Onion model for process integration
Pinch Analysis: Targeting Heat Recovery in Processes
The Pinch Design Method for Heat Recovery Systems
A Pinch Study Performed on A Major Operating Plant
Utility Selection for Individual Processes
Putting It into Practice
Concluding Remarks

Chen CL

Systematic Approach
for

Chemical Process Design

Chen CL

Chemical Process Design

How do we go about the design of a chemical process?

Chen CL

Chemical Process Design

How do we go about the design of a chemical process?

Chen CL

Chemical Process Design

How do we go about the design of a chemical process?

Chen CL

Chemical Process Design

How do we go about the design of a chemical process?

Chen CL

10

Chemical Process Design

How do we go about the design of a chemical process?

Finished Process ?
UNFORTUNATELY
This is inefficient in energy use!
So lets consider heat recovery
to reduce the energy consumption

Chen CL

11

Chemical Process Design

How do we go about the design of a chemical process?

Some streams need to be cooled down

and some need to be heated up

Chen CL

12

Chemical Process Design

How do we go about the design of a chemical process?

Recover heat between a stream that needs to be

cooled down and one that needs to be heated up

Chen CL

13

Chemical Process Design

How do we go about the design of a chemical process?

and more heat recovery completes the design

Chen CL

14

Chemical Process Design

How do we go about the design of a chemical process?

different possibilities for heat integration

Chen CL

15

Chemical Process Design

How do we go about the design of a chemical process?

Changing the reactor dictates

a different separation and recycle problem

Chen CL

16

Chemical Process Design

How do we go about the design of a chemical process?

Changing the reactor dictates

a different separation and recycle problem

Chen CL

17

Chemical Process Design

How do we go about the design of a chemical process?

leads to a different separation system and different heat recovery

Chen CL

18

Chemical Process Design

How do we go about the design of a chemical process?

leads to a different separation system and different heat recovery

Chen CL

19

What Is
Process Integration ?

Chen CL

20

What Is Process Integration?

First choose a series of processing steps

Chen CL

21

What Is Process Integration?

Then connect these processing steps together

To give an integrated manufacturing system that is:

Environmentally acceptable; Safe; Profitable; Operable

Chen CL

22

What Is Process Integration?

First Process Integration:

Then Process Simulation:

Chen CL

23

Onion Model
for

Process Integration

Chen CL

24

Onion Model
Start With The Reactor

Chen CL

25

Onion Model
Then Add Separation System and Connect Up Recycle

Chen CL

26

Onion Model
Recover Heat Where Possible

Chen CL

27

Onion Model
Dictate The Need for External Utilities

Chen CL

28

Hierarchy of Process Design

Reactor Design

Separation
System Design

HEN Design

Utility
System Design
Process design is strongly coupled with Heat Exchanger Networks

Chen CL

Process Integration (for Heat Recovery)

Process Integration:
using process streams to heat and cool other streams
Hot streams gives off heat to another streams
Cold streams absorbs heat from another streams
Additional heating or cooling is done using utility streams
Heat recovery reduces utility requirements, and therefore
operating costs

29

Chen CL

30

Process Integration (for Heat Recovery)

Ex: 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.

Chen CL

31

Process Integration (for Heat Recovery)

Ex: The Front End of A Specialty chemicals Process

The alternative flowsheet uses only four heat transfer units and the
utility heating load is reduced by about 40% (1, 068 kW) with
cooling no longer required.

Chen CL

32

Thank You for Your Attention

Questions Are Welcome