Presents comprehensive coverage of process intensification and integration for sustainable design, along with fundamental techniques and experiences from the industry
Drawing from fundamental techniques and recent industrial experiences, this book discusses the many developments in process intensification and integration and focuses on increasing sustainability via several overarching topics such as Sustainable Manufacturing, Energy Saving Technologies, and Resource Conservation and Pollution Prevention Techniques.
Process Intensification and Integration for Sustainable Design starts discussions on: shale gas as an option for the production of chemicals and challenges for process intensification; the design and techno-economic analysis of separation units to handle feedstock variability in shale gas treatment; RO-PRO desalination; and techno-economic and environmental assessment of ultrathin polysulfone membranes for oxygen-enriched combustion. Next, it looks at process intensification of membrane-based systems for water, energy, and environment applications; the design of internally heat-integrated distillation column (HIDiC); and graphical analysis and integration of heat exchanger networks with heat pumps. Decomposition and implementation of large-scale interplant heat integration is covered, as is the synthesis of combined heat and mass exchange networks (CHAMENs) with renewables. The book also covers optimization strategies for integrating and intensifying housing complexes; a sustainable biomass conversion process assessment; and more.
- Covers the many advances and changes in process intensification and integration
- Provides side-by-side discussions of fundamental techniques and recent industrial experiences to guide practitioners in their own processes
- Presents comprehensive coverage of topics relevant, among others, to the process industry, biorefineries, and plant energy management
- Offers insightful analysis and integration of reactor and heat exchanger network
- Looks at optimization of integrated water and multi-regenerator membrane systems involving multi-contaminants
Process Intensification and Integration for Sustainable Design is an ideal book for process engineers, chemical engineers, engineering scientists, engineering consultants, and chemists.
Table of Contents
Preface xv
1 Shale Gas as an Option for the Production of Chemicals and Challenges for Process Intensification 1
Andrea P. Ortiz-Espinoza and Arturo Jiménez-Gutiérrez
1.1 Introduction 1
1.2 Where Is It Found? 1
1.3 Shale Gas Composition 3
1.4 Shale Gas Effect on Natural Gas Prices 3
1.5 Alternatives to Produce Chemicals from Shale Gas 4
1.6 Synthesis Gas 4
1.7 Methanol 5
1.8 Ethylene 6
1.9 Benzene 7
1.10 Propylene 7
1.11 Process Intensification Opportunities 8
1.12 Potential Benefits and Tradeoffs Associated with Process Intensification 10
1.13 Conclusions 11
References 11
2 Design and Techno-Economic Analysis of Separation Units to Handle Feedstock Variability in Shale Gas Treatment 15
Eric Bohac, Debalina Sengupta, andMahmoud M. El-Halwagi
2.1 Introduction 15
2.2 Problem Statement 16
2.3 Methodology 17
2.4 Case Study 17
2.4.1 Data 18
2.4.2 Process Simulations and Economic Evaluation 19
2.4.2.1 Changes in Fixed and Variable Costs 20
2.4.2.2 Revenue 21
2.4.2.3 Economic Calculations 21
2.4.3 Safety Index Calculations 22
2.5 Discussion 23
2.5.1 Process Simulations 23
2.5.1.1 Dehydration Process 23
2.5.1.2 NGL Recovery Process 23
2.5.1.3 Fractionation Train 26
2.5.1.4 Acid Gas Removal 26
2.5.2 Profitability Assessment 26
2.5.3 High Acid Gas Case Economics 30
2.5.4 Safety Index Results 30
2.5.5 Sensitivity Analysis 32
2.5.5.1 Heating Value Cases 33
2.5.5.2 NGL Price Cases 34
2.6 Conclusions 35
Appendices 35
2.A Appendix A: Key Parameters for the Dehydration Process 36
2.B Appendix B: Key Parameters for the Turboexpander Process 36
2.C Appendix C: Key Parameters for the Fractionation Train 37
2.D Appendix D: Key Parameters for the Acid Gas Removal System 37
References 39
3 Sustainable Design and Model-Based Optimization of Hybrid RO-PRO Desalination Process 43
Zhibin Lu, Chang He, Bingjian Zhang, Qinglin Chen, and Ming Pan
3.1 Introduction 43
3.2 Unit Model Description and Hybrid Process Design 47
3.2.1 The Process Description 47
3.2.2 Unit Model and Performance Metrics 49
3.2.2.1 RO Unit Model 49
3.2.2.2 PRO Unit Model 52
3.2.3 The RO-PRO Hybrid Processes 54
3.2.3.1 Open-Loop Configuration 54
3.2.3.2 Closed-Loop Configuration 55
3.3 Unified Model-Based Analysis and Optimization 56
3.3.1 Dimensionless Mathematical Modeling 56
3.3.2 Mathematical Model and Objectives 58
3.3.3 Optimization Results and Comparative Analysis 59
3.4 Conclusion 62
Nomenclature 63
References 65
4 Techno-economic and Environmental Assessment of Ultrathin Polysulfone Membranes for Oxygen-Enriched Combustion 69
Serene Sow Mun Lock, Kok Keong Lau, Azmi Mohd Shariff, Yin Fong Yeong, and Norwahyu Jusoh
4.1 Introduction 69
4.2 Numerical Methodology for Membrane Gas Separation Design 70
4.3 Methodology 73
4.3.1 Simulation and Elucidation of Mixed Gas Transport Properties of Ultrathin PSF Membranes (Molecular Scale) 73
4.3.2 Simulation of Mathematical Model Interfaced in Aspen HYSYS for Mass and Heat Balance (Mesoscale) 75
4.3.3 Design of Oxygen-Enriched Combustion Using Ultrathin PSF Membranes 75
4.4 Results and Discussion 77
4.4.1 Simulation and Elucidation of Mixed Gas Transport Properties of Ultrathin PSF Membranes (Molecular) 77
4.4.2 Simulation of Mathematical Model Interfaced in Aspen HYSYS for Mass and Heat Balance (Mesoscale) 79
4.4.3 Design of Oxygen-Enriched Combustion Using Ultrathin PSF Membranes 82
4.4.3.1 Membrane Area Requirement 82
4.4.3.2 Compressor Power Requirement 83
4.4.3.3 Turbine Power Requirement 85
4.4.3.4 Economic Parameter 88
4.5 Conclusion 90
Acknowledgment 91
References 91
5 Process Intensification of Membrane-Based Systems for Water, Energy, and Environment Applications 97
Nik A. H.M. Nordin, Zulfan A. Putra, Muhammad R. Bilad, Mohd D. H.Wirzal, Lila Balasubramaniam, Anis S. Ishak, and Sawin Kaur Ranjit Singh
5.1 Introduction 97
5.2 Membrane Electrocoagulation Flocculation for Dye Removal 99
5.3 Carbonation Bioreactor for Microalgae Cultivation 102
5.4 Forward Osmosis and Electrolysis for Energy Storage and Treatment of Emerging Pollutant 107
5.5 Conclusions and Future Perspective 111
References 113
6 Design of Internally Heat-Integrated Distillation Column (HIDiC) 117
Vasu Harvindran and Dominic C. Y. Foo
6.1 Introduction 117
6.2 Example and Conceptual Design of Conventional Column 119
6.3 Basic Design of HIDiC 120
6.4 Complete Design of HIDiC 122
6.4.1 Top-Integrated Column 122
6.4.2 Bottom-Integrated Column 123
6.4.3 Geometrical Analysis for Heat Panels 124
6.5 Energy Savings and Economic Evaluation 126
6.6 Concluding Thoughts 128
References 128
7 Graphical Analysis and Integration of Heat Exchanger Networks with Heat Pumps 131
Minbo Yang and Xiao Feng
7.1 Introduction 131
7.2 Influences of Heat Pumps on HENs 132
7.2.1 Case 1 133
7.2.2 Case 2 134
7.2.3 Case 3 134
7.2.4 Case 4 135
7.2.5 Case 5 136
7.2.6 Case 6 136
7.2.7 Case 7 136
7.3 Integration of Heat Pump Assisted Distillation in the Overall Process 138
7.3.1 Increase of Pinch Temperature 138
7.3.2 Decrease of Pinch Temperature 140
7.3.3 No Change in Pinch Temperature 141
7.3.4 Heat Pump Placement 142
7.4 Case Study 145
7.5 Conclusion 148
References 148
8 Insightful Analysis and Integration of Reactor and Heat Exchanger Network 151
Di Zhang, Guilian Liu, and Xiao Feng
8.1 Introduction 151
8.2 Influence of Temperature Variation on HEN 152
8.2.1 Location of Cold and Hot Streams 152
8.2.2 Effect of Temperature Variation 153
8.3 Relation Among Reactor Parameters 156
8.3.1 Relation Among Temperatures, Selectivity, and Conversion of Reactor 157
8.3.1.1 CSTR 159
8.3.1.2 PFR 159
8.3.2 Reactor Characteristic Diagram 160
8.4 Coupling Optimization of HEN and Reactor 161
8.5 Case Study 163
8.6 Conclusions 165
References 166
9 Fouling Mitigation in Heat Exchanger Network Through Process Optimization 167
Yufei Wang and Xiao Feng
9.1 Introduction 167
9.2 Operation Parameter Optimization for Fouling Mitigation in HENs 169
9.2.1 Description on Velocity Optimization 169
9.2.2 Fouling Threshold Model 171
9.2.3 Heat Transfer Related Models 172
9.2.4 Pressure Drop Related Models 174
9.3 Optimization of Cleaning Schedule 175
9.4 Application of Backup Heat Exchangers 175
9.5 Optimization Constraints and Objective Function 176
9.5.1 Optimization Constraints 176
9.5.2 Objective Function 177
9.5.3 Optimization Algorithm 178
9.6 Case Studies 178
9.6.1 Case Study 1: Consideration of Velocity Optimization Alone 178
9.6.1.1 Optimization Results 180
9.6.2 Case Study 2: Simultaneous Consideration of Velocity and Cleaning Schedule Optimization 186
9.6.2.1 Constraints for Case Study 188
9.6.2.2 Results and Discussion 189
9.6.2.3 Considering Backup Heat Exchanger 194
9.7 Conclusion 194
Acknowledgments 196
References 198
10 Decomposition and Implementation of Large-Scale Interplant Heat Integration 201
Runrun Song, Xiao Feng, Mahmoud M. El-Halwagi, and Yufei Wang
10.1 Introduction 201
10.1.1 Reviews and Discussions for Stream Selection 202
10.1.2 Reviews and Discussions for Plant Selection 204
10.1.3 Reviews and Discussions for Plant Integration 204
10.2 Methodology 205
10.2.1 Strategy 1 - Overview 205
10.2.2 Identification of Heat Sources/Sinks for IPHI from Individual Plants 206
10.2.3 Decomposition of a Large-Scale IPHI Problem into Small-Scale Subsections 207
10.2.4 Strategy 2 for Indirect IPHI 209
10.3 Case Study 212
10.3.1 Example 1 212
10.3.2 Example 2 215
10.4 Conclusion 217
References 218
11 Multi-objective Optimisation of Integrated Heat, Mass and Regeneration Networks with Renewables Considering Economics and Environmental Impact 221
So-Mang Kim, Adeniyi J. Isafiade, and Michael Short
11.1 Introduction 221
11.2 Literature Review 222
11.2.1 Regeneration in Process Synthesis 222
11.2.2 The Analogy of MEN and REN 222
11.2.3 Combined Heat and Mass Exchange Networks (CHAMENs) 224
11.3 Environmental Impact in Process Synthesis 225
11.3.1 Life Cycle Assessment 225
11.4 The Synthesis Method and Model Formulation 226
11.4.1 Synthesis Approach 227
11.4.2 Assumptions 229
11.4.3 MINLP Model Formulation 230
11.4.3.1 HENS Model Equations 230
11.4.3.2 MEN and REN Model Equations 233
11.4.3.3 The Combined Economic Objective Function 236
11.4.3.4 Initializations and Convergence 239
11.5 Case Study 240
11.5.1 H2S Removal 240
11.5.1.1 Synthesis of MEN (The First Step) 242
11.5.1.2 Simultaneous Synthesis of MEN and REN (The Second Step) 243
11.5.1.3 Simultaneous Synthesis of MEN, REN, and HEN (The Third Step) 244
11.5.1.4 Absorption and Regeneration Temperature Optimization 247
11.5.1.5 The Synthesis of Combined Model Using MOO 252
11.6 Conclusions and Future Works 254
References 256
12 Optimization of Integrated Water and Multi-regenerator Membrane Systems Involving Multi-contaminants: A Water-Energy Nexus Aspect 261
Musah Abass and Thokozani Majozi
12.1 Introduction 261
12.2 Problem Statement 263
12.3 Model Formulation 263
12.3.1 Material Balances for Sources 264
12.3.2 Mass and Contaminants Balances for Regeneration Units 265
12.3.3 Mass and Contaminant Balances for Permeate and Reject Streams 265
12.3.4 Mass and Contaminant Balances for Sinks 266
12.3.5 Modeling of the Regeneration Units 266
12.3.5.1 Performance of Regeneration Units 266
12.3.6 Logical Constraints 267
12.3.7 The Objective Function 267
12.4 Illustrative Example 268
12.5 Conclusion 272
Acknowledgments 272
12.A Appendix: Detailed Models for the ED and RO Modules 273
Nomenclature 280
References 282
13 Optimization Strategies for Integrating and Intensifying Housing Complexes 285
Jesús M. Núñez-López, and JoséM. Ponce-Ortega
13.1 Introduction 285
13.2 Methods 288
13.2.1 Total Annual Cost for the Integrated System 289
13.2.2 FreshWater Consumption 289
13.2.3 GHGE Emissions 290
13.2.4 Environmental Impact 290
13.2.5 Sustainability Return of Investment 293
13.2.6 Process Route Healthiness Index 293
13.2.7 Multistakeholder Approach 295
13.3 Case Study 295
13.4 Results 296
13.5 Conclusions 296
References 299
14 Sustainable Biomass Conversion Process Assessment 301
Eric C. D. Tan
14.1 Introduction 301
14.2 Methodology and Assumptions 302
14.3 Results and Discussion 305
14.3.1 Environmental Indicators 305
14.3.2 Energy Indicators 310
14.3.3 Efficiency Indicators 312
14.3.4 Economic Indicators 313
14.4 Conclusions 314
Acknowledgments 316
References 317
Index 319
