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This dissertation is a complete unifying approach to the fundamentals, industrial applications and software implementation of an important branch of process-engineering principles and practice, called process integration. The latter refers to the system-oriented, thermodynamically-based and integrated approaches to the analysis, synthesis and retrofit of process plants, focusing on integrating the use of materials and energy, and minimizing the generation of emissions and wastes. This work extends process integration to include applications for industrial water reuse and wastewater minimization and presents previous developments in a unified manner. The basic ideas of process integration are: (1) to consider first the big picture by looking at the entire manufacturing process as an integrated system; (2) to apply process-engineering principles to key process steps to establish a priori targets for the use of materials and energy, and for the generation of emissions and wastes; and (3) to finalize the details of the process design and retrofit later to support the integrated view, particularly in meeting the established targets. Pinch technology is a set of primarily graphical tools for analyzing a process plant's potential for energy conservation, emission reduction and waste minimization. Here, we identify targets for the minimum consumption of heating and cooling utilities, mass-separating agents, freshwater consumption, wastewater generation and effluent treatment and propose economical grassroots designs and retrofit projects to meet these goals. An emerging alternative approach to pinch technology, especially when analyzing complex water-using operations and effluent-treatment systems, is mathematical optimization. We solve nonlinear programming problems for simple water-using operations through readily available commercial software. However, more complex, nonconvex problems require sophisticated reformulation techniques to guarantee optimality and are the subject of continuing academic and commercial development. This work develops the principles and practice of an environmentally significant breakthrough of process integration, called water-pinch technology. The new technology enables the practicing engineers to maximize water reuse, reduce wastewater generation, and minimize effluent treatment through pinch technology and mathematical optimization. It applies the technology in an industrial water-reuse demonstration project in a petrochemical complex in Taiwan, increasing the average water reuse (and thus reducing the wastewater treatment) in the five manufacturing facilities from 18.6% to 37%. This dissertation presents complete conceptual and software developments to unify the known branches of process integration, such as heat and mass integration, and wastewater minimization, and explores new frontiers of applications to greatly simplify the tools of process integration for practicing engineers. / Ph. D.

The purpose of this thesis is to use a model to optimize the heat exchanger network for process industry and to estimate the minimum cost required for the heat exchanger network without compromising the energy demand by each stream as much as possible with the help of MATLAB programming software. Here, the optimization is done without considering stream splitting and stream combining. The first phase involves with deriving a simple heat exchanger network consisting of four streams i.e... Two hot streams and two cold streams required for the heat exchanger using the traditional Pinch Analysis method. The second phase of this work deals with randomly placing the heat exchanger network between the hot and cold streams and calculating the minimum cost of the heat exchanger network using genetic coding which is nothing but thousands of randomly created heat exchangers which are evolved over series of population.

Orientador: Antonio Carlos Bannwart / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-07-25T04:21:28Z (GMT). No. of bitstreams: 1 Higa_Marcio_M.pdf: 7914219 bytes, checksum: c0df34dbad62f75065ad547646e7c5c8 (MD5) Previous issue date: 1999 / Resumo: Através dos métodos do "pinch-point" e da programação linear, foram realizadas diversas simulações e análises térmicas de uma planta típica de produção de açúcar e álcool, visando a máxima recuperação de calor e a redução do consumo de vapor. As simulações foram divididas em três grupos. No primeiro, usou-se o método do "pinch-point" para investigar basicamente a planta de produção de açúcar, analisando também a influência de diversas alternativas (eliminação de sangrias de vapor entre estágios de evaporação, número de efeitos de evaporação, compressão mecânica do vapor do último estágio de evaporação, área e número de trocadores de calor). No segundo grupo, na mesma planta, empregou-se o método de programação linear, a fIm de determinar a distribuição otimizada das sangrias de vapor para pré-aquecimento do caldo. No terceiro grupo de análises, considerando também o consumo na produção de álcool, retomou-se ao método do "pinch-point", onde as sangrias foram primeiramente maxirnizadas nos últimos estágios de evaporação e em seguida ajustadas para satisfazer as áreas dos evaporadores existentes na planta básica. Para tanto, foi desenvolvido um programa de computador específico que permite a simulação do efeito das diversas variáveis, inclusive a razão de produção açúcar/álcool. Diversas alternativas de grande impacto no consumo de vapor são apresentadas / Abstract: Using pinch technology and linear prograrnrning, several simulations of thermal analysis of a typical sugar cane plant and alcohol production were performed. The objective was the maximum heat recovery and the reduction of steam consumption. The simulations were divided into three groups. In the fIrst, pinch technology was applied to analyze only the sugar cane basic plant production and the influence of several alte~natives (elimination of vapor bleed between evaporator effects, number of evaporator effects, mechanical compression of vapor in the last effect of evaporation, area and number of heat exchangers). In the second group, use was made of linear prograrnrningin the same plant to determine the optimized confIguration of vapor bleeds for juice preheating. In the third group, pinch technology was again applied, including the consumption from alcohol production. First of ali, the maximum vapor bleed was assumed at the last effects of evaporation, then adjusted to adapt to the evaporator areas of basic plant. Therefore, a specifIc computer programming was developed to simulate the several variable, including the ratio of production sugar/alcohoL Several alternatives of deep impact in steam consumption were investigated. / Mestrado / Termica e Fluidos / Mestre em Engenharia Mecânica

Thesis submitted in fulfilment of the requirements for the degree of Master of Technology: Chemical Engineering, In the Faculty of Engineering, Cape Peninsula University of Technology 2014 / Energy efficiency has become an important feature in the design of process plants due to the rising cost of energy and the more stringent environmental regulations being implemented worldwide. In South Africa as in other African countries, most of the chemical plants were built during the era of cheap energy with little emphasis placed on energy efficiency due to the abundance of cheap utility sources such as coal and crude oil. In most of these plants, there exists significant potential for substantial process heat recovery by conceptual integration of the plant’s heat exchangers. Pinch Technology (PT) has been demonstrated to be a simple and very effective technique for heat integration and process optimization. This study applies the PT approach to retrofit the heat exchangers network of the Crude Distillation Unit (CDU), of a complex petroleum refinery with the aim to reduce utilities requirement and the associated gaseous pollutants emission. This objective is accomplished by firstly conducting an energy audit of the unit to scope for potential energy saving. The existing Heat Exchanger Network (HEN) was re-designed using the remaining problem analysis (RPA) to achieve improved process energy recovery while making maximum use of the existing exchangers. The aim is to maintain the existing plant topology as much as possible. This network was later relaxed trading heat recovery with number of heat transfer unit so as to optimize the capital cost. These were implemented in AspenPlus v7.2 environment. The cost implications of the retrofitted and evolved networks including the capital and operating costs were determined on a 5 years payback time basis. The Problem Table (PT) analysis revealed that the minimum utilities requirements are 75 MW and 55 MW for the hot and cold utilities respectively. Compared to the existing utilities requirements of 103 MW for hot utility and 83 MW for cold utility, this represent a potential savings of about 26 % and 33 % savings for the hot and cold utilities respectively. The target utilities usage in the re-designed network after applying Remaining Problem Analysis (RPA) was found to be 55 MW for the cold utility and 75 MW for hot utility. The relaxed HEN required a cold utility of 62.5 MW and hot utility of 81 MW. From the total cost estimation, it was found that, although an energy saving of 34% can be achieved by the re-designed network before relaxation, the capital cost, US$ 1670000 is significantly higher than for the existing network (about US$ 980000). The final relaxed network gave an energy saving of 34% and with total cost of US$ 1100000. It was recommended from the study after cost comparisons of the four different networks (the original network, the MER network, the relaxed network and a grass-root design) that the best network for the retrofit purpose was the relaxed HEN, because there is no major shift in deviation from the topology of the original network. From the analysis it was found that a 34% saving in energy cost could be achieved from this retrofit. The Total Annual Cost (TAC) for this network gives credence to the fact that this retrofit which applied the rules of pinch analysis can bring about real saving in energy usage.

The objectives of this doctoral thesis are to give a basisincluding methods for the development of stationary polymerelectrolyte fuel cell (PEFC) systems for combined heat andpower production. Moreover, the objectives include identifyingprerequisites, requirements and possibilities for PEFC systemsproducing heat and power for buildings in Sweden. The PEFCsystem is still in a pre-commercial state, but low emissionlevels, fast dynamics and high efficiencies are promisingcharacteristics. A thermodynamic model to simulate stationary PEFC systemshas been constructed and pinch technology and exergy analysesare utilised to design and evaluate the system. The finalsystem configuration implies a high total efficiency ofapproximately 98 % (LHV). A flexible test facility was built in connection with theresearch project to experimentally evaluate small-scalestationary PEFC systems at KTH. The research PEFC system hasextensive measurement equipment, a rigorous control system andallows fuel cell systems from approximately 0.2 to 4 kWel insize to be tested. The simulation models of the fuel processorand the fuel cell stack are verified with experimental datataken from the test facility. The initial evaluation andsimulation of the first residential installation of a PEFCsystem in Sweden is also reported. This PEFC system, fuelled bybiogas and hydrogen, is installed in an energy system alsoincluding a photovoltaic array, an electrolyser and hydrogenstorage. Technical aspects of designing a fuel cell system-basedenergy system, including storages and grid connections, whichprovides heat and power to a building are presented in thisthesis. As a basis for the technical and economic evaluations,exemplifying energy systems are constructed and simulated. Fuelcell system installations are predicted to be economicallyunviable for probable near-term conditions in Sweden. The mainfactor in the economic evaluations is the fuel price. However,fuel cell system installations are shown to have a higher fuelutilisation than the conventional method of energy supply. The methods presented in this thesis serve as a collectedbasis for continued research and development in the area. Keywords:Small-scale, stationary, fuel cell system,polymer electrolyte fuel cell, PEFC system, reformer,thermodynamic modelling, pinch technology, exergy analyses,system configuration, test facility, experiments, application,simulation, installation, energy system, energy storage, heatand power demand.

<p>The objectives of this doctoral thesis are to give a basisincluding methods for the development of stationary polymerelectrolyte fuel cell (PEFC) systems for combined heat andpower production. Moreover, the objectives include identifyingprerequisites, requirements and possibilities for PEFC systemsproducing heat and power for buildings in Sweden. The PEFCsystem is still in a pre-commercial state, but low emissionlevels, fast dynamics and high efficiencies are promisingcharacteristics.</p><p>A thermodynamic model to simulate stationary PEFC systemshas been constructed and pinch technology and exergy analysesare utilised to design and evaluate the system. The finalsystem configuration implies a high total efficiency ofapproximately 98 % (LHV).</p><p>A flexible test facility was built in connection with theresearch project to experimentally evaluate small-scalestationary PEFC systems at KTH. The research PEFC system hasextensive measurement equipment, a rigorous control system andallows fuel cell systems from approximately 0.2 to 4 kWel insize to be tested. The simulation models of the fuel processorand the fuel cell stack are verified with experimental datataken from the test facility. The initial evaluation andsimulation of the first residential installation of a PEFCsystem in Sweden is also reported. This PEFC system, fuelled bybiogas and hydrogen, is installed in an energy system alsoincluding a photovoltaic array, an electrolyser and hydrogenstorage.</p><p>Technical aspects of designing a fuel cell system-basedenergy system, including storages and grid connections, whichprovides heat and power to a building are presented in thisthesis. As a basis for the technical and economic evaluations,exemplifying energy systems are constructed and simulated. Fuelcell system installations are predicted to be economicallyunviable for probable near-term conditions in Sweden. The mainfactor in the economic evaluations is the fuel price. However,fuel cell system installations are shown to have a higher fuelutilisation than the conventional method of energy supply.</p><p>The methods presented in this thesis serve as a collectedbasis for continued research and development in the area.</p><p><b>Keywords:</b>Small-scale, stationary, fuel cell system,polymer electrolyte fuel cell, PEFC system, reformer,thermodynamic modelling, pinch technology, exergy analyses,system configuration, test facility, experiments, application,simulation, installation, energy system, energy storage, heatand power demand.</p>