the role of process integration in the ghg and haze/smog ... · 1990 – 2004. centre for process...
TRANSCRIPT
The role of Process Integration in the GHG and HazeSmog
Emissions Reduction
Jiřiacute Jaromiacuter Klemeš Yee Van Fan Petar Sabev VarbanovSustainable Process Integration Laboratory (SPIL) NETME CENTRE Brno
University of Technology VUT ndash Brno Czech Republic
The RouteUnited Kingdomrarr Hungary rarr Czech Republic
Edinburgh
Manchester
Brno
BudapestVeszprem
UMIST ndash Pioneering Pinch AnalysisDepartment of Process Integration at UMIST
1990 ndash 2004
Centre for Process Integration and Intensification - CPI2
University of Pannonia Hungary
PhD and Graduates
Dr Anja Kostevšek Jun Yow Yong楊俊耀
Dr Wan NorlindaRoshana bt Mohd Nawi
Dr Xia Liu刘 霞
Dr Luca De Benedetto
SUMMA CUM LAUDE
DDr Hon Loong Lam
林汉龙SUMMA CUM LAUDE
Dr Laacuteszloacute SikosSUMMA CUM LAUDE
Dr Zsoacutefia FodorCUM LAUDE
Dr Kew Hong Chew
周桂凤DEANS AWARD
BEST PhD
Dr Peng Yen Liew
廖炳彥UTM CHANCELLOR AWARD - BEST PhD
Dr Lidija ČučekSUMMA CUM LAUDE
DDr Andreja NemetCUM LAUDE
Dr Nor Erniza BtMohammad Rozali
UTM PRO-CHANCELLOR
AWARD
Prof Jiřiacute KlemešCPI2 Head
Dr Petar VarbanovCPI2 Deputy Head
Prof Zdravko KravanjaUniversity of Maribor
Slovenia
Ir Dr Sharifah RafidahWan Alwi
Prof ZainuddinAbdul Manan
Universiti Teknologi Malaysia
Prof Yu Qian钱 宇
South China University of Technology
Dr SiYu Yang杨思宇
Brno
Mahen Theatre
Petrov
Freedom Square
Vegetable Market
View of Brno
Spilberk Castle
Old Town Hall + Information centre
Jošt horse statue
Tramvaj-Christmas market
HodyTraditional Moravian Celebration
Punkva Caves
Morzart Statue and Reduta theatre
The second largest city of Czech Republic
6
Sustainable Process Integration Laboratory (SPIL)
Prof Zdravko KravanjaUniversity of Maribor
Slovenia
Prof Ferenc Friedler
PPKE BudapestHungary
Prof Zainuddin Abd Manan
Universiti Teknologi Malaysia
Prof Chew Tin Lee
Universiti Teknologi Malaysia
Prof Zhiyong Liu刘智勇教授
Hebei University of TechnologyTianjin PR China
Prof Robin Smith
The University of ManchesterUK
Prof Sharifah Rafidah Wan Alwi
Universiti Teknologi Malaysia
Prof Yutao Wang王玉涛教授
Fudan UniversityShanghai PR China
Prof Michael Walmsley
The University of WaikatoHamilton New Zealand
Prof Dr Jiřiacute Jaromiacuter KlemešSPIL Head
Dr Lubomiacuter KlimešJunior Researcher
Michal ŠpilaacutečekJunior Researcher
Xuexiu Jia 贾学秀
Junior Researcher
Collaborators
Assoc Prof Dr Petar Sabev VarbanovSPIL Deputy Head
Dr Šaacuterka ZemanovaacuteAssistant to Prof Klemeš
Assoc Prof Dr Jiřiacute PospiacutešilSenior Researcher
Assoc Prof DrTimothy Gordon Walmsley
Researcher
Dr Martin PavlasSenior Researcher
Dr AbdoulmohammadGholamzadeh Chofreh
Researcher
Prof Qiuwang Wang王秋旺教授
Xian Jiaotong UniversityXirsquoan PR China
Dr Radovan ŠomplaacutekJunior Researcher
Dr Vojtěch TurekJunior Researcher
Xuechao Wang 王雪超
Junior Researcher
Yee Van Fan 范忆雯
Junior Researcher
Hon Huin Chin钱汉轩
Junior Researcher
Prof Raymond Tan
De La Salle University Philippines
Dr Kathleen Aviso
De La Salle University Philippines
Prof Olga Petrivna
ArsenyevaNational Technical University Kharkiv
Ukraine
Prof Petro Oleksiyovich
KapustenkoNational TechnicalUniversity Kharkiv
UkraineLimei Gai盖丽梅
Junior Researcher
Assoc Prof Dr Yiming Wu
Prof Dr Jiřiacute Jaromiacuter Klemeš DScProject Coordinator (VUT)
Xue-Chao Wang王雪超
Researcher
Hon Huin Chin钱汉轩
Researcher
Ing Milan HemzalCoordinating Researcher
Dr Šaacuterka ZemanovaacuteAssistant of Prof Klemeš
Assoc Prof Dr Petar Sabev Varbanov
Project Manager
Bohong Wang王博弘
Researcher
Dr Feybi Ariani GoniResearcher
Eng Jan Hanus
Prof Dr Petr Stehliacutek
Eng Viacutet Freisleben
Prof Min ZengProject Coordinator (XJTU)
Assoc Prof Dr Ting Ma
Xuan Tong Nianqi Li Wei Li Pengbo Zhao Chaodong Jian
Prof Weisheng Yang
Dr Xia Liu Prof Laibing He
Eng Yi Guo Eng De Pan Eng Peng Zhao
CZ-CN INTER-ACTION Project
Cooperation with Foreign Universities
SLOVENIAUKHUNGARY
CHINA (HeBei)
NEW ZEALAND
CHINA (Fudan)
MALAYSIA
CHINA (Xirsquoan)
PHILIPPINES
Google Scholar
Mendeley
Speed up research by harnessing the power of peer review
98th Percentile
Currently serves on 20 editorial boardsTotally serves on 25 editorial boards
Editor-in-Chief President
Has reviewed for 106 journals
High Citations Papers
Web of Sciencehttpappswebofknowledgecom
Journal of Cleaner Production
17
JCLP Co-Editors-in-Chief
18
JCLP Impact
Total Articles
Total Cites
19
JCLP ndash Contributors
20
Main Co-Authors of this lectureS Bandyopadhyay Indian Institute of Technology INCY Chang National Cheng Kung University Tainan TPQ Wang X Feng Xirsquoan Jiaotong Univ ampChina Univ of Petroleum I E Grossmann Carnegie Mellon University Pittsburgh PA UST Gundersen NUST Trondheim Norway NOJ-K Kim Hanyang University Seoul KRH Matos Instituto Superior TeacutecnicoUniversidade de Lisboa PTT Majozi University of the Witwatersrand Johannesburg ZAF Mareacutechal EacutePFL Lausanne Sion CHHL Lam D Ng D C Y Foo Uni of Nottingham MY Campus KL Panjeshahi N Tahouni University of Tehran IR M Picoacuten-Nuacutentildeez University of Guanajuato Mexico MXSR Wan Alvi Z A Manan UTM Johor Bahru amp KLCC MYU Shenoy Synew Technologies Mumbai INR Smith I Bulatov UMIST amp The University of Manchester UKR Tan K Aviso University De La Salle Manila PHM Walmsley University of Waikato Hamilton NZT Zhelev dagger University of Limerick IR
21
World Coverage Co-Authors
22
Heat Integration using Pinch Analysis
23
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
The First Steps ndash HEN synthesisPinch Analysis Hohmann E C 1971 Optimum networks for heat exchange PhD thesis University of Southern California LA USALinnhoff B Flower JR 1978 Synthesis of heat exchanger networks I Systematic generation of energy optimal networks AIChE Journal 24(4) 633ndash642Umeda T Harada T Shiroko KA 1979 Thermodynamic approach to the synthesis of heat integration systems in chemical processes Computers amp Chemical Engineering 3(1-4) 273ndash282
Heuristic methodsPonton J W Donaldson R A B 1974 A fast method for the synthesis of optimal heat exchanger networks ChemEngSci 29 2375-2377 (1974)
Mathematical programing Papoulias SA Grossmann IE1983 A structural optimization approach in process synthesis-II Heat recovery networks CompChemEng 7 (6) 707-721Yee TF Grossmann IE1990 Optimization models for heat integrationmdashII Heat exchanger network synthesis ComputChemEng 14 1165ndash1184
25
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
The RouteUnited Kingdomrarr Hungary rarr Czech Republic
Edinburgh
Manchester
Brno
BudapestVeszprem
UMIST ndash Pioneering Pinch AnalysisDepartment of Process Integration at UMIST
1990 ndash 2004
Centre for Process Integration and Intensification - CPI2
University of Pannonia Hungary
PhD and Graduates
Dr Anja Kostevšek Jun Yow Yong楊俊耀
Dr Wan NorlindaRoshana bt Mohd Nawi
Dr Xia Liu刘 霞
Dr Luca De Benedetto
SUMMA CUM LAUDE
DDr Hon Loong Lam
林汉龙SUMMA CUM LAUDE
Dr Laacuteszloacute SikosSUMMA CUM LAUDE
Dr Zsoacutefia FodorCUM LAUDE
Dr Kew Hong Chew
周桂凤DEANS AWARD
BEST PhD
Dr Peng Yen Liew
廖炳彥UTM CHANCELLOR AWARD - BEST PhD
Dr Lidija ČučekSUMMA CUM LAUDE
DDr Andreja NemetCUM LAUDE
Dr Nor Erniza BtMohammad Rozali
UTM PRO-CHANCELLOR
AWARD
Prof Jiřiacute KlemešCPI2 Head
Dr Petar VarbanovCPI2 Deputy Head
Prof Zdravko KravanjaUniversity of Maribor
Slovenia
Ir Dr Sharifah RafidahWan Alwi
Prof ZainuddinAbdul Manan
Universiti Teknologi Malaysia
Prof Yu Qian钱 宇
South China University of Technology
Dr SiYu Yang杨思宇
Brno
Mahen Theatre
Petrov
Freedom Square
Vegetable Market
View of Brno
Spilberk Castle
Old Town Hall + Information centre
Jošt horse statue
Tramvaj-Christmas market
HodyTraditional Moravian Celebration
Punkva Caves
Morzart Statue and Reduta theatre
The second largest city of Czech Republic
6
Sustainable Process Integration Laboratory (SPIL)
Prof Zdravko KravanjaUniversity of Maribor
Slovenia
Prof Ferenc Friedler
PPKE BudapestHungary
Prof Zainuddin Abd Manan
Universiti Teknologi Malaysia
Prof Chew Tin Lee
Universiti Teknologi Malaysia
Prof Zhiyong Liu刘智勇教授
Hebei University of TechnologyTianjin PR China
Prof Robin Smith
The University of ManchesterUK
Prof Sharifah Rafidah Wan Alwi
Universiti Teknologi Malaysia
Prof Yutao Wang王玉涛教授
Fudan UniversityShanghai PR China
Prof Michael Walmsley
The University of WaikatoHamilton New Zealand
Prof Dr Jiřiacute Jaromiacuter KlemešSPIL Head
Dr Lubomiacuter KlimešJunior Researcher
Michal ŠpilaacutečekJunior Researcher
Xuexiu Jia 贾学秀
Junior Researcher
Collaborators
Assoc Prof Dr Petar Sabev VarbanovSPIL Deputy Head
Dr Šaacuterka ZemanovaacuteAssistant to Prof Klemeš
Assoc Prof Dr Jiřiacute PospiacutešilSenior Researcher
Assoc Prof DrTimothy Gordon Walmsley
Researcher
Dr Martin PavlasSenior Researcher
Dr AbdoulmohammadGholamzadeh Chofreh
Researcher
Prof Qiuwang Wang王秋旺教授
Xian Jiaotong UniversityXirsquoan PR China
Dr Radovan ŠomplaacutekJunior Researcher
Dr Vojtěch TurekJunior Researcher
Xuechao Wang 王雪超
Junior Researcher
Yee Van Fan 范忆雯
Junior Researcher
Hon Huin Chin钱汉轩
Junior Researcher
Prof Raymond Tan
De La Salle University Philippines
Dr Kathleen Aviso
De La Salle University Philippines
Prof Olga Petrivna
ArsenyevaNational Technical University Kharkiv
Ukraine
Prof Petro Oleksiyovich
KapustenkoNational TechnicalUniversity Kharkiv
UkraineLimei Gai盖丽梅
Junior Researcher
Assoc Prof Dr Yiming Wu
Prof Dr Jiřiacute Jaromiacuter Klemeš DScProject Coordinator (VUT)
Xue-Chao Wang王雪超
Researcher
Hon Huin Chin钱汉轩
Researcher
Ing Milan HemzalCoordinating Researcher
Dr Šaacuterka ZemanovaacuteAssistant of Prof Klemeš
Assoc Prof Dr Petar Sabev Varbanov
Project Manager
Bohong Wang王博弘
Researcher
Dr Feybi Ariani GoniResearcher
Eng Jan Hanus
Prof Dr Petr Stehliacutek
Eng Viacutet Freisleben
Prof Min ZengProject Coordinator (XJTU)
Assoc Prof Dr Ting Ma
Xuan Tong Nianqi Li Wei Li Pengbo Zhao Chaodong Jian
Prof Weisheng Yang
Dr Xia Liu Prof Laibing He
Eng Yi Guo Eng De Pan Eng Peng Zhao
CZ-CN INTER-ACTION Project
Cooperation with Foreign Universities
SLOVENIAUKHUNGARY
CHINA (HeBei)
NEW ZEALAND
CHINA (Fudan)
MALAYSIA
CHINA (Xirsquoan)
PHILIPPINES
Google Scholar
Mendeley
Speed up research by harnessing the power of peer review
98th Percentile
Currently serves on 20 editorial boardsTotally serves on 25 editorial boards
Editor-in-Chief President
Has reviewed for 106 journals
High Citations Papers
Web of Sciencehttpappswebofknowledgecom
Journal of Cleaner Production
17
JCLP Co-Editors-in-Chief
18
JCLP Impact
Total Articles
Total Cites
19
JCLP ndash Contributors
20
Main Co-Authors of this lectureS Bandyopadhyay Indian Institute of Technology INCY Chang National Cheng Kung University Tainan TPQ Wang X Feng Xirsquoan Jiaotong Univ ampChina Univ of Petroleum I E Grossmann Carnegie Mellon University Pittsburgh PA UST Gundersen NUST Trondheim Norway NOJ-K Kim Hanyang University Seoul KRH Matos Instituto Superior TeacutecnicoUniversidade de Lisboa PTT Majozi University of the Witwatersrand Johannesburg ZAF Mareacutechal EacutePFL Lausanne Sion CHHL Lam D Ng D C Y Foo Uni of Nottingham MY Campus KL Panjeshahi N Tahouni University of Tehran IR M Picoacuten-Nuacutentildeez University of Guanajuato Mexico MXSR Wan Alvi Z A Manan UTM Johor Bahru amp KLCC MYU Shenoy Synew Technologies Mumbai INR Smith I Bulatov UMIST amp The University of Manchester UKR Tan K Aviso University De La Salle Manila PHM Walmsley University of Waikato Hamilton NZT Zhelev dagger University of Limerick IR
21
World Coverage Co-Authors
22
Heat Integration using Pinch Analysis
23
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
The First Steps ndash HEN synthesisPinch Analysis Hohmann E C 1971 Optimum networks for heat exchange PhD thesis University of Southern California LA USALinnhoff B Flower JR 1978 Synthesis of heat exchanger networks I Systematic generation of energy optimal networks AIChE Journal 24(4) 633ndash642Umeda T Harada T Shiroko KA 1979 Thermodynamic approach to the synthesis of heat integration systems in chemical processes Computers amp Chemical Engineering 3(1-4) 273ndash282
Heuristic methodsPonton J W Donaldson R A B 1974 A fast method for the synthesis of optimal heat exchanger networks ChemEngSci 29 2375-2377 (1974)
Mathematical programing Papoulias SA Grossmann IE1983 A structural optimization approach in process synthesis-II Heat recovery networks CompChemEng 7 (6) 707-721Yee TF Grossmann IE1990 Optimization models for heat integrationmdashII Heat exchanger network synthesis ComputChemEng 14 1165ndash1184
25
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
UMIST ndash Pioneering Pinch AnalysisDepartment of Process Integration at UMIST
1990 ndash 2004
Centre for Process Integration and Intensification - CPI2
University of Pannonia Hungary
PhD and Graduates
Dr Anja Kostevšek Jun Yow Yong楊俊耀
Dr Wan NorlindaRoshana bt Mohd Nawi
Dr Xia Liu刘 霞
Dr Luca De Benedetto
SUMMA CUM LAUDE
DDr Hon Loong Lam
林汉龙SUMMA CUM LAUDE
Dr Laacuteszloacute SikosSUMMA CUM LAUDE
Dr Zsoacutefia FodorCUM LAUDE
Dr Kew Hong Chew
周桂凤DEANS AWARD
BEST PhD
Dr Peng Yen Liew
廖炳彥UTM CHANCELLOR AWARD - BEST PhD
Dr Lidija ČučekSUMMA CUM LAUDE
DDr Andreja NemetCUM LAUDE
Dr Nor Erniza BtMohammad Rozali
UTM PRO-CHANCELLOR
AWARD
Prof Jiřiacute KlemešCPI2 Head
Dr Petar VarbanovCPI2 Deputy Head
Prof Zdravko KravanjaUniversity of Maribor
Slovenia
Ir Dr Sharifah RafidahWan Alwi
Prof ZainuddinAbdul Manan
Universiti Teknologi Malaysia
Prof Yu Qian钱 宇
South China University of Technology
Dr SiYu Yang杨思宇
Brno
Mahen Theatre
Petrov
Freedom Square
Vegetable Market
View of Brno
Spilberk Castle
Old Town Hall + Information centre
Jošt horse statue
Tramvaj-Christmas market
HodyTraditional Moravian Celebration
Punkva Caves
Morzart Statue and Reduta theatre
The second largest city of Czech Republic
6
Sustainable Process Integration Laboratory (SPIL)
Prof Zdravko KravanjaUniversity of Maribor
Slovenia
Prof Ferenc Friedler
PPKE BudapestHungary
Prof Zainuddin Abd Manan
Universiti Teknologi Malaysia
Prof Chew Tin Lee
Universiti Teknologi Malaysia
Prof Zhiyong Liu刘智勇教授
Hebei University of TechnologyTianjin PR China
Prof Robin Smith
The University of ManchesterUK
Prof Sharifah Rafidah Wan Alwi
Universiti Teknologi Malaysia
Prof Yutao Wang王玉涛教授
Fudan UniversityShanghai PR China
Prof Michael Walmsley
The University of WaikatoHamilton New Zealand
Prof Dr Jiřiacute Jaromiacuter KlemešSPIL Head
Dr Lubomiacuter KlimešJunior Researcher
Michal ŠpilaacutečekJunior Researcher
Xuexiu Jia 贾学秀
Junior Researcher
Collaborators
Assoc Prof Dr Petar Sabev VarbanovSPIL Deputy Head
Dr Šaacuterka ZemanovaacuteAssistant to Prof Klemeš
Assoc Prof Dr Jiřiacute PospiacutešilSenior Researcher
Assoc Prof DrTimothy Gordon Walmsley
Researcher
Dr Martin PavlasSenior Researcher
Dr AbdoulmohammadGholamzadeh Chofreh
Researcher
Prof Qiuwang Wang王秋旺教授
Xian Jiaotong UniversityXirsquoan PR China
Dr Radovan ŠomplaacutekJunior Researcher
Dr Vojtěch TurekJunior Researcher
Xuechao Wang 王雪超
Junior Researcher
Yee Van Fan 范忆雯
Junior Researcher
Hon Huin Chin钱汉轩
Junior Researcher
Prof Raymond Tan
De La Salle University Philippines
Dr Kathleen Aviso
De La Salle University Philippines
Prof Olga Petrivna
ArsenyevaNational Technical University Kharkiv
Ukraine
Prof Petro Oleksiyovich
KapustenkoNational TechnicalUniversity Kharkiv
UkraineLimei Gai盖丽梅
Junior Researcher
Assoc Prof Dr Yiming Wu
Prof Dr Jiřiacute Jaromiacuter Klemeš DScProject Coordinator (VUT)
Xue-Chao Wang王雪超
Researcher
Hon Huin Chin钱汉轩
Researcher
Ing Milan HemzalCoordinating Researcher
Dr Šaacuterka ZemanovaacuteAssistant of Prof Klemeš
Assoc Prof Dr Petar Sabev Varbanov
Project Manager
Bohong Wang王博弘
Researcher
Dr Feybi Ariani GoniResearcher
Eng Jan Hanus
Prof Dr Petr Stehliacutek
Eng Viacutet Freisleben
Prof Min ZengProject Coordinator (XJTU)
Assoc Prof Dr Ting Ma
Xuan Tong Nianqi Li Wei Li Pengbo Zhao Chaodong Jian
Prof Weisheng Yang
Dr Xia Liu Prof Laibing He
Eng Yi Guo Eng De Pan Eng Peng Zhao
CZ-CN INTER-ACTION Project
Cooperation with Foreign Universities
SLOVENIAUKHUNGARY
CHINA (HeBei)
NEW ZEALAND
CHINA (Fudan)
MALAYSIA
CHINA (Xirsquoan)
PHILIPPINES
Google Scholar
Mendeley
Speed up research by harnessing the power of peer review
98th Percentile
Currently serves on 20 editorial boardsTotally serves on 25 editorial boards
Editor-in-Chief President
Has reviewed for 106 journals
High Citations Papers
Web of Sciencehttpappswebofknowledgecom
Journal of Cleaner Production
17
JCLP Co-Editors-in-Chief
18
JCLP Impact
Total Articles
Total Cites
19
JCLP ndash Contributors
20
Main Co-Authors of this lectureS Bandyopadhyay Indian Institute of Technology INCY Chang National Cheng Kung University Tainan TPQ Wang X Feng Xirsquoan Jiaotong Univ ampChina Univ of Petroleum I E Grossmann Carnegie Mellon University Pittsburgh PA UST Gundersen NUST Trondheim Norway NOJ-K Kim Hanyang University Seoul KRH Matos Instituto Superior TeacutecnicoUniversidade de Lisboa PTT Majozi University of the Witwatersrand Johannesburg ZAF Mareacutechal EacutePFL Lausanne Sion CHHL Lam D Ng D C Y Foo Uni of Nottingham MY Campus KL Panjeshahi N Tahouni University of Tehran IR M Picoacuten-Nuacutentildeez University of Guanajuato Mexico MXSR Wan Alvi Z A Manan UTM Johor Bahru amp KLCC MYU Shenoy Synew Technologies Mumbai INR Smith I Bulatov UMIST amp The University of Manchester UKR Tan K Aviso University De La Salle Manila PHM Walmsley University of Waikato Hamilton NZT Zhelev dagger University of Limerick IR
21
World Coverage Co-Authors
22
Heat Integration using Pinch Analysis
23
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
The First Steps ndash HEN synthesisPinch Analysis Hohmann E C 1971 Optimum networks for heat exchange PhD thesis University of Southern California LA USALinnhoff B Flower JR 1978 Synthesis of heat exchanger networks I Systematic generation of energy optimal networks AIChE Journal 24(4) 633ndash642Umeda T Harada T Shiroko KA 1979 Thermodynamic approach to the synthesis of heat integration systems in chemical processes Computers amp Chemical Engineering 3(1-4) 273ndash282
Heuristic methodsPonton J W Donaldson R A B 1974 A fast method for the synthesis of optimal heat exchanger networks ChemEngSci 29 2375-2377 (1974)
Mathematical programing Papoulias SA Grossmann IE1983 A structural optimization approach in process synthesis-II Heat recovery networks CompChemEng 7 (6) 707-721Yee TF Grossmann IE1990 Optimization models for heat integrationmdashII Heat exchanger network synthesis ComputChemEng 14 1165ndash1184
25
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Centre for Process Integration and Intensification - CPI2
University of Pannonia Hungary
PhD and Graduates
Dr Anja Kostevšek Jun Yow Yong楊俊耀
Dr Wan NorlindaRoshana bt Mohd Nawi
Dr Xia Liu刘 霞
Dr Luca De Benedetto
SUMMA CUM LAUDE
DDr Hon Loong Lam
林汉龙SUMMA CUM LAUDE
Dr Laacuteszloacute SikosSUMMA CUM LAUDE
Dr Zsoacutefia FodorCUM LAUDE
Dr Kew Hong Chew
周桂凤DEANS AWARD
BEST PhD
Dr Peng Yen Liew
廖炳彥UTM CHANCELLOR AWARD - BEST PhD
Dr Lidija ČučekSUMMA CUM LAUDE
DDr Andreja NemetCUM LAUDE
Dr Nor Erniza BtMohammad Rozali
UTM PRO-CHANCELLOR
AWARD
Prof Jiřiacute KlemešCPI2 Head
Dr Petar VarbanovCPI2 Deputy Head
Prof Zdravko KravanjaUniversity of Maribor
Slovenia
Ir Dr Sharifah RafidahWan Alwi
Prof ZainuddinAbdul Manan
Universiti Teknologi Malaysia
Prof Yu Qian钱 宇
South China University of Technology
Dr SiYu Yang杨思宇
Brno
Mahen Theatre
Petrov
Freedom Square
Vegetable Market
View of Brno
Spilberk Castle
Old Town Hall + Information centre
Jošt horse statue
Tramvaj-Christmas market
HodyTraditional Moravian Celebration
Punkva Caves
Morzart Statue and Reduta theatre
The second largest city of Czech Republic
6
Sustainable Process Integration Laboratory (SPIL)
Prof Zdravko KravanjaUniversity of Maribor
Slovenia
Prof Ferenc Friedler
PPKE BudapestHungary
Prof Zainuddin Abd Manan
Universiti Teknologi Malaysia
Prof Chew Tin Lee
Universiti Teknologi Malaysia
Prof Zhiyong Liu刘智勇教授
Hebei University of TechnologyTianjin PR China
Prof Robin Smith
The University of ManchesterUK
Prof Sharifah Rafidah Wan Alwi
Universiti Teknologi Malaysia
Prof Yutao Wang王玉涛教授
Fudan UniversityShanghai PR China
Prof Michael Walmsley
The University of WaikatoHamilton New Zealand
Prof Dr Jiřiacute Jaromiacuter KlemešSPIL Head
Dr Lubomiacuter KlimešJunior Researcher
Michal ŠpilaacutečekJunior Researcher
Xuexiu Jia 贾学秀
Junior Researcher
Collaborators
Assoc Prof Dr Petar Sabev VarbanovSPIL Deputy Head
Dr Šaacuterka ZemanovaacuteAssistant to Prof Klemeš
Assoc Prof Dr Jiřiacute PospiacutešilSenior Researcher
Assoc Prof DrTimothy Gordon Walmsley
Researcher
Dr Martin PavlasSenior Researcher
Dr AbdoulmohammadGholamzadeh Chofreh
Researcher
Prof Qiuwang Wang王秋旺教授
Xian Jiaotong UniversityXirsquoan PR China
Dr Radovan ŠomplaacutekJunior Researcher
Dr Vojtěch TurekJunior Researcher
Xuechao Wang 王雪超
Junior Researcher
Yee Van Fan 范忆雯
Junior Researcher
Hon Huin Chin钱汉轩
Junior Researcher
Prof Raymond Tan
De La Salle University Philippines
Dr Kathleen Aviso
De La Salle University Philippines
Prof Olga Petrivna
ArsenyevaNational Technical University Kharkiv
Ukraine
Prof Petro Oleksiyovich
KapustenkoNational TechnicalUniversity Kharkiv
UkraineLimei Gai盖丽梅
Junior Researcher
Assoc Prof Dr Yiming Wu
Prof Dr Jiřiacute Jaromiacuter Klemeš DScProject Coordinator (VUT)
Xue-Chao Wang王雪超
Researcher
Hon Huin Chin钱汉轩
Researcher
Ing Milan HemzalCoordinating Researcher
Dr Šaacuterka ZemanovaacuteAssistant of Prof Klemeš
Assoc Prof Dr Petar Sabev Varbanov
Project Manager
Bohong Wang王博弘
Researcher
Dr Feybi Ariani GoniResearcher
Eng Jan Hanus
Prof Dr Petr Stehliacutek
Eng Viacutet Freisleben
Prof Min ZengProject Coordinator (XJTU)
Assoc Prof Dr Ting Ma
Xuan Tong Nianqi Li Wei Li Pengbo Zhao Chaodong Jian
Prof Weisheng Yang
Dr Xia Liu Prof Laibing He
Eng Yi Guo Eng De Pan Eng Peng Zhao
CZ-CN INTER-ACTION Project
Cooperation with Foreign Universities
SLOVENIAUKHUNGARY
CHINA (HeBei)
NEW ZEALAND
CHINA (Fudan)
MALAYSIA
CHINA (Xirsquoan)
PHILIPPINES
Google Scholar
Mendeley
Speed up research by harnessing the power of peer review
98th Percentile
Currently serves on 20 editorial boardsTotally serves on 25 editorial boards
Editor-in-Chief President
Has reviewed for 106 journals
High Citations Papers
Web of Sciencehttpappswebofknowledgecom
Journal of Cleaner Production
17
JCLP Co-Editors-in-Chief
18
JCLP Impact
Total Articles
Total Cites
19
JCLP ndash Contributors
20
Main Co-Authors of this lectureS Bandyopadhyay Indian Institute of Technology INCY Chang National Cheng Kung University Tainan TPQ Wang X Feng Xirsquoan Jiaotong Univ ampChina Univ of Petroleum I E Grossmann Carnegie Mellon University Pittsburgh PA UST Gundersen NUST Trondheim Norway NOJ-K Kim Hanyang University Seoul KRH Matos Instituto Superior TeacutecnicoUniversidade de Lisboa PTT Majozi University of the Witwatersrand Johannesburg ZAF Mareacutechal EacutePFL Lausanne Sion CHHL Lam D Ng D C Y Foo Uni of Nottingham MY Campus KL Panjeshahi N Tahouni University of Tehran IR M Picoacuten-Nuacutentildeez University of Guanajuato Mexico MXSR Wan Alvi Z A Manan UTM Johor Bahru amp KLCC MYU Shenoy Synew Technologies Mumbai INR Smith I Bulatov UMIST amp The University of Manchester UKR Tan K Aviso University De La Salle Manila PHM Walmsley University of Waikato Hamilton NZT Zhelev dagger University of Limerick IR
21
World Coverage Co-Authors
22
Heat Integration using Pinch Analysis
23
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
The First Steps ndash HEN synthesisPinch Analysis Hohmann E C 1971 Optimum networks for heat exchange PhD thesis University of Southern California LA USALinnhoff B Flower JR 1978 Synthesis of heat exchanger networks I Systematic generation of energy optimal networks AIChE Journal 24(4) 633ndash642Umeda T Harada T Shiroko KA 1979 Thermodynamic approach to the synthesis of heat integration systems in chemical processes Computers amp Chemical Engineering 3(1-4) 273ndash282
Heuristic methodsPonton J W Donaldson R A B 1974 A fast method for the synthesis of optimal heat exchanger networks ChemEngSci 29 2375-2377 (1974)
Mathematical programing Papoulias SA Grossmann IE1983 A structural optimization approach in process synthesis-II Heat recovery networks CompChemEng 7 (6) 707-721Yee TF Grossmann IE1990 Optimization models for heat integrationmdashII Heat exchanger network synthesis ComputChemEng 14 1165ndash1184
25
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Brno
Mahen Theatre
Petrov
Freedom Square
Vegetable Market
View of Brno
Spilberk Castle
Old Town Hall + Information centre
Jošt horse statue
Tramvaj-Christmas market
HodyTraditional Moravian Celebration
Punkva Caves
Morzart Statue and Reduta theatre
The second largest city of Czech Republic
6
Sustainable Process Integration Laboratory (SPIL)
Prof Zdravko KravanjaUniversity of Maribor
Slovenia
Prof Ferenc Friedler
PPKE BudapestHungary
Prof Zainuddin Abd Manan
Universiti Teknologi Malaysia
Prof Chew Tin Lee
Universiti Teknologi Malaysia
Prof Zhiyong Liu刘智勇教授
Hebei University of TechnologyTianjin PR China
Prof Robin Smith
The University of ManchesterUK
Prof Sharifah Rafidah Wan Alwi
Universiti Teknologi Malaysia
Prof Yutao Wang王玉涛教授
Fudan UniversityShanghai PR China
Prof Michael Walmsley
The University of WaikatoHamilton New Zealand
Prof Dr Jiřiacute Jaromiacuter KlemešSPIL Head
Dr Lubomiacuter KlimešJunior Researcher
Michal ŠpilaacutečekJunior Researcher
Xuexiu Jia 贾学秀
Junior Researcher
Collaborators
Assoc Prof Dr Petar Sabev VarbanovSPIL Deputy Head
Dr Šaacuterka ZemanovaacuteAssistant to Prof Klemeš
Assoc Prof Dr Jiřiacute PospiacutešilSenior Researcher
Assoc Prof DrTimothy Gordon Walmsley
Researcher
Dr Martin PavlasSenior Researcher
Dr AbdoulmohammadGholamzadeh Chofreh
Researcher
Prof Qiuwang Wang王秋旺教授
Xian Jiaotong UniversityXirsquoan PR China
Dr Radovan ŠomplaacutekJunior Researcher
Dr Vojtěch TurekJunior Researcher
Xuechao Wang 王雪超
Junior Researcher
Yee Van Fan 范忆雯
Junior Researcher
Hon Huin Chin钱汉轩
Junior Researcher
Prof Raymond Tan
De La Salle University Philippines
Dr Kathleen Aviso
De La Salle University Philippines
Prof Olga Petrivna
ArsenyevaNational Technical University Kharkiv
Ukraine
Prof Petro Oleksiyovich
KapustenkoNational TechnicalUniversity Kharkiv
UkraineLimei Gai盖丽梅
Junior Researcher
Assoc Prof Dr Yiming Wu
Prof Dr Jiřiacute Jaromiacuter Klemeš DScProject Coordinator (VUT)
Xue-Chao Wang王雪超
Researcher
Hon Huin Chin钱汉轩
Researcher
Ing Milan HemzalCoordinating Researcher
Dr Šaacuterka ZemanovaacuteAssistant of Prof Klemeš
Assoc Prof Dr Petar Sabev Varbanov
Project Manager
Bohong Wang王博弘
Researcher
Dr Feybi Ariani GoniResearcher
Eng Jan Hanus
Prof Dr Petr Stehliacutek
Eng Viacutet Freisleben
Prof Min ZengProject Coordinator (XJTU)
Assoc Prof Dr Ting Ma
Xuan Tong Nianqi Li Wei Li Pengbo Zhao Chaodong Jian
Prof Weisheng Yang
Dr Xia Liu Prof Laibing He
Eng Yi Guo Eng De Pan Eng Peng Zhao
CZ-CN INTER-ACTION Project
Cooperation with Foreign Universities
SLOVENIAUKHUNGARY
CHINA (HeBei)
NEW ZEALAND
CHINA (Fudan)
MALAYSIA
CHINA (Xirsquoan)
PHILIPPINES
Google Scholar
Mendeley
Speed up research by harnessing the power of peer review
98th Percentile
Currently serves on 20 editorial boardsTotally serves on 25 editorial boards
Editor-in-Chief President
Has reviewed for 106 journals
High Citations Papers
Web of Sciencehttpappswebofknowledgecom
Journal of Cleaner Production
17
JCLP Co-Editors-in-Chief
18
JCLP Impact
Total Articles
Total Cites
19
JCLP ndash Contributors
20
Main Co-Authors of this lectureS Bandyopadhyay Indian Institute of Technology INCY Chang National Cheng Kung University Tainan TPQ Wang X Feng Xirsquoan Jiaotong Univ ampChina Univ of Petroleum I E Grossmann Carnegie Mellon University Pittsburgh PA UST Gundersen NUST Trondheim Norway NOJ-K Kim Hanyang University Seoul KRH Matos Instituto Superior TeacutecnicoUniversidade de Lisboa PTT Majozi University of the Witwatersrand Johannesburg ZAF Mareacutechal EacutePFL Lausanne Sion CHHL Lam D Ng D C Y Foo Uni of Nottingham MY Campus KL Panjeshahi N Tahouni University of Tehran IR M Picoacuten-Nuacutentildeez University of Guanajuato Mexico MXSR Wan Alvi Z A Manan UTM Johor Bahru amp KLCC MYU Shenoy Synew Technologies Mumbai INR Smith I Bulatov UMIST amp The University of Manchester UKR Tan K Aviso University De La Salle Manila PHM Walmsley University of Waikato Hamilton NZT Zhelev dagger University of Limerick IR
21
World Coverage Co-Authors
22
Heat Integration using Pinch Analysis
23
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
The First Steps ndash HEN synthesisPinch Analysis Hohmann E C 1971 Optimum networks for heat exchange PhD thesis University of Southern California LA USALinnhoff B Flower JR 1978 Synthesis of heat exchanger networks I Systematic generation of energy optimal networks AIChE Journal 24(4) 633ndash642Umeda T Harada T Shiroko KA 1979 Thermodynamic approach to the synthesis of heat integration systems in chemical processes Computers amp Chemical Engineering 3(1-4) 273ndash282
Heuristic methodsPonton J W Donaldson R A B 1974 A fast method for the synthesis of optimal heat exchanger networks ChemEngSci 29 2375-2377 (1974)
Mathematical programing Papoulias SA Grossmann IE1983 A structural optimization approach in process synthesis-II Heat recovery networks CompChemEng 7 (6) 707-721Yee TF Grossmann IE1990 Optimization models for heat integrationmdashII Heat exchanger network synthesis ComputChemEng 14 1165ndash1184
25
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
6
Sustainable Process Integration Laboratory (SPIL)
Prof Zdravko KravanjaUniversity of Maribor
Slovenia
Prof Ferenc Friedler
PPKE BudapestHungary
Prof Zainuddin Abd Manan
Universiti Teknologi Malaysia
Prof Chew Tin Lee
Universiti Teknologi Malaysia
Prof Zhiyong Liu刘智勇教授
Hebei University of TechnologyTianjin PR China
Prof Robin Smith
The University of ManchesterUK
Prof Sharifah Rafidah Wan Alwi
Universiti Teknologi Malaysia
Prof Yutao Wang王玉涛教授
Fudan UniversityShanghai PR China
Prof Michael Walmsley
The University of WaikatoHamilton New Zealand
Prof Dr Jiřiacute Jaromiacuter KlemešSPIL Head
Dr Lubomiacuter KlimešJunior Researcher
Michal ŠpilaacutečekJunior Researcher
Xuexiu Jia 贾学秀
Junior Researcher
Collaborators
Assoc Prof Dr Petar Sabev VarbanovSPIL Deputy Head
Dr Šaacuterka ZemanovaacuteAssistant to Prof Klemeš
Assoc Prof Dr Jiřiacute PospiacutešilSenior Researcher
Assoc Prof DrTimothy Gordon Walmsley
Researcher
Dr Martin PavlasSenior Researcher
Dr AbdoulmohammadGholamzadeh Chofreh
Researcher
Prof Qiuwang Wang王秋旺教授
Xian Jiaotong UniversityXirsquoan PR China
Dr Radovan ŠomplaacutekJunior Researcher
Dr Vojtěch TurekJunior Researcher
Xuechao Wang 王雪超
Junior Researcher
Yee Van Fan 范忆雯
Junior Researcher
Hon Huin Chin钱汉轩
Junior Researcher
Prof Raymond Tan
De La Salle University Philippines
Dr Kathleen Aviso
De La Salle University Philippines
Prof Olga Petrivna
ArsenyevaNational Technical University Kharkiv
Ukraine
Prof Petro Oleksiyovich
KapustenkoNational TechnicalUniversity Kharkiv
UkraineLimei Gai盖丽梅
Junior Researcher
Assoc Prof Dr Yiming Wu
Prof Dr Jiřiacute Jaromiacuter Klemeš DScProject Coordinator (VUT)
Xue-Chao Wang王雪超
Researcher
Hon Huin Chin钱汉轩
Researcher
Ing Milan HemzalCoordinating Researcher
Dr Šaacuterka ZemanovaacuteAssistant of Prof Klemeš
Assoc Prof Dr Petar Sabev Varbanov
Project Manager
Bohong Wang王博弘
Researcher
Dr Feybi Ariani GoniResearcher
Eng Jan Hanus
Prof Dr Petr Stehliacutek
Eng Viacutet Freisleben
Prof Min ZengProject Coordinator (XJTU)
Assoc Prof Dr Ting Ma
Xuan Tong Nianqi Li Wei Li Pengbo Zhao Chaodong Jian
Prof Weisheng Yang
Dr Xia Liu Prof Laibing He
Eng Yi Guo Eng De Pan Eng Peng Zhao
CZ-CN INTER-ACTION Project
Cooperation with Foreign Universities
SLOVENIAUKHUNGARY
CHINA (HeBei)
NEW ZEALAND
CHINA (Fudan)
MALAYSIA
CHINA (Xirsquoan)
PHILIPPINES
Google Scholar
Mendeley
Speed up research by harnessing the power of peer review
98th Percentile
Currently serves on 20 editorial boardsTotally serves on 25 editorial boards
Editor-in-Chief President
Has reviewed for 106 journals
High Citations Papers
Web of Sciencehttpappswebofknowledgecom
Journal of Cleaner Production
17
JCLP Co-Editors-in-Chief
18
JCLP Impact
Total Articles
Total Cites
19
JCLP ndash Contributors
20
Main Co-Authors of this lectureS Bandyopadhyay Indian Institute of Technology INCY Chang National Cheng Kung University Tainan TPQ Wang X Feng Xirsquoan Jiaotong Univ ampChina Univ of Petroleum I E Grossmann Carnegie Mellon University Pittsburgh PA UST Gundersen NUST Trondheim Norway NOJ-K Kim Hanyang University Seoul KRH Matos Instituto Superior TeacutecnicoUniversidade de Lisboa PTT Majozi University of the Witwatersrand Johannesburg ZAF Mareacutechal EacutePFL Lausanne Sion CHHL Lam D Ng D C Y Foo Uni of Nottingham MY Campus KL Panjeshahi N Tahouni University of Tehran IR M Picoacuten-Nuacutentildeez University of Guanajuato Mexico MXSR Wan Alvi Z A Manan UTM Johor Bahru amp KLCC MYU Shenoy Synew Technologies Mumbai INR Smith I Bulatov UMIST amp The University of Manchester UKR Tan K Aviso University De La Salle Manila PHM Walmsley University of Waikato Hamilton NZT Zhelev dagger University of Limerick IR
21
World Coverage Co-Authors
22
Heat Integration using Pinch Analysis
23
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
The First Steps ndash HEN synthesisPinch Analysis Hohmann E C 1971 Optimum networks for heat exchange PhD thesis University of Southern California LA USALinnhoff B Flower JR 1978 Synthesis of heat exchanger networks I Systematic generation of energy optimal networks AIChE Journal 24(4) 633ndash642Umeda T Harada T Shiroko KA 1979 Thermodynamic approach to the synthesis of heat integration systems in chemical processes Computers amp Chemical Engineering 3(1-4) 273ndash282
Heuristic methodsPonton J W Donaldson R A B 1974 A fast method for the synthesis of optimal heat exchanger networks ChemEngSci 29 2375-2377 (1974)
Mathematical programing Papoulias SA Grossmann IE1983 A structural optimization approach in process synthesis-II Heat recovery networks CompChemEng 7 (6) 707-721Yee TF Grossmann IE1990 Optimization models for heat integrationmdashII Heat exchanger network synthesis ComputChemEng 14 1165ndash1184
25
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Sustainable Process Integration Laboratory (SPIL)
Prof Zdravko KravanjaUniversity of Maribor
Slovenia
Prof Ferenc Friedler
PPKE BudapestHungary
Prof Zainuddin Abd Manan
Universiti Teknologi Malaysia
Prof Chew Tin Lee
Universiti Teknologi Malaysia
Prof Zhiyong Liu刘智勇教授
Hebei University of TechnologyTianjin PR China
Prof Robin Smith
The University of ManchesterUK
Prof Sharifah Rafidah Wan Alwi
Universiti Teknologi Malaysia
Prof Yutao Wang王玉涛教授
Fudan UniversityShanghai PR China
Prof Michael Walmsley
The University of WaikatoHamilton New Zealand
Prof Dr Jiřiacute Jaromiacuter KlemešSPIL Head
Dr Lubomiacuter KlimešJunior Researcher
Michal ŠpilaacutečekJunior Researcher
Xuexiu Jia 贾学秀
Junior Researcher
Collaborators
Assoc Prof Dr Petar Sabev VarbanovSPIL Deputy Head
Dr Šaacuterka ZemanovaacuteAssistant to Prof Klemeš
Assoc Prof Dr Jiřiacute PospiacutešilSenior Researcher
Assoc Prof DrTimothy Gordon Walmsley
Researcher
Dr Martin PavlasSenior Researcher
Dr AbdoulmohammadGholamzadeh Chofreh
Researcher
Prof Qiuwang Wang王秋旺教授
Xian Jiaotong UniversityXirsquoan PR China
Dr Radovan ŠomplaacutekJunior Researcher
Dr Vojtěch TurekJunior Researcher
Xuechao Wang 王雪超
Junior Researcher
Yee Van Fan 范忆雯
Junior Researcher
Hon Huin Chin钱汉轩
Junior Researcher
Prof Raymond Tan
De La Salle University Philippines
Dr Kathleen Aviso
De La Salle University Philippines
Prof Olga Petrivna
ArsenyevaNational Technical University Kharkiv
Ukraine
Prof Petro Oleksiyovich
KapustenkoNational TechnicalUniversity Kharkiv
UkraineLimei Gai盖丽梅
Junior Researcher
Assoc Prof Dr Yiming Wu
Prof Dr Jiřiacute Jaromiacuter Klemeš DScProject Coordinator (VUT)
Xue-Chao Wang王雪超
Researcher
Hon Huin Chin钱汉轩
Researcher
Ing Milan HemzalCoordinating Researcher
Dr Šaacuterka ZemanovaacuteAssistant of Prof Klemeš
Assoc Prof Dr Petar Sabev Varbanov
Project Manager
Bohong Wang王博弘
Researcher
Dr Feybi Ariani GoniResearcher
Eng Jan Hanus
Prof Dr Petr Stehliacutek
Eng Viacutet Freisleben
Prof Min ZengProject Coordinator (XJTU)
Assoc Prof Dr Ting Ma
Xuan Tong Nianqi Li Wei Li Pengbo Zhao Chaodong Jian
Prof Weisheng Yang
Dr Xia Liu Prof Laibing He
Eng Yi Guo Eng De Pan Eng Peng Zhao
CZ-CN INTER-ACTION Project
Cooperation with Foreign Universities
SLOVENIAUKHUNGARY
CHINA (HeBei)
NEW ZEALAND
CHINA (Fudan)
MALAYSIA
CHINA (Xirsquoan)
PHILIPPINES
Google Scholar
Mendeley
Speed up research by harnessing the power of peer review
98th Percentile
Currently serves on 20 editorial boardsTotally serves on 25 editorial boards
Editor-in-Chief President
Has reviewed for 106 journals
High Citations Papers
Web of Sciencehttpappswebofknowledgecom
Journal of Cleaner Production
17
JCLP Co-Editors-in-Chief
18
JCLP Impact
Total Articles
Total Cites
19
JCLP ndash Contributors
20
Main Co-Authors of this lectureS Bandyopadhyay Indian Institute of Technology INCY Chang National Cheng Kung University Tainan TPQ Wang X Feng Xirsquoan Jiaotong Univ ampChina Univ of Petroleum I E Grossmann Carnegie Mellon University Pittsburgh PA UST Gundersen NUST Trondheim Norway NOJ-K Kim Hanyang University Seoul KRH Matos Instituto Superior TeacutecnicoUniversidade de Lisboa PTT Majozi University of the Witwatersrand Johannesburg ZAF Mareacutechal EacutePFL Lausanne Sion CHHL Lam D Ng D C Y Foo Uni of Nottingham MY Campus KL Panjeshahi N Tahouni University of Tehran IR M Picoacuten-Nuacutentildeez University of Guanajuato Mexico MXSR Wan Alvi Z A Manan UTM Johor Bahru amp KLCC MYU Shenoy Synew Technologies Mumbai INR Smith I Bulatov UMIST amp The University of Manchester UKR Tan K Aviso University De La Salle Manila PHM Walmsley University of Waikato Hamilton NZT Zhelev dagger University of Limerick IR
21
World Coverage Co-Authors
22
Heat Integration using Pinch Analysis
23
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
The First Steps ndash HEN synthesisPinch Analysis Hohmann E C 1971 Optimum networks for heat exchange PhD thesis University of Southern California LA USALinnhoff B Flower JR 1978 Synthesis of heat exchanger networks I Systematic generation of energy optimal networks AIChE Journal 24(4) 633ndash642Umeda T Harada T Shiroko KA 1979 Thermodynamic approach to the synthesis of heat integration systems in chemical processes Computers amp Chemical Engineering 3(1-4) 273ndash282
Heuristic methodsPonton J W Donaldson R A B 1974 A fast method for the synthesis of optimal heat exchanger networks ChemEngSci 29 2375-2377 (1974)
Mathematical programing Papoulias SA Grossmann IE1983 A structural optimization approach in process synthesis-II Heat recovery networks CompChemEng 7 (6) 707-721Yee TF Grossmann IE1990 Optimization models for heat integrationmdashII Heat exchanger network synthesis ComputChemEng 14 1165ndash1184
25
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Assoc Prof Dr Yiming Wu
Prof Dr Jiřiacute Jaromiacuter Klemeš DScProject Coordinator (VUT)
Xue-Chao Wang王雪超
Researcher
Hon Huin Chin钱汉轩
Researcher
Ing Milan HemzalCoordinating Researcher
Dr Šaacuterka ZemanovaacuteAssistant of Prof Klemeš
Assoc Prof Dr Petar Sabev Varbanov
Project Manager
Bohong Wang王博弘
Researcher
Dr Feybi Ariani GoniResearcher
Eng Jan Hanus
Prof Dr Petr Stehliacutek
Eng Viacutet Freisleben
Prof Min ZengProject Coordinator (XJTU)
Assoc Prof Dr Ting Ma
Xuan Tong Nianqi Li Wei Li Pengbo Zhao Chaodong Jian
Prof Weisheng Yang
Dr Xia Liu Prof Laibing He
Eng Yi Guo Eng De Pan Eng Peng Zhao
CZ-CN INTER-ACTION Project
Cooperation with Foreign Universities
SLOVENIAUKHUNGARY
CHINA (HeBei)
NEW ZEALAND
CHINA (Fudan)
MALAYSIA
CHINA (Xirsquoan)
PHILIPPINES
Google Scholar
Mendeley
Speed up research by harnessing the power of peer review
98th Percentile
Currently serves on 20 editorial boardsTotally serves on 25 editorial boards
Editor-in-Chief President
Has reviewed for 106 journals
High Citations Papers
Web of Sciencehttpappswebofknowledgecom
Journal of Cleaner Production
17
JCLP Co-Editors-in-Chief
18
JCLP Impact
Total Articles
Total Cites
19
JCLP ndash Contributors
20
Main Co-Authors of this lectureS Bandyopadhyay Indian Institute of Technology INCY Chang National Cheng Kung University Tainan TPQ Wang X Feng Xirsquoan Jiaotong Univ ampChina Univ of Petroleum I E Grossmann Carnegie Mellon University Pittsburgh PA UST Gundersen NUST Trondheim Norway NOJ-K Kim Hanyang University Seoul KRH Matos Instituto Superior TeacutecnicoUniversidade de Lisboa PTT Majozi University of the Witwatersrand Johannesburg ZAF Mareacutechal EacutePFL Lausanne Sion CHHL Lam D Ng D C Y Foo Uni of Nottingham MY Campus KL Panjeshahi N Tahouni University of Tehran IR M Picoacuten-Nuacutentildeez University of Guanajuato Mexico MXSR Wan Alvi Z A Manan UTM Johor Bahru amp KLCC MYU Shenoy Synew Technologies Mumbai INR Smith I Bulatov UMIST amp The University of Manchester UKR Tan K Aviso University De La Salle Manila PHM Walmsley University of Waikato Hamilton NZT Zhelev dagger University of Limerick IR
21
World Coverage Co-Authors
22
Heat Integration using Pinch Analysis
23
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
The First Steps ndash HEN synthesisPinch Analysis Hohmann E C 1971 Optimum networks for heat exchange PhD thesis University of Southern California LA USALinnhoff B Flower JR 1978 Synthesis of heat exchanger networks I Systematic generation of energy optimal networks AIChE Journal 24(4) 633ndash642Umeda T Harada T Shiroko KA 1979 Thermodynamic approach to the synthesis of heat integration systems in chemical processes Computers amp Chemical Engineering 3(1-4) 273ndash282
Heuristic methodsPonton J W Donaldson R A B 1974 A fast method for the synthesis of optimal heat exchanger networks ChemEngSci 29 2375-2377 (1974)
Mathematical programing Papoulias SA Grossmann IE1983 A structural optimization approach in process synthesis-II Heat recovery networks CompChemEng 7 (6) 707-721Yee TF Grossmann IE1990 Optimization models for heat integrationmdashII Heat exchanger network synthesis ComputChemEng 14 1165ndash1184
25
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Cooperation with Foreign Universities
SLOVENIAUKHUNGARY
CHINA (HeBei)
NEW ZEALAND
CHINA (Fudan)
MALAYSIA
CHINA (Xirsquoan)
PHILIPPINES
Google Scholar
Mendeley
Speed up research by harnessing the power of peer review
98th Percentile
Currently serves on 20 editorial boardsTotally serves on 25 editorial boards
Editor-in-Chief President
Has reviewed for 106 journals
High Citations Papers
Web of Sciencehttpappswebofknowledgecom
Journal of Cleaner Production
17
JCLP Co-Editors-in-Chief
18
JCLP Impact
Total Articles
Total Cites
19
JCLP ndash Contributors
20
Main Co-Authors of this lectureS Bandyopadhyay Indian Institute of Technology INCY Chang National Cheng Kung University Tainan TPQ Wang X Feng Xirsquoan Jiaotong Univ ampChina Univ of Petroleum I E Grossmann Carnegie Mellon University Pittsburgh PA UST Gundersen NUST Trondheim Norway NOJ-K Kim Hanyang University Seoul KRH Matos Instituto Superior TeacutecnicoUniversidade de Lisboa PTT Majozi University of the Witwatersrand Johannesburg ZAF Mareacutechal EacutePFL Lausanne Sion CHHL Lam D Ng D C Y Foo Uni of Nottingham MY Campus KL Panjeshahi N Tahouni University of Tehran IR M Picoacuten-Nuacutentildeez University of Guanajuato Mexico MXSR Wan Alvi Z A Manan UTM Johor Bahru amp KLCC MYU Shenoy Synew Technologies Mumbai INR Smith I Bulatov UMIST amp The University of Manchester UKR Tan K Aviso University De La Salle Manila PHM Walmsley University of Waikato Hamilton NZT Zhelev dagger University of Limerick IR
21
World Coverage Co-Authors
22
Heat Integration using Pinch Analysis
23
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
The First Steps ndash HEN synthesisPinch Analysis Hohmann E C 1971 Optimum networks for heat exchange PhD thesis University of Southern California LA USALinnhoff B Flower JR 1978 Synthesis of heat exchanger networks I Systematic generation of energy optimal networks AIChE Journal 24(4) 633ndash642Umeda T Harada T Shiroko KA 1979 Thermodynamic approach to the synthesis of heat integration systems in chemical processes Computers amp Chemical Engineering 3(1-4) 273ndash282
Heuristic methodsPonton J W Donaldson R A B 1974 A fast method for the synthesis of optimal heat exchanger networks ChemEngSci 29 2375-2377 (1974)
Mathematical programing Papoulias SA Grossmann IE1983 A structural optimization approach in process synthesis-II Heat recovery networks CompChemEng 7 (6) 707-721Yee TF Grossmann IE1990 Optimization models for heat integrationmdashII Heat exchanger network synthesis ComputChemEng 14 1165ndash1184
25
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Google Scholar
Mendeley
Speed up research by harnessing the power of peer review
98th Percentile
Currently serves on 20 editorial boardsTotally serves on 25 editorial boards
Editor-in-Chief President
Has reviewed for 106 journals
High Citations Papers
Web of Sciencehttpappswebofknowledgecom
Journal of Cleaner Production
17
JCLP Co-Editors-in-Chief
18
JCLP Impact
Total Articles
Total Cites
19
JCLP ndash Contributors
20
Main Co-Authors of this lectureS Bandyopadhyay Indian Institute of Technology INCY Chang National Cheng Kung University Tainan TPQ Wang X Feng Xirsquoan Jiaotong Univ ampChina Univ of Petroleum I E Grossmann Carnegie Mellon University Pittsburgh PA UST Gundersen NUST Trondheim Norway NOJ-K Kim Hanyang University Seoul KRH Matos Instituto Superior TeacutecnicoUniversidade de Lisboa PTT Majozi University of the Witwatersrand Johannesburg ZAF Mareacutechal EacutePFL Lausanne Sion CHHL Lam D Ng D C Y Foo Uni of Nottingham MY Campus KL Panjeshahi N Tahouni University of Tehran IR M Picoacuten-Nuacutentildeez University of Guanajuato Mexico MXSR Wan Alvi Z A Manan UTM Johor Bahru amp KLCC MYU Shenoy Synew Technologies Mumbai INR Smith I Bulatov UMIST amp The University of Manchester UKR Tan K Aviso University De La Salle Manila PHM Walmsley University of Waikato Hamilton NZT Zhelev dagger University of Limerick IR
21
World Coverage Co-Authors
22
Heat Integration using Pinch Analysis
23
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
The First Steps ndash HEN synthesisPinch Analysis Hohmann E C 1971 Optimum networks for heat exchange PhD thesis University of Southern California LA USALinnhoff B Flower JR 1978 Synthesis of heat exchanger networks I Systematic generation of energy optimal networks AIChE Journal 24(4) 633ndash642Umeda T Harada T Shiroko KA 1979 Thermodynamic approach to the synthesis of heat integration systems in chemical processes Computers amp Chemical Engineering 3(1-4) 273ndash282
Heuristic methodsPonton J W Donaldson R A B 1974 A fast method for the synthesis of optimal heat exchanger networks ChemEngSci 29 2375-2377 (1974)
Mathematical programing Papoulias SA Grossmann IE1983 A structural optimization approach in process synthesis-II Heat recovery networks CompChemEng 7 (6) 707-721Yee TF Grossmann IE1990 Optimization models for heat integrationmdashII Heat exchanger network synthesis ComputChemEng 14 1165ndash1184
25
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Mendeley
Speed up research by harnessing the power of peer review
98th Percentile
Currently serves on 20 editorial boardsTotally serves on 25 editorial boards
Editor-in-Chief President
Has reviewed for 106 journals
High Citations Papers
Web of Sciencehttpappswebofknowledgecom
Journal of Cleaner Production
17
JCLP Co-Editors-in-Chief
18
JCLP Impact
Total Articles
Total Cites
19
JCLP ndash Contributors
20
Main Co-Authors of this lectureS Bandyopadhyay Indian Institute of Technology INCY Chang National Cheng Kung University Tainan TPQ Wang X Feng Xirsquoan Jiaotong Univ ampChina Univ of Petroleum I E Grossmann Carnegie Mellon University Pittsburgh PA UST Gundersen NUST Trondheim Norway NOJ-K Kim Hanyang University Seoul KRH Matos Instituto Superior TeacutecnicoUniversidade de Lisboa PTT Majozi University of the Witwatersrand Johannesburg ZAF Mareacutechal EacutePFL Lausanne Sion CHHL Lam D Ng D C Y Foo Uni of Nottingham MY Campus KL Panjeshahi N Tahouni University of Tehran IR M Picoacuten-Nuacutentildeez University of Guanajuato Mexico MXSR Wan Alvi Z A Manan UTM Johor Bahru amp KLCC MYU Shenoy Synew Technologies Mumbai INR Smith I Bulatov UMIST amp The University of Manchester UKR Tan K Aviso University De La Salle Manila PHM Walmsley University of Waikato Hamilton NZT Zhelev dagger University of Limerick IR
21
World Coverage Co-Authors
22
Heat Integration using Pinch Analysis
23
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
The First Steps ndash HEN synthesisPinch Analysis Hohmann E C 1971 Optimum networks for heat exchange PhD thesis University of Southern California LA USALinnhoff B Flower JR 1978 Synthesis of heat exchanger networks I Systematic generation of energy optimal networks AIChE Journal 24(4) 633ndash642Umeda T Harada T Shiroko KA 1979 Thermodynamic approach to the synthesis of heat integration systems in chemical processes Computers amp Chemical Engineering 3(1-4) 273ndash282
Heuristic methodsPonton J W Donaldson R A B 1974 A fast method for the synthesis of optimal heat exchanger networks ChemEngSci 29 2375-2377 (1974)
Mathematical programing Papoulias SA Grossmann IE1983 A structural optimization approach in process synthesis-II Heat recovery networks CompChemEng 7 (6) 707-721Yee TF Grossmann IE1990 Optimization models for heat integrationmdashII Heat exchanger network synthesis ComputChemEng 14 1165ndash1184
25
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Speed up research by harnessing the power of peer review
98th Percentile
Currently serves on 20 editorial boardsTotally serves on 25 editorial boards
Editor-in-Chief President
Has reviewed for 106 journals
High Citations Papers
Web of Sciencehttpappswebofknowledgecom
Journal of Cleaner Production
17
JCLP Co-Editors-in-Chief
18
JCLP Impact
Total Articles
Total Cites
19
JCLP ndash Contributors
20
Main Co-Authors of this lectureS Bandyopadhyay Indian Institute of Technology INCY Chang National Cheng Kung University Tainan TPQ Wang X Feng Xirsquoan Jiaotong Univ ampChina Univ of Petroleum I E Grossmann Carnegie Mellon University Pittsburgh PA UST Gundersen NUST Trondheim Norway NOJ-K Kim Hanyang University Seoul KRH Matos Instituto Superior TeacutecnicoUniversidade de Lisboa PTT Majozi University of the Witwatersrand Johannesburg ZAF Mareacutechal EacutePFL Lausanne Sion CHHL Lam D Ng D C Y Foo Uni of Nottingham MY Campus KL Panjeshahi N Tahouni University of Tehran IR M Picoacuten-Nuacutentildeez University of Guanajuato Mexico MXSR Wan Alvi Z A Manan UTM Johor Bahru amp KLCC MYU Shenoy Synew Technologies Mumbai INR Smith I Bulatov UMIST amp The University of Manchester UKR Tan K Aviso University De La Salle Manila PHM Walmsley University of Waikato Hamilton NZT Zhelev dagger University of Limerick IR
21
World Coverage Co-Authors
22
Heat Integration using Pinch Analysis
23
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
The First Steps ndash HEN synthesisPinch Analysis Hohmann E C 1971 Optimum networks for heat exchange PhD thesis University of Southern California LA USALinnhoff B Flower JR 1978 Synthesis of heat exchanger networks I Systematic generation of energy optimal networks AIChE Journal 24(4) 633ndash642Umeda T Harada T Shiroko KA 1979 Thermodynamic approach to the synthesis of heat integration systems in chemical processes Computers amp Chemical Engineering 3(1-4) 273ndash282
Heuristic methodsPonton J W Donaldson R A B 1974 A fast method for the synthesis of optimal heat exchanger networks ChemEngSci 29 2375-2377 (1974)
Mathematical programing Papoulias SA Grossmann IE1983 A structural optimization approach in process synthesis-II Heat recovery networks CompChemEng 7 (6) 707-721Yee TF Grossmann IE1990 Optimization models for heat integrationmdashII Heat exchanger network synthesis ComputChemEng 14 1165ndash1184
25
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Currently serves on 20 editorial boardsTotally serves on 25 editorial boards
Editor-in-Chief President
Has reviewed for 106 journals
High Citations Papers
Web of Sciencehttpappswebofknowledgecom
Journal of Cleaner Production
17
JCLP Co-Editors-in-Chief
18
JCLP Impact
Total Articles
Total Cites
19
JCLP ndash Contributors
20
Main Co-Authors of this lectureS Bandyopadhyay Indian Institute of Technology INCY Chang National Cheng Kung University Tainan TPQ Wang X Feng Xirsquoan Jiaotong Univ ampChina Univ of Petroleum I E Grossmann Carnegie Mellon University Pittsburgh PA UST Gundersen NUST Trondheim Norway NOJ-K Kim Hanyang University Seoul KRH Matos Instituto Superior TeacutecnicoUniversidade de Lisboa PTT Majozi University of the Witwatersrand Johannesburg ZAF Mareacutechal EacutePFL Lausanne Sion CHHL Lam D Ng D C Y Foo Uni of Nottingham MY Campus KL Panjeshahi N Tahouni University of Tehran IR M Picoacuten-Nuacutentildeez University of Guanajuato Mexico MXSR Wan Alvi Z A Manan UTM Johor Bahru amp KLCC MYU Shenoy Synew Technologies Mumbai INR Smith I Bulatov UMIST amp The University of Manchester UKR Tan K Aviso University De La Salle Manila PHM Walmsley University of Waikato Hamilton NZT Zhelev dagger University of Limerick IR
21
World Coverage Co-Authors
22
Heat Integration using Pinch Analysis
23
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
The First Steps ndash HEN synthesisPinch Analysis Hohmann E C 1971 Optimum networks for heat exchange PhD thesis University of Southern California LA USALinnhoff B Flower JR 1978 Synthesis of heat exchanger networks I Systematic generation of energy optimal networks AIChE Journal 24(4) 633ndash642Umeda T Harada T Shiroko KA 1979 Thermodynamic approach to the synthesis of heat integration systems in chemical processes Computers amp Chemical Engineering 3(1-4) 273ndash282
Heuristic methodsPonton J W Donaldson R A B 1974 A fast method for the synthesis of optimal heat exchanger networks ChemEngSci 29 2375-2377 (1974)
Mathematical programing Papoulias SA Grossmann IE1983 A structural optimization approach in process synthesis-II Heat recovery networks CompChemEng 7 (6) 707-721Yee TF Grossmann IE1990 Optimization models for heat integrationmdashII Heat exchanger network synthesis ComputChemEng 14 1165ndash1184
25
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Has reviewed for 106 journals
High Citations Papers
Web of Sciencehttpappswebofknowledgecom
Journal of Cleaner Production
17
JCLP Co-Editors-in-Chief
18
JCLP Impact
Total Articles
Total Cites
19
JCLP ndash Contributors
20
Main Co-Authors of this lectureS Bandyopadhyay Indian Institute of Technology INCY Chang National Cheng Kung University Tainan TPQ Wang X Feng Xirsquoan Jiaotong Univ ampChina Univ of Petroleum I E Grossmann Carnegie Mellon University Pittsburgh PA UST Gundersen NUST Trondheim Norway NOJ-K Kim Hanyang University Seoul KRH Matos Instituto Superior TeacutecnicoUniversidade de Lisboa PTT Majozi University of the Witwatersrand Johannesburg ZAF Mareacutechal EacutePFL Lausanne Sion CHHL Lam D Ng D C Y Foo Uni of Nottingham MY Campus KL Panjeshahi N Tahouni University of Tehran IR M Picoacuten-Nuacutentildeez University of Guanajuato Mexico MXSR Wan Alvi Z A Manan UTM Johor Bahru amp KLCC MYU Shenoy Synew Technologies Mumbai INR Smith I Bulatov UMIST amp The University of Manchester UKR Tan K Aviso University De La Salle Manila PHM Walmsley University of Waikato Hamilton NZT Zhelev dagger University of Limerick IR
21
World Coverage Co-Authors
22
Heat Integration using Pinch Analysis
23
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
The First Steps ndash HEN synthesisPinch Analysis Hohmann E C 1971 Optimum networks for heat exchange PhD thesis University of Southern California LA USALinnhoff B Flower JR 1978 Synthesis of heat exchanger networks I Systematic generation of energy optimal networks AIChE Journal 24(4) 633ndash642Umeda T Harada T Shiroko KA 1979 Thermodynamic approach to the synthesis of heat integration systems in chemical processes Computers amp Chemical Engineering 3(1-4) 273ndash282
Heuristic methodsPonton J W Donaldson R A B 1974 A fast method for the synthesis of optimal heat exchanger networks ChemEngSci 29 2375-2377 (1974)
Mathematical programing Papoulias SA Grossmann IE1983 A structural optimization approach in process synthesis-II Heat recovery networks CompChemEng 7 (6) 707-721Yee TF Grossmann IE1990 Optimization models for heat integrationmdashII Heat exchanger network synthesis ComputChemEng 14 1165ndash1184
25
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
High Citations Papers
Web of Sciencehttpappswebofknowledgecom
Journal of Cleaner Production
17
JCLP Co-Editors-in-Chief
18
JCLP Impact
Total Articles
Total Cites
19
JCLP ndash Contributors
20
Main Co-Authors of this lectureS Bandyopadhyay Indian Institute of Technology INCY Chang National Cheng Kung University Tainan TPQ Wang X Feng Xirsquoan Jiaotong Univ ampChina Univ of Petroleum I E Grossmann Carnegie Mellon University Pittsburgh PA UST Gundersen NUST Trondheim Norway NOJ-K Kim Hanyang University Seoul KRH Matos Instituto Superior TeacutecnicoUniversidade de Lisboa PTT Majozi University of the Witwatersrand Johannesburg ZAF Mareacutechal EacutePFL Lausanne Sion CHHL Lam D Ng D C Y Foo Uni of Nottingham MY Campus KL Panjeshahi N Tahouni University of Tehran IR M Picoacuten-Nuacutentildeez University of Guanajuato Mexico MXSR Wan Alvi Z A Manan UTM Johor Bahru amp KLCC MYU Shenoy Synew Technologies Mumbai INR Smith I Bulatov UMIST amp The University of Manchester UKR Tan K Aviso University De La Salle Manila PHM Walmsley University of Waikato Hamilton NZT Zhelev dagger University of Limerick IR
21
World Coverage Co-Authors
22
Heat Integration using Pinch Analysis
23
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
The First Steps ndash HEN synthesisPinch Analysis Hohmann E C 1971 Optimum networks for heat exchange PhD thesis University of Southern California LA USALinnhoff B Flower JR 1978 Synthesis of heat exchanger networks I Systematic generation of energy optimal networks AIChE Journal 24(4) 633ndash642Umeda T Harada T Shiroko KA 1979 Thermodynamic approach to the synthesis of heat integration systems in chemical processes Computers amp Chemical Engineering 3(1-4) 273ndash282
Heuristic methodsPonton J W Donaldson R A B 1974 A fast method for the synthesis of optimal heat exchanger networks ChemEngSci 29 2375-2377 (1974)
Mathematical programing Papoulias SA Grossmann IE1983 A structural optimization approach in process synthesis-II Heat recovery networks CompChemEng 7 (6) 707-721Yee TF Grossmann IE1990 Optimization models for heat integrationmdashII Heat exchanger network synthesis ComputChemEng 14 1165ndash1184
25
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Journal of Cleaner Production
17
JCLP Co-Editors-in-Chief
18
JCLP Impact
Total Articles
Total Cites
19
JCLP ndash Contributors
20
Main Co-Authors of this lectureS Bandyopadhyay Indian Institute of Technology INCY Chang National Cheng Kung University Tainan TPQ Wang X Feng Xirsquoan Jiaotong Univ ampChina Univ of Petroleum I E Grossmann Carnegie Mellon University Pittsburgh PA UST Gundersen NUST Trondheim Norway NOJ-K Kim Hanyang University Seoul KRH Matos Instituto Superior TeacutecnicoUniversidade de Lisboa PTT Majozi University of the Witwatersrand Johannesburg ZAF Mareacutechal EacutePFL Lausanne Sion CHHL Lam D Ng D C Y Foo Uni of Nottingham MY Campus KL Panjeshahi N Tahouni University of Tehran IR M Picoacuten-Nuacutentildeez University of Guanajuato Mexico MXSR Wan Alvi Z A Manan UTM Johor Bahru amp KLCC MYU Shenoy Synew Technologies Mumbai INR Smith I Bulatov UMIST amp The University of Manchester UKR Tan K Aviso University De La Salle Manila PHM Walmsley University of Waikato Hamilton NZT Zhelev dagger University of Limerick IR
21
World Coverage Co-Authors
22
Heat Integration using Pinch Analysis
23
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
The First Steps ndash HEN synthesisPinch Analysis Hohmann E C 1971 Optimum networks for heat exchange PhD thesis University of Southern California LA USALinnhoff B Flower JR 1978 Synthesis of heat exchanger networks I Systematic generation of energy optimal networks AIChE Journal 24(4) 633ndash642Umeda T Harada T Shiroko KA 1979 Thermodynamic approach to the synthesis of heat integration systems in chemical processes Computers amp Chemical Engineering 3(1-4) 273ndash282
Heuristic methodsPonton J W Donaldson R A B 1974 A fast method for the synthesis of optimal heat exchanger networks ChemEngSci 29 2375-2377 (1974)
Mathematical programing Papoulias SA Grossmann IE1983 A structural optimization approach in process synthesis-II Heat recovery networks CompChemEng 7 (6) 707-721Yee TF Grossmann IE1990 Optimization models for heat integrationmdashII Heat exchanger network synthesis ComputChemEng 14 1165ndash1184
25
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
17
JCLP Co-Editors-in-Chief
18
JCLP Impact
Total Articles
Total Cites
19
JCLP ndash Contributors
20
Main Co-Authors of this lectureS Bandyopadhyay Indian Institute of Technology INCY Chang National Cheng Kung University Tainan TPQ Wang X Feng Xirsquoan Jiaotong Univ ampChina Univ of Petroleum I E Grossmann Carnegie Mellon University Pittsburgh PA UST Gundersen NUST Trondheim Norway NOJ-K Kim Hanyang University Seoul KRH Matos Instituto Superior TeacutecnicoUniversidade de Lisboa PTT Majozi University of the Witwatersrand Johannesburg ZAF Mareacutechal EacutePFL Lausanne Sion CHHL Lam D Ng D C Y Foo Uni of Nottingham MY Campus KL Panjeshahi N Tahouni University of Tehran IR M Picoacuten-Nuacutentildeez University of Guanajuato Mexico MXSR Wan Alvi Z A Manan UTM Johor Bahru amp KLCC MYU Shenoy Synew Technologies Mumbai INR Smith I Bulatov UMIST amp The University of Manchester UKR Tan K Aviso University De La Salle Manila PHM Walmsley University of Waikato Hamilton NZT Zhelev dagger University of Limerick IR
21
World Coverage Co-Authors
22
Heat Integration using Pinch Analysis
23
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
The First Steps ndash HEN synthesisPinch Analysis Hohmann E C 1971 Optimum networks for heat exchange PhD thesis University of Southern California LA USALinnhoff B Flower JR 1978 Synthesis of heat exchanger networks I Systematic generation of energy optimal networks AIChE Journal 24(4) 633ndash642Umeda T Harada T Shiroko KA 1979 Thermodynamic approach to the synthesis of heat integration systems in chemical processes Computers amp Chemical Engineering 3(1-4) 273ndash282
Heuristic methodsPonton J W Donaldson R A B 1974 A fast method for the synthesis of optimal heat exchanger networks ChemEngSci 29 2375-2377 (1974)
Mathematical programing Papoulias SA Grossmann IE1983 A structural optimization approach in process synthesis-II Heat recovery networks CompChemEng 7 (6) 707-721Yee TF Grossmann IE1990 Optimization models for heat integrationmdashII Heat exchanger network synthesis ComputChemEng 14 1165ndash1184
25
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
18
JCLP Impact
Total Articles
Total Cites
19
JCLP ndash Contributors
20
Main Co-Authors of this lectureS Bandyopadhyay Indian Institute of Technology INCY Chang National Cheng Kung University Tainan TPQ Wang X Feng Xirsquoan Jiaotong Univ ampChina Univ of Petroleum I E Grossmann Carnegie Mellon University Pittsburgh PA UST Gundersen NUST Trondheim Norway NOJ-K Kim Hanyang University Seoul KRH Matos Instituto Superior TeacutecnicoUniversidade de Lisboa PTT Majozi University of the Witwatersrand Johannesburg ZAF Mareacutechal EacutePFL Lausanne Sion CHHL Lam D Ng D C Y Foo Uni of Nottingham MY Campus KL Panjeshahi N Tahouni University of Tehran IR M Picoacuten-Nuacutentildeez University of Guanajuato Mexico MXSR Wan Alvi Z A Manan UTM Johor Bahru amp KLCC MYU Shenoy Synew Technologies Mumbai INR Smith I Bulatov UMIST amp The University of Manchester UKR Tan K Aviso University De La Salle Manila PHM Walmsley University of Waikato Hamilton NZT Zhelev dagger University of Limerick IR
21
World Coverage Co-Authors
22
Heat Integration using Pinch Analysis
23
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
The First Steps ndash HEN synthesisPinch Analysis Hohmann E C 1971 Optimum networks for heat exchange PhD thesis University of Southern California LA USALinnhoff B Flower JR 1978 Synthesis of heat exchanger networks I Systematic generation of energy optimal networks AIChE Journal 24(4) 633ndash642Umeda T Harada T Shiroko KA 1979 Thermodynamic approach to the synthesis of heat integration systems in chemical processes Computers amp Chemical Engineering 3(1-4) 273ndash282
Heuristic methodsPonton J W Donaldson R A B 1974 A fast method for the synthesis of optimal heat exchanger networks ChemEngSci 29 2375-2377 (1974)
Mathematical programing Papoulias SA Grossmann IE1983 A structural optimization approach in process synthesis-II Heat recovery networks CompChemEng 7 (6) 707-721Yee TF Grossmann IE1990 Optimization models for heat integrationmdashII Heat exchanger network synthesis ComputChemEng 14 1165ndash1184
25
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
19
JCLP ndash Contributors
20
Main Co-Authors of this lectureS Bandyopadhyay Indian Institute of Technology INCY Chang National Cheng Kung University Tainan TPQ Wang X Feng Xirsquoan Jiaotong Univ ampChina Univ of Petroleum I E Grossmann Carnegie Mellon University Pittsburgh PA UST Gundersen NUST Trondheim Norway NOJ-K Kim Hanyang University Seoul KRH Matos Instituto Superior TeacutecnicoUniversidade de Lisboa PTT Majozi University of the Witwatersrand Johannesburg ZAF Mareacutechal EacutePFL Lausanne Sion CHHL Lam D Ng D C Y Foo Uni of Nottingham MY Campus KL Panjeshahi N Tahouni University of Tehran IR M Picoacuten-Nuacutentildeez University of Guanajuato Mexico MXSR Wan Alvi Z A Manan UTM Johor Bahru amp KLCC MYU Shenoy Synew Technologies Mumbai INR Smith I Bulatov UMIST amp The University of Manchester UKR Tan K Aviso University De La Salle Manila PHM Walmsley University of Waikato Hamilton NZT Zhelev dagger University of Limerick IR
21
World Coverage Co-Authors
22
Heat Integration using Pinch Analysis
23
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
The First Steps ndash HEN synthesisPinch Analysis Hohmann E C 1971 Optimum networks for heat exchange PhD thesis University of Southern California LA USALinnhoff B Flower JR 1978 Synthesis of heat exchanger networks I Systematic generation of energy optimal networks AIChE Journal 24(4) 633ndash642Umeda T Harada T Shiroko KA 1979 Thermodynamic approach to the synthesis of heat integration systems in chemical processes Computers amp Chemical Engineering 3(1-4) 273ndash282
Heuristic methodsPonton J W Donaldson R A B 1974 A fast method for the synthesis of optimal heat exchanger networks ChemEngSci 29 2375-2377 (1974)
Mathematical programing Papoulias SA Grossmann IE1983 A structural optimization approach in process synthesis-II Heat recovery networks CompChemEng 7 (6) 707-721Yee TF Grossmann IE1990 Optimization models for heat integrationmdashII Heat exchanger network synthesis ComputChemEng 14 1165ndash1184
25
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
20
Main Co-Authors of this lectureS Bandyopadhyay Indian Institute of Technology INCY Chang National Cheng Kung University Tainan TPQ Wang X Feng Xirsquoan Jiaotong Univ ampChina Univ of Petroleum I E Grossmann Carnegie Mellon University Pittsburgh PA UST Gundersen NUST Trondheim Norway NOJ-K Kim Hanyang University Seoul KRH Matos Instituto Superior TeacutecnicoUniversidade de Lisboa PTT Majozi University of the Witwatersrand Johannesburg ZAF Mareacutechal EacutePFL Lausanne Sion CHHL Lam D Ng D C Y Foo Uni of Nottingham MY Campus KL Panjeshahi N Tahouni University of Tehran IR M Picoacuten-Nuacutentildeez University of Guanajuato Mexico MXSR Wan Alvi Z A Manan UTM Johor Bahru amp KLCC MYU Shenoy Synew Technologies Mumbai INR Smith I Bulatov UMIST amp The University of Manchester UKR Tan K Aviso University De La Salle Manila PHM Walmsley University of Waikato Hamilton NZT Zhelev dagger University of Limerick IR
21
World Coverage Co-Authors
22
Heat Integration using Pinch Analysis
23
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
The First Steps ndash HEN synthesisPinch Analysis Hohmann E C 1971 Optimum networks for heat exchange PhD thesis University of Southern California LA USALinnhoff B Flower JR 1978 Synthesis of heat exchanger networks I Systematic generation of energy optimal networks AIChE Journal 24(4) 633ndash642Umeda T Harada T Shiroko KA 1979 Thermodynamic approach to the synthesis of heat integration systems in chemical processes Computers amp Chemical Engineering 3(1-4) 273ndash282
Heuristic methodsPonton J W Donaldson R A B 1974 A fast method for the synthesis of optimal heat exchanger networks ChemEngSci 29 2375-2377 (1974)
Mathematical programing Papoulias SA Grossmann IE1983 A structural optimization approach in process synthesis-II Heat recovery networks CompChemEng 7 (6) 707-721Yee TF Grossmann IE1990 Optimization models for heat integrationmdashII Heat exchanger network synthesis ComputChemEng 14 1165ndash1184
25
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Main Co-Authors of this lectureS Bandyopadhyay Indian Institute of Technology INCY Chang National Cheng Kung University Tainan TPQ Wang X Feng Xirsquoan Jiaotong Univ ampChina Univ of Petroleum I E Grossmann Carnegie Mellon University Pittsburgh PA UST Gundersen NUST Trondheim Norway NOJ-K Kim Hanyang University Seoul KRH Matos Instituto Superior TeacutecnicoUniversidade de Lisboa PTT Majozi University of the Witwatersrand Johannesburg ZAF Mareacutechal EacutePFL Lausanne Sion CHHL Lam D Ng D C Y Foo Uni of Nottingham MY Campus KL Panjeshahi N Tahouni University of Tehran IR M Picoacuten-Nuacutentildeez University of Guanajuato Mexico MXSR Wan Alvi Z A Manan UTM Johor Bahru amp KLCC MYU Shenoy Synew Technologies Mumbai INR Smith I Bulatov UMIST amp The University of Manchester UKR Tan K Aviso University De La Salle Manila PHM Walmsley University of Waikato Hamilton NZT Zhelev dagger University of Limerick IR
21
World Coverage Co-Authors
22
Heat Integration using Pinch Analysis
23
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
The First Steps ndash HEN synthesisPinch Analysis Hohmann E C 1971 Optimum networks for heat exchange PhD thesis University of Southern California LA USALinnhoff B Flower JR 1978 Synthesis of heat exchanger networks I Systematic generation of energy optimal networks AIChE Journal 24(4) 633ndash642Umeda T Harada T Shiroko KA 1979 Thermodynamic approach to the synthesis of heat integration systems in chemical processes Computers amp Chemical Engineering 3(1-4) 273ndash282
Heuristic methodsPonton J W Donaldson R A B 1974 A fast method for the synthesis of optimal heat exchanger networks ChemEngSci 29 2375-2377 (1974)
Mathematical programing Papoulias SA Grossmann IE1983 A structural optimization approach in process synthesis-II Heat recovery networks CompChemEng 7 (6) 707-721Yee TF Grossmann IE1990 Optimization models for heat integrationmdashII Heat exchanger network synthesis ComputChemEng 14 1165ndash1184
25
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
World Coverage Co-Authors
22
Heat Integration using Pinch Analysis
23
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
The First Steps ndash HEN synthesisPinch Analysis Hohmann E C 1971 Optimum networks for heat exchange PhD thesis University of Southern California LA USALinnhoff B Flower JR 1978 Synthesis of heat exchanger networks I Systematic generation of energy optimal networks AIChE Journal 24(4) 633ndash642Umeda T Harada T Shiroko KA 1979 Thermodynamic approach to the synthesis of heat integration systems in chemical processes Computers amp Chemical Engineering 3(1-4) 273ndash282
Heuristic methodsPonton J W Donaldson R A B 1974 A fast method for the synthesis of optimal heat exchanger networks ChemEngSci 29 2375-2377 (1974)
Mathematical programing Papoulias SA Grossmann IE1983 A structural optimization approach in process synthesis-II Heat recovery networks CompChemEng 7 (6) 707-721Yee TF Grossmann IE1990 Optimization models for heat integrationmdashII Heat exchanger network synthesis ComputChemEng 14 1165ndash1184
25
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Heat Integration using Pinch Analysis
23
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
The First Steps ndash HEN synthesisPinch Analysis Hohmann E C 1971 Optimum networks for heat exchange PhD thesis University of Southern California LA USALinnhoff B Flower JR 1978 Synthesis of heat exchanger networks I Systematic generation of energy optimal networks AIChE Journal 24(4) 633ndash642Umeda T Harada T Shiroko KA 1979 Thermodynamic approach to the synthesis of heat integration systems in chemical processes Computers amp Chemical Engineering 3(1-4) 273ndash282
Heuristic methodsPonton J W Donaldson R A B 1974 A fast method for the synthesis of optimal heat exchanger networks ChemEngSci 29 2375-2377 (1974)
Mathematical programing Papoulias SA Grossmann IE1983 A structural optimization approach in process synthesis-II Heat recovery networks CompChemEng 7 (6) 707-721Yee TF Grossmann IE1990 Optimization models for heat integrationmdashII Heat exchanger network synthesis ComputChemEng 14 1165ndash1184
25
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
UMIST History
1824 Created by industrialists as the Manchester Mechanics Institution
1905 Faculty of Technology University of Manchester
1956 Royal Charter granted to Manchester College of Science and Technology
1965 University of Manchester Institute of Science and Technology
The First Steps ndash HEN synthesisPinch Analysis Hohmann E C 1971 Optimum networks for heat exchange PhD thesis University of Southern California LA USALinnhoff B Flower JR 1978 Synthesis of heat exchanger networks I Systematic generation of energy optimal networks AIChE Journal 24(4) 633ndash642Umeda T Harada T Shiroko KA 1979 Thermodynamic approach to the synthesis of heat integration systems in chemical processes Computers amp Chemical Engineering 3(1-4) 273ndash282
Heuristic methodsPonton J W Donaldson R A B 1974 A fast method for the synthesis of optimal heat exchanger networks ChemEngSci 29 2375-2377 (1974)
Mathematical programing Papoulias SA Grossmann IE1983 A structural optimization approach in process synthesis-II Heat recovery networks CompChemEng 7 (6) 707-721Yee TF Grossmann IE1990 Optimization models for heat integrationmdashII Heat exchanger network synthesis ComputChemEng 14 1165ndash1184
25
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
The First Steps ndash HEN synthesisPinch Analysis Hohmann E C 1971 Optimum networks for heat exchange PhD thesis University of Southern California LA USALinnhoff B Flower JR 1978 Synthesis of heat exchanger networks I Systematic generation of energy optimal networks AIChE Journal 24(4) 633ndash642Umeda T Harada T Shiroko KA 1979 Thermodynamic approach to the synthesis of heat integration systems in chemical processes Computers amp Chemical Engineering 3(1-4) 273ndash282
Heuristic methodsPonton J W Donaldson R A B 1974 A fast method for the synthesis of optimal heat exchanger networks ChemEngSci 29 2375-2377 (1974)
Mathematical programing Papoulias SA Grossmann IE1983 A structural optimization approach in process synthesis-II Heat recovery networks CompChemEng 7 (6) 707-721Yee TF Grossmann IE1990 Optimization models for heat integrationmdashII Heat exchanger network synthesis ComputChemEng 14 1165ndash1184
25
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
The Roots of Pinch Analysis
bull Hohmann E C (1971) Optimum networks for heat exchange PhD thesis University of Southern California Los Angeles USA
bull Linnhoff B (1972) Thermodynamic analysis of the cement burning process (Thermodynamische Analyse des Zementbrennprozesses) Diploma work Abteilung IIIa ETH Zurich (1972) (in German)
bull Hohmann E C Lockhart F J (1976) Optimum heat exchanger network synthesis AIChE 82nd National Meeting Atlantic City NJ USA Paper No 22a
26
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
The ldquoRed Bookrdquo27
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
SPIL VUT Brno 2 May 2018Prof Bodo Linnhoff Pioneer of Pinch Analysis
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
What is Process (Heat) Integration
29
A family of methodologies for combining several processes to reduce consumption of resources andor harmful emissions to the environment
It started as Heat Integration stimulated by the energy crisis in the 1970s
Definition of Process Integration by IEASystematic and General Methods for Designing Integrated Production Systems ranging from Individual Processes to Total Sites with special emphasis on the Efficient Use of Energy and reducing Environmental Effects
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Pinch based approach
T
H (Enthapy)
QH
QC
Hot Composite Curve
Cold Composite Curve
Complicated Flowsheet Simple Diagram
Composite Curves
Pinch
30
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Mathematical Programming OR Pinch
31
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Pinch AND Mathematical Programming
32
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Benefits of Process Integration
33
Heat Integration roots
minus Identify heat recovery targets and aid in synthesizingmaximum heat recovery systems
minus Minimise utility demands and CO2 emissions of a process
Minimisation of resource consumption
minus Total Sites Optimisationminus Supply Chainsminus Optimal time scheduling and tracking
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
34
Research Consortium MembersPresent and Past Members
Air Products - USAAspen UK Ltd - UKBOC - UKBP Amoco - UKCanmet - CanadaChinese Petroleum Corp - TaiwanDegussa - GermanyEngineers India - IndiaExxonMobil - USAInstitut Francais du Petrole - FranceITRI - TaiwanJGC Corporation - JapanLinnhoff March KCB - UK USMitsubishi Chemical Co - Japan
MW Kellogg - UK USNorsk Hydro - NorwayPetrobras - BrazilUT Petronas - MalaysiaPetrom - RomaniaPowerGen - UKSaudi Aramco - Saudi ArabiaShell Global Solutions - NetherlandsSinopec Tech - ChinaTechnip Benelux - NetherlandsTotal - FrancelsquoPolitechnicarsquo Bucharest - RomaniaUOP - USA UKVito - Belgium
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Handbook of Process Integration (PI)Minimisation of energy and water use waste and
emissionsHandbook of Process Integration (PI) Minimisation of energy and water use waste and emissionsEdited by J Klemes University of Pannonia Hungary
Woodhead Publishing Series in Energy No 61
ISBN 0 85709 593 5ISBN-13 978 0 85709 593 0July 20131184 pages 234 x 156mm hardback
ltwwwwoodheadpublishingcomenbookaspxbookID=2687gt
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Composite Curves - ΔTmin = 10 degC
QCmin = 1000 QREC = 5150 QHmin = 750
H (kW)
T(degC)
250
200
150
100
50
0
Pinch
∆Tmin=10deg
36
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Pinch Design Principle37
ΔH
PINCH
T
1 Start at the Pinch
2 Then move AWAY
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Pinch Analysis More in ndash More out
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 Process Integration and IntensificationSaving Energy Water and Resources De Gruyter Berlin Germany 38
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
A Comprehensive Textbook
PublisherWalter de Gruyter GmbHBerlin GermanyISBN 978-3-11-030685-9
ltwwwdegruytercomviewproduct204103gt
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z 2014 2nd ed 2018 Process Integration and Intensification Saving Energy Water and Resources De Gruyter Berlin Germany
39
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Pinch Design Method40
PINCH
2
4
1
3
250 ordm40 ordm
200 ordm80 ordm
180 ordm
230 ordm
20 ordm
140 ordm
CPkW bull (ordmC)-1
15
25
20
30
QHmin = 750 kW QCmin = 1000 kW
150 ordm
150 ordm
140 ordm
800 kW
2033 ordm
1817 ordm
700 kW
H205 ordm
750 kW
1750 kW
525 ordm
650 kW
C 1067 ordm
1000 kW
1250 kW
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Grand Composite Curves41
ΔH (kW)
T [degC]
0
100
300
2000 4000 6000 8000
200
1000
1200
1400
400300
900
750
ΔH (kW)0
T [degC]
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
The Grand Composite Curve (GCC)
42
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
CC ndash Sugar and Ethanol Production
43
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
PA for Integration of Heat Exchanger Networks with Heat
Pumps
Multi-HPs strategy Heat pumps can be set across the new Pinch Point Heat pumps can be used to change the pinch temperature to facilitate
the heat integration of background process with distillation
T
H0
PHP
Q2
Q1
GCC
W
NewGCC
T1
T2
P1
Hpoc H2
QHmin-Hpoc
QCmin-(Q2-(Q1-Hpoc))
H1
New pinch
Pinch
Changes of Pinch Pemperature
T
0
P
QHmin
Qcond
Qreb
QCmin
QC=QCmin+Qcond
QH=QHmin+Qreb
(a)
BPGCC
(b)H0
BPGCC
NewBPGCC
T
Qcond
Qreb
P1
P
Heat integration with distillation
44
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
45
Tube-side intensification (tube inserts)
HEN retrofit with intensification
hiTRANreg
Coiled Wire
Twisted Tape
Gough M J (2012) Process heat transfer enhancement to upgrade performancethroughput and reduced energy use Chemical Engineering Transactions 29 1-6
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Intensification of Heat Transfer In Process Industries
Kapustenko P Kukulka D Arsenyeva O 2015 Intensification of heat transfer processes Chemical Engineering Transactions 45 1729-1734 Klemes JJ Arsenyeva O Kapustenko P Tovazhnyanskyy L 2015 Compact heat exchangers for energy transfer intensification low grade heat and fouling mitigation CRC Press Boca Raton FL USA 46
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
47
000 005 010 015 020 025 030 035 040 045000
005
010
015
020
025
030
035
040
045
f p
redi
cted
f numerical data
+10
-10
+5-5
bull With the increase of Re the Nuincreases while f decreases but the Nu and f change little when the row number is greater than 9
bull Both the Nu and f decrease with the increase of transverse pitch and longitudinal pitch
bull Multiple correlations of Nu and fare fitted
Li L Ma T Xu XY Zeng M Wang QW 2014 Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped Printed Circuit Heat Exchanger Chemical Engineering Transactions 39 895-900
Study on Heat Transfer and Pressure Drop Performances of Airfoil-Shaped
Printed Circuit HE
Airfoil PCHE plate Numerical model
f comparison between predicted and numerical results
10 15 20 25 30 35 40 45 5010
15
20
25
30
35
40
45
50
Nu p
redi
cted
Nu numerical data
+5
-5
Nu comparison between predicted and numerical results
035035 049475 1033682 07264934700654 Re ( ) ( )t l
h lf NP P
minus minus=
010518 0615001 0268556 0155274020756 Re ( ) ( )t l
h lNu NP P
minus=
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Multi-Stream Heat Exchangers Thermo-hydraulic design of MSHE using GA (based on Pinch) Considering variable physical properties Minimizing the number of sections required for a given duty
Panjeshahi M H Joda F Tahouni N Pressure Drop Optimization in Multi-Stream Heat Exchanger Networksby Genetic Algorithms Chemical Engineering Transactions 21 247-253 2010Tahouni N Miryahyaie S Joda F Fallahi H R Panjeshahi M H Pressure Drop Optimization in Design ofMulti-Stream Plate-Fin Heat Exchangers Considering Variable Physical Properties The Canadian Journal ofChemical Engineering 91 1650-1659 2013
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Total Site (Site-wide) Integration
49
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
An Industrial Site
Fuel
Fuel
Fuel PROCESS A PROCESS BFuel
POWER
HIGH PRESS
MED PRESS
LOW PRESS
PROCESS C
COOLING WATER
COND
AirW
Raissi K 1994 Total Site Integration PhD Thesis UMIST Manchester UK
Klemeš J DholeVR Raissi K Perry SJ Puigjaner L 1997 Targeting and Design Methodology for Reduction of Fuel Power and CO2 on Total Sites Applied Thermal Engineering 17(810) 993-1003
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Maximising Total Site Heat Recovery
51
T
HTotal Site Profiles
Site Source Profile Site Sink ProfileT
Process A
Process B
T H
H
-ΔTmin2 +ΔTmin2T1
T1
T4
T2
T2
T3
T3
T4
T5
T6
T5
T6
T7
T8
T9
T10
T11T12
T7
T8
T9
T10
T11
T12
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Total Site Profiles52
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Integrating Renewable Energy Sources into Extended Total Sites
Perry S Klemeš J Bulatov I Chemical Engineering Transactions 12 2007 593-598Perry S Klemeš J Bulatov I Energy 33 1489-1497 2008
53
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Industrial Implementations of TSHI methodology
a) Oil and Petrochemicalsb) Pulp and Paperc) Low temperature Refrigeration d) Large Utility Hubse) Food and Drinkf) Locally Integrated Energy Systemsg) CHP including Renewablesh) Desalinationi) helliphelliphelliphellipKlemeš JJ (ed) 2013 Handbook of Process Integration (PI) Minimisation of Energy and Water Use Waste
and Emissions WoodheadElsevier Cambridge UK 1184 ps
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Mass and Water Integration
55
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Water Pinch The Foundation
C (ppm)
∆m (kgh)2191
50100
400
Pinch Point
800
Limiting Composite Curve
Water supply line
56
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
57Setting the Water Recovery Target
Minimum fresh resource
Maximum recovery
Minimum waste
discharge
PinchPinch sets
Absolute Limits for
Process Water
Recovery
Cum flowrate(th)
Cum
ulat
ive
load
(kg
h)
Sink Composite
Curve
Source Composite
Curve
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Decomposing the Pinch Problem
Minimum fresh resource
Minimum waste
discharge
Pinch
Cumulative flowrate (th)
Cum
ulat
ive
load
(kg
h)
Above Pinch Region
Below Pinch Region
Klemeš JJ Varbanov PS Wan Alwi SR Abdul Manan Z (2014) Process Integration and Intensification Saving Energy Water and Resources Series De Gruyter Textbook De Gruyter Berlin Germany
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Improved Pinch to Target Regeneration ReuseRecycle
Water Networks
0
20
40
60
80
100
120
140
1 2 3 4 5 6 7Cumulative Massload (kgh)
Impu
rity
Con
cent
ratio
n (m
gL)
A
B
C
E G
D
F
J
I
outRC
inRC
H J
K
L
Limiting Composite Curve
Optimal Water Supply Line (Direct Reuse)
Optimal Water Supply Line (Regeneration ReuseRecycle)
Regeneration Process
Regeneration Concentration
Post-Regeneration Concentration
Water Pinch(Direct Reuse)
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
Operation 1
Operation 2
Operation 3
Wastewater Fresh Water
(a) Direct Reuse
(b) Regeneration Reuse
(c) Regeneration Recycle
Regeneration
Regeneration
Optimal regeneration concentration would Equal Less than or Greater than the pinch concentration (Direct Reuse)
59
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Combined Energy and Water Integration
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Renewables Integration
61
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Targeting Time Slice 1
1363 kWh inSTORAGE
bull 12454 kWh MP steambull 15379 kWh Cooling Water
Varbanov P Klemeš J 2010 Total Sites Integrating Renewables with Extended Heat Transfer andRecovery Heat Transfer Engineering 31(9) 733 ndash 741
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Breakthrough in Energy Storage
ltelectrekco20180511tesla-giant-battery-australia-reduced-grid-service-costgt accessed 19 May 2018
bull 100 MWh lithium ion batterybull Stores huge amounts of energy from renewable sources and funnels it out
to the grid when usage is high
TESLA giant Powerpack battery in Australia
In successful operation for 6 months now
Reduced the cost of the grid service that it performs by 90
Rapid accurate cheaper and with low emissions
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Assessment and System Design
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
bull Footprint is a quantitative measure showing theappropriation of natural resources by human beings
Classification of Footprintbull Environmentalbull Socialbull Economical bull Combinedbull Composite
Footprints
Hoekstra A Y 2008 Water neutral Reducing and offsetting the impacts of water footprints Value of Water Research Report Series No 28 UNESCO-IHE Delft the Netherlands
Čuček L Klemeš J J amp Kravanja Z (2012) A review of footprint analysis tools for monitoring impacts on sustainability Journal of Cleaner Production 34 9-20
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Environmental Footprint
Carbon footprint (CFP)
Nitrogen footprint (NFP)
Water footprint (WFP)
Ecological footprint (ECOFP)
Energy footprint (EFP)
Land footprint (LFP)
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Virtual GHGs Emissions Flows in the International Trade
1
2
5
6
8
9
47
3
10
375
368
322
175
172238157
149
141
137
1 China to US (Queacutereacute et al 2014) 2 China to EU ( Carbon Trust 2011) 3 China to Rest of Asia (Carbon Trust 2011)5 Russian Federation to EU (Peters et al 2012) 6 China to Japan (Carbon Trust 2011)
4 Rest of Asia to EU (Peters et al 2012)
8 US to EU (Peters et al 2012) 9 Canada to EU (Petar et al 2012)7 Africa to EU (Peters et al 2012)10 EU to US (Petar et al 2012)
Liu X Klemeš J J Varbanov P S Čuček L Qian Y (2017) Virtual carbon and water flows embodied in international trade a review on consumption-based analysis Journal of Cleaner Production 146 20-28
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
System DesignEngineering ModelProcess Integration (Heat Water CO2 amp GHG Emissions )A strong tool for Circular EconomyHeat Integration roots
bull Identify heat recovery targets and aid in synthesizing maximum heat recovery systems
bull Minimise utility demands and CO2 emissions of a process
bull Minimisation of resource consumption
bull Total Sites Optimisation
bull Supply Chains
bull Optimal time scheduling and tracking
Klemeš JJ Varbanov PV Walmsley TG Jia XX 2018 New directions in the implementation of Pinch Methodology (PM) Renewable and Sustainable Energy Reviews 98 439-468
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Global Energy Use
Forman C Muritala I K Pardemann R Meyer B (2016) Estimating the global waste heatpotential Renewable and Sustainable Energy Reviews 57 1568-1579
718
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
ltnewsletterspectatorcoukq122MWckxFYqrhfpswu45wvgt accessed 14 April 2018
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
CO2 GHG Emission Integration
71
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
The Total Annual AnthropogenicGHG Emissions
72
(FOLU - Forestry and Other Land Use F-Gases = Fluorinated Gases)
IPCC (Intergovernmental Panel on Climate Change) Developed from Climate Change 2014Synthesis Report Report Graphic IPCC Secretariat World Meteorological Organization Geneva Switzerland
ltwwwipccchreportgraphicsindexphpt=Assessment20Reportsampr=AR520-20Synthesis20Reportampf=Topic 203gt
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
Header Geological reservoir storage
S1 S2 S3 S4
D2D1S CO2 SourceD CO2 Demand
Captured CO2 injected into dedicated header along to be utilised in Demands or sent to geological storage
Remaining CO2 captured after utilised are injected into dedicated storage
Mohd Nawi W N R Wan Alwi S R Manan ZA Klemeš J J 2016 Pinch Analysis Targeting for CO2 TotalSite Planning Clean Technologies and Environmental Policy doi 101007s10098-016-1154-7 73
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Carbon Emissions Pinch Analysis
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400
Cum
Mas
s Lo
ad (T
hr)
Cum CO2 Flowrate (Thr)
Demand Composite
Source Composite
D1D2
D3
D4
S1
S2
S3
S4
S5
S6
Pinch
Emitted CO2 = 9917 Thr
Fresh CO2 = 8966 Thr
Typical Gas Pinch Analysis would use lsquoCum Gas Flowratersquo
This mass load correspond to amount of other gases aside from CO2 in the flue gas
Sadiq M M Manan Z A Wan Alwi S R 2012 Holistic Carbon Planning for Industrial Parks - A Waste-to-Resources Process Integration Approach Journal of Cleaner Production 33 74-85
Cum
Mas
s Lo
ad (t
h)
Cum CO2 Flowrate (th)
74
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Matching of CO2 Sources amp Sinks
5
10
15
0 100
20
25
200 300 400 500 600 700 800 900
Amount of CO2 (Mt)
Sink composite
curve
Flow
rate
of C
O2
Mty
)
250 Mt surplus storage capacity
30
35
40
45
1000 1100
Source composite
curvePinch
125 Mty surplus
injectivity
50 Mt uncaptured CO2
75
Diamante J A R Tan R R Foo D C Y Ng D K S Aviso K B Bandyopadhyay S 2013 A Graphical Approach to Pinch-Based Source-Sink Matching and Sensitivity Analysis in Carbon Capture and Storage Systems Industrial amp Engineering Chemistry Research 52(22) 7211-7222
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Industrial and Practical Issues
76
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
77
Process Integration Research and Applications in Industries
PRESrsquo01 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Process integration in coal-tar productionPRESrsquo02 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Heat integration improvement for EasternEuropean sugarPRESrsquo03 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Optimal heat recovery system for coal tardistillationPRESrsquo04 ndash Tovazhnyansky L Kapustenko P Perevertaylenko O Boldyryev SO Garev AO Energy saving retrofitof refrigerating section of dairy factoryPRESrsquo05 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Tarnovsky M 2005 Energy integration of theearly crude oil units with take into account different regimes Chemical Engineering Transactions 7 103-108PRESrsquo06 ndash Kapustenko P Ulyev L Boldyryev S Garev A 2008 Integration of heat pump into the heat supplysystem of cheese production plant Energy 33(6) 882-889PRESrsquo07 ndash Tovazhnyanskyy L Sherstyuk V Kapustenko P Khavin G Perevertaylenko O Boldyrev S Garev A2007 Plate heat exchangers for environmentally friendly heat pumps Chemical Engineering Transactions 12213 217
Results
INDUSTRY Saving PaybackmonthsHeating Cooling
ChemicalTitanium dioxide production 81 89 14
Oil and GasReforming 55 90 10Crude oil distillation 45 55 12
Coke to chemicalsCoal tar distillation 52 67 12Benzene hydrocarbons production 32 12 12
Food and beveragesSugar production 17 32 4Cheese production (cooling cycle HWS) 100 64 10Vegetable oils purification 67 71 5Ethanol production 13 36 11
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT YlaquoKHPIraquo
AO SODRUGESTVO-T
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
78
Integrated Processes for Phosphorous Containing Chemicals
PRESrsquo08 ndash Kapustenko P Boldyryev S Arsenyeva O Khavin G 2009 The use of plate heat exchangers toimprove energy efficiency in phosphoric acid production Journal of Cleaner Production 17 951ndash958PRESrsquo09 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2009 Synthesis of energy saving integratedflowsheet for sodium hypophosphite production Chemical Engineering Transactions 18 93-98PRESrsquo10 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S Arsenyeva O 2010 Process integration ofsodium hypophosphite production Applied Thermal Engineering 30 (16) 2306-2314PRESrsquo11 ndash Tovazhnyansky L Kapustenko P Ulyev L Boldyryev S 2011 Heat Integration Improvement forBenzene Hydrocarbons Extraction from Coke-Oven Gas Chemical Engineering Transaction 25 153-158
laquoKH
AR
KIV
POLYTECHNIC INSTITU
TE
raquoNAT
IONA
L TECHNICAL UNIVERSIT Y
laquoKHPIraquoAO SODRUGESTVO-T
Dependence of total surface area of heat exchanger network from ∆Tmin 1 ndash shell and tube type 2 ndash plate type
Integrated sodium hypophosphite production
The optimised design is expected to yield reduction 55 of hot and 70 of cold utilities
Plate types
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
TSI for Industrial Milk Drying
Keys to Energy Savings
bull Increased heat recovery (dryer amp boiler exhausts)
bull Correct placement of heat pumps (MVR)
bull Smart HEN design for process and utility (BFW coolingheating)
bull Emerging technology (new integration problem)
bull High efficiency utility system design
Ultra-low energy design -515 fuel (NG) -190 electricity -486 GHG emissions
Walmsley TG Atkins MJ Neale JR Walmsley MRW Philipp M Peesel RH Schumm G 2016 Total Site Utility Systems Optimisation for Milk Powder Production Chemical Engineering Transactions 52 235-240Walmsley TG Atkins MJ MRW Walmsley MRW Philipp M Peesel RH 2017 Process and Utility Systems Integration and Optimisation for Ultra-Low Energy Milk Powder Production Energy DOI 101016jenergy201704142
Current
Future
79
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Process IntegrationUltra-low Energy Dairy Processing
Aim To develop highly energy efficient dairy processes using advanced energy recovery techniques such as vapour compression
New Integrated Milk Evaporator Design Spray Dryer Exhaust Heat RecoveryPilot Plant Performance Testing
Effect 1 Effect 2
Milk247 th
Cold CowStorage
HotCold
MVR
Concentrate
Condenser
8degC
61degC
13degC
68degC
79degC
84degC
68degC
56degC
73degC 61degC
51degC
VapourBleed
H
Cow69degC
FlashVessel
84degC
68degC
DSI
2210 kW
A
MVR
117 kW
230kW
MVR
95degC
80
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
81
bull The sinter strength is very sensitive to the operating parameters of fixed carbon content sintering pressure and fuel reactivity
bull A sinter quality on-line control system is designed to reduce sinter strength fluctuation and achieve uniform sintering
bull Bi-objective optimization of major variables in the sinter cooler for waste heat recovery is conducted based on the decision making process
Liu Y Yang J Wang J Cheng ZL Wang QW 2014 Cost benefits analysis for waste heat utilization in sinter cooling bed Chemical Engineering Transactions 39 841-846 Cheng ZL Yang J Zhou L Li WX Liu Y Wang QW 2015 Experimental study on characteristics of flame front in the iron ore sintering process Chemical Engineering Transactions 45 877-882
Efficient iron ore sintering and waste heat recovery of hot sinters
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Industrial Implementation Issues of Total Site Heat Integration
Highly Cited Top 1 Referenced Work (Report from Web of Science Thomson Reuters on
MarchAprilSeptOct 2015)
82
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
CO2 Emission Pinch Analysis
D1 = production facility eg carbonated
plant
D2=EOR
S1 = Factories
Targeted Fresh CO2 Excess Emissions-amount of
energyemissionsreduction
Pinch point
Cum CO2 th
D3=natural sink ndash flora
S2 = Buildings
S3 = Vehicles sewage waste
Carbon Demand
Cum f
low
of o
ther
ga
ses
th
Baseline Fresh CO2 Demand
Baseline Total CO2 Source
Carbon Source
Maximum Carbon Exchange (MCE)
Carbon Source
Carbon Demand
Sadiq MM Manan ZA Wan Alwi SR 2012 Holistic carbon planning for industrial parks - A waste-to-resources process integration approach Journal of Cleaner Production 33 74-85 83
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Challengesbull Huge and growing energy and water demandsbull Subject of considerable losses and a potential danger
for the environment
Combination of large volumes and large loss rates
bull There are implications and opportunities at several levels ranging from plantsite level up to regional and country level
84
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Scales of Material and Energy Cycles
85
Need
Opportunitiesamp
Losses
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Exploit System Links as Synergies
bull Example Energy-Water Nexusbull Works both ways ndash not only in the direction of
causing problemsbull Energy and water savings amplify each otherbull Potential synergy mechanismbull So far applied mainly at process level by the
discussed methodologiesbull Extend the scope of energywater integration to
site and supply chain level
86
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Conclusionsbull Sustainability requirements increase the challenges
before industrial deign and operationbull Industrial systems have to be optimised ndash a
complex taskbull Process Integration provides performance targetsbull Guides the designbull New applications of the method
bull Trade-offs between quality and quantitybull Need to have the full tool set ndash from targeting to
designbull Needs to track other indicators beside energy
and water demandsbull An example specific GHG footprint
87
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
ltwwwnaturecomnewspollution-three-steps-to-a-green-shipping-industry-119369gt
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Conclusion
bull Need of Assessment Action and Appropriate Implementationbull Rather than having circularity as a goal a more pragmatic
vision for a material future would be aim to meet human needs (demand) while minimising the environmental impact
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Handbooks and the TextbooksBook Title Editors Publication
1 Handbook of water and energy management in food processing (English and Chinese version)
Jiřiacute Klemeš Robin Smith and Jin-Kuk
Kim
Woodhead Publishing Ltd Elsevier
中国轻工业出版社
2 Handbook of Process Integration (PI) Minimisation of energy and water use waste and emissions
Jiřiacute Klemeš Woodhead Publishing Series in Energy No
61
3 Sustainability in the process industry Jiřiacute Klemeš Ferenc Friedler
Igor Bulatov Petar Varbanov
McGraw-Hill Professional
4 Process integration and intensification Jiriacute Jaromiacuter Klemeš Petar Varbanov
Sharifah Rafidah Wan Wan Alwi Zainuddin
Abdul
De Gruyter
5 Assessing and Measuring Environmental Impact and Sustainability
Jiriacute Jaromiacuter Klemeš Butterworth-HeinemannElsevier
6 Compact heat exchangers for energy transfer intensification Low grade heat and fouling mitigation
Jiriacute Jaromiacuter Klemeš Olga ArsenyevaPetro Kapustenko Leonid Tovazhnyanskyy
CRC Press Taylor and Francis Group
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
20ndash23 October 2019Crete Greece
ltconferenceprescomgt | ltpres2019cpericerthgrgt
22nd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
17ndash21 August 2019Xirsquoan China
ltconferenceprescomgt
23rd Conference Process Integration Modelling and Optimisation for Energy Saving and Pollution Reduction
IF=10556 IF=6395 IF=5537 IF=2707
(open access)
IF=1092
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Special Session InvitationSDEWES 2020 Gold Coast Australia
ltwwwgoldcoast2020sdewesorggt 1st Asia Pacific SDEWES (Sustainable Development on Energy and Water Systems)
Engineering a Sustainable Circular Economy Materials Energy and Infrastructure Integration for Smart Cities and Industry
Timothy Gordon Walmsley Jiřiacute Jaromiacuter Klemeš Kim Pickering Petar Sabev VarbanovCorresponding email spilfmevutbrcz
Abstract submission (session invitation code) gc2020esce
6 - 9 April 2020
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Special Session InvitationSEE 2020 Bosnia and
Herzegovina
ltwwwsarajevo2020sdewesorggtIntegration of Smart cities and Smart Industry for Circular Economy Energy Water and Waste to Secondary raw material for Sustainable FutureContact us for invitation email and more informationYee Van Fan fanfmevutbrcz Jiřiacute Jaromiacuter Klemeš jiriklemesvutbrczPetar Sabev Varbanov varbanovfmevutbrcz
abstract submission (session invitation code)
sdsee20scsi
28 June - 2 July 2020
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Acknowledgement
bull To all contributors from 27 partner institutions fromthe academia and industry
bull To the EC project Sustainable Process IntegrationLaboratory ndash SPIL funded as project NoCZ02101000015_0030000456 by CzechRepublic Operational Programme Research andDevelopment Education Priority 1 Strengtheningcapacity for quality research and by the collaborationagreement with the Universiti Teknologi Malaysia(UTM) The University of Manchester UKUniversity of Maribor Slovenia Hebei Universityof Technology Tianjin China and Paacutezmaacuteny PeacuteterCatholic University Hungary based on the SPILproject
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
AcknowledgmentThe presented research results have been supported by the project LTACH19033 ldquoTransmission Enhancement and Energy Optimised Integration of Heat Exchangers in Petrochemical Industry Waste Heat Utilisationrdquo under the bilateral collaboration of the PR China and the Czech Republic and (partners Xian Jiao Tong University and Sinopec Research Institute Shanghai SPIL VUT Brno University of Technology and EVECO sro Brno) programme INTER-EXCELLENCE INTER-ACTION of the Czech Ministry of Education Youth and Sports
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-
Thank you 97
- The role of Process Integration in the GHG and HazeSmog Emissions Reduction
- The RouteUnited Kingdomrarr Hungary rarr Czech Republic
- UMIST ndash Pioneering Pinch Analysis
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Cooperation with Foreign Universities
- Google Scholar
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Web of Sciencehttpappswebofknowledgecom
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Main Co-Authors of this lecture
- World Coverage Co-Authors
- Heat Integration using Pinch Analysis
- Slide Number 24
- The First Steps ndash HEN synthesis
- The Roots of Pinch Analysis
- The ldquoRed Bookrdquo
- SPIL VUT Brno 2 May 2018
- What is Process (Heat) Integration
- Pinch based approach
- Mathematical Programming OR Pinch
- Pinch AND Mathematical Programming
- Benefits of Process Integration
- Slide Number 34
- Handbook of Process Integration (PI)
- Composite Curves - ΔTmin = 10 degC
- Pinch Design Principle
- Pinch Analysis More in ndash More out
- A Comprehensive Textbook
- Pinch Design Method
- Grand Composite Curves
- The Grand Composite Curve (GCC)
- Slide Number 43
- PA for Integration of Heat Exchanger Networks with Heat Pumps
- Slide Number 45
- Intensification of Heat Transfer In Process Industries
- Slide Number 47
- Multi-Stream Heat Exchangers
- Total Site (Site-wide) Integration
- An Industrial Site
- Maximising Total Site Heat Recovery
- Total Site Profiles
- Integrating Renewable Energy Sources into Extended Total Sites
- Industrial Implementations of TSHI methodology
- Mass and Water Integration
- Water Pinch The Foundation
- Setting the Water Recovery Target
- Decomposing the Pinch Problem
- Improved Pinch to Target Regeneration ReuseRecycle Water Networks
- Combined Energy and Water Integration
- Renewables Integration
- Targeting Time Slice 1
- Breakthrough in Energy Storage
- Assessment and System Design
- Footprints
- Environmental Footprint
- Virtual GHGs Emissions Flows in the International Trade
- System DesignEngineering Model
- Global Energy Use
- Slide Number 70
- CO2 GHG Emission Integration
- The Total Annual AnthropogenicGHG Emissions
- Pinch Analysis Tool for Optimising CO2 Capture Utilisation and Storage
- Carbon Emissions Pinch Analysis
- Matching of CO2 Sources amp Sinks
- Industrial and Practical Issues
- Process Integration Research and Applications in Industries
- Slide Number 78
- TSI for Industrial Milk Drying
- Process IntegrationUltra-low Energy Dairy Processing
- Slide Number 81
- Industrial Implementation Issues of Total Site Heat Integration
- CO2 Emission Pinch Analysis
- Challenges
- Scales of Material and Energy Cycles
- Exploit System Links as Synergies
- Conclusions
- Slide Number 88
- Conclusion
- Handbooks and the Textbooks
- Slide Number 91
- Slide Number 92
- Special Session InvitationSDEWES 2020 Gold Coast Australia
- Special Session InvitationSEE 2020 Bosnia and Herzegovina
- Acknowledgement
- Acknowledgment
- Slide Number 97
-