El-Halwagi Sustainable Design Through Process Integration

Fundamentals and Applications to Industrial Pollution Prevention, Resource Conservation, and Profitability Enhancement
1. Auflage 2011
ISBN: 978-0-08-096161-3
Verlag: Elsevier Science & Techn.
Format: EPUB
Kopierschutz: Adobe DRM (»Systemvoraussetzungen)

E-Book, Englisch, 448 Seiten

This timely book provides authoritative, comprehensive, and easy-to-follow coverage of the fundamental concepts and practical techniques on the use of process integration to maximize the efficiency and sustainability of industrial processes. Over the past three decades, significant advances have been made in treating, designing, and operating chemical processes as integrated systems. Whether you are a process engineer, an industrial decision maker, or a researcher, this book will be an indispensable resource tool for systematically enhancing process performance and developing novel and sustainable process designs. The book is also ideal for use as a text in an upper level undergraduate or an introductory graduate course on process design and sustainability. This ground breaking reference enhances and reconciles various process and sustainability objectives, such as cost effectiveness, yield improvement, energy efficiency, and pollution prevention. The detailed tools and applications within are written by one of the world's foremost process integration and design experts and will save you time and money. - Contains state-of-the-art process integration approaches and applications including graphical, algebraic, and mathematical techniques - Covers applications that include process economics, targeting for conservation of mass and energy, synthesis of innovative processes, retrofitting of existing systems, design and assessment of renewable energy systems, and in-process pollution prevention - Presents fundamentals and step-by-step procedures that can be applied to the design and optimization of new processes as well the retrofitting and operation of existing processes, as well as including numerous examples and case studies for a broad array of industrial systems and processes

Dr. Mahmoud El-Halwagi is professor and holder of the McFerrin Professorship at the Artie McFerrin Department of Chemical Engineering, Texas A&M University. He is internationally recognized for pioneering contributions in the principles and applications of process integration and sustainable design. He has served as a consultant to a wide variety of processing industries. He is a fellow of the American Institute of Chemical Engineers (AIChE) and is the recipient of prestigious research and educational awards including the American AIChE Sustainable Engineering Forum Research Excellence Award, the Celanese and the Fluor Distinguished Teaching Awards, and the US National Science Foundation's National Young Investigator Award.

Autoren/Hrsg.

El-Halwagi, Mahmoud M.

Inhaltsverzeichnis

1;Front Cover;1
2;Sustainable Design Through Process Integration;4
3;Copyright Page;5
4;Contents;8
5;Preface;10
6;1 Introduction to Sustainability, Sustainable Design, and Process Integration;14
6.1;What is Sustainability?;14
6.2;What is Sustainable Design Through Process Integration;16
6.3;Motivating Examples on the Generation and Integration of Sustainable Design Alternatives;18
6.4;Structure and Learning Outcomes of the Book;25
6.5;References;26
7;2 Overview of Process Economics;28
7.1;Cost Types and Estimation;28
7.2;Depreciation;39
7.3;Break-Even Analysis;44
7.4;Time-Value of Money;46
7.5;Profitabilty Analysis;53
7.6;Homework problems;71
7.7;References;73
8;3 Benchmarking Process Performance Through Overall Mass Targeting;76
8.1;Stoichiometry-Based Targeting;76
8.2;Mass-Integration Targeting;79
8.3;Mass Integration Strategies for Attaining the Targets;96
8.4;Homework problems;97
8.5;References;101
9;4 Direct-Recycle Networks: A Graphical Approach;102
9.1;Problem Statement for the Design of Direct-Recycle Networks;102
9.2;Selection of Sources, Sinks, and Recycle Routes;103
9.3;Direct-Recycle Targets through Material Recycle Pinch Diagram;104
9.4;Design Rules from the Material Recycle Pinch Diagram;106
9.5;Extension to the Case of Impure Fresh;107
9.6;Insights for Process Modifications;107
9.7;The Source-Sink Mapping Diagram for Matching Sources and Sinks;111
9.8;Multicomponent Source-Sink Mapping Diagram;118
9.9;Homework problems;119
9.10;References;122
10;5 Synthesis of Mass-Exchange Networks: A Graphical Approach;124
10.1;Mass-Exchange Network Synthesis Task;124
10.2;The MEN-Targeting Approach;125
10.3;The Corresponding Composition Scales;125
10.4;The Mass-Exchange Pinch Diagram;126
10.5;Constructing Pinch Diagrams without Process MSAs;133
10.6;Construction of the Men Configuratiovn with Minimum Number of Exchangers;135
10.7;Trading Off Fixed Cost versus Operating Cost;138
10.8;Homework Problems;140
10.9;Nomenclature;144
10.10;References;144
11;6 Combining Mass-Integration Strategies;146
11.1;Process Representation from a Mass-Integration Species Perspective;146
11.2;Homework Problems;156
11.3;References;158
12;7 Heat Integration;160
12.1;HEN-Synthesis Problem Statement;160
12.2;Minimum Utility Targets via the Thermal Pinch Diagram;161
12.3;Minimum Utility Targets Using the Algebraic Cascade Diagram;165
12.4;Screening of Multiple Utilities Using the Grand Composite Representation;167
12.5;Stream Matching and the Synthesis of Heat-Exchange Networks;169
12.6;Homework Problems;173
12.7;Nomenclature;176
12.8;References;176
13;8 Integration of Combined Heat and Power Systems;178
13.1;Heat Engines;178
13.2;Steam Turbines and Power Plants;180
13.3;Placement of Heat Engines and Integration with Thermal Pinch Analysis;187
13.4;Heat Pumps;191
13.5;Closed-Cycle Vapor-Compression Heat Pumps Using a Separate Working Fluid (Refrigerant);192
13.6;Vapor-Compression Heat Pumps and Thermal Pinch Diagram;198
13.7;Open-Cycle Mechanical Vapor Recompression Using a Process Stream as the Working Fluid;199
13.8;Absorption Refrigeration Cycles;203
13.9;Cogeneration Targeting;207
13.10;Additional Readings;211
13.11;Homework Problems;211
13.12;References;213
14;9 Property Integration;214
14.1;Property-Based Material Recycle/reuse Pinch Diagram;214
14.2;Process Modification Based on Property-Based Pinch Diagram;216
14.3;Clustering Techniques for Multiple Properties;220
14.4;Cluster-Based Source-Sink Mapping Diagram for Property-Based Recycle and Interception;222
14.5;Property-Based Design Rules for Recycle and Interception;223
14.6;Dealing with Multiplicity of Cluster-to-Property Mapping (El-Halwagi et al., 2004);224
14.7;Relationship Between Clusters and Mass Fractions;231
14.8;Additional Readings;232
14.9;Homework Problems;232
14.10;Nomenclature;234
14.11;References;235
15;10 Direct-Recycle Networks: An Algebraic Approach;236
15.1;Problem Statement;236
15.2;Algebraic Targeting Approach;236
15.3;Algebraic Targeting Procedure;239
15.4;Case Study: Targeting for Water Usage and Discharge in a Formic Acid Plant;239
15.5;Homework Problems;241
15.6;Nomenclature;242
15.7;References;242
16;11 Synthesis of Mass-Exchange Networks: An Algebraic Approach;244
16.1;The Composition-Interval Diagram;244
16.2;Table of Exchangeable Loads;244
16.3;Mass-Exchange Cascade Diagram;245
16.4;Homework Problems;247
16.5;Nomenclature;248
16.6;References;248
17;12 Synthesis of Heat-Induced Separation Networks for Condensation of Volatile Organic Compounds;250
17.1;Problem Statement;250
17.2;System Configuration;250
17.3;Integration of Mass and Heat Objectives;251
17.4;Design Approach;251
17.5;Special Case: Dilute Waste Streams;252
17.6;Effect of Pressure;254
17.7;Homework Problems;254
17.8;Nomenclature;255
17.9;References;255
18;13 Design of Membrane-Separation Systems;256
18.1;Classification of Membrane Separations;256
18.2;Reverse-Osmosis Systems;256
18.3;Designing Systems of Multiple Reverse-Osmosis Modules;260
18.4;Homework Problems;264
18.5;Symbols;266
18.6;Greek letters;266
18.7;Subscripts;267
18.8;Superscripts;267
18.9;References;267
19;14 Overview of Optimization;268
19.1;What Is Mathematical Programming?;268
19.2;How to Formulate an Optimization Model?;268
19.3;Using the Software LINGO to Solve Optimization Problems;271
19.4;Interpreting Dual Prices in the Results of a Lingo Solution;272
19.5;A Brief Introduction to Sets, Convex Analysis, and Symbols Used in Optimization;279
19.6;The Use of 0–1 Binary-Integer Variables;280
19.7;Enumerating Multiple Solutions Using Integer Cuts;282
19.8;Modeling Disjunctions and Discontinuous Functions with Binary Integer Variables;283
19.9;Using Set Formulations in Lingo;290
19.10;Homework Problems;296
19.11;References;298
20;15 An Optimization Approach to Direct Recycle;300
20.1;Problem Statement;300
20.2;Problem Representation;300
20.3;Optimization Formulation;300
20.4;Additional Readings;309
20.5;Homework problems;309
20.6;References;311
21;16 Synthesis of Mass-Exchange Networks: A Mathematical Programming Approach;312
21.1;Generalization of the Composition Interval Diagram;312
21.2;Problem Formulation;312
21.3;Optimization of Outlet Compositions;316
21.4;Stream Matching and Network Synthesis;318
21.5;Homework Problems;322
21.6;Nomenclature;325
21.7;References;326
22;17 Synthesis of Reactive Mass-Exchange Networks;328
22.1;Objectives of Reamen Synthesis;328
22.2;Corresponding Composition Scales for Reactive Mass Exchange;328
22.3;Synthesis Approach;331
22.4;Homework Problems;335
22.5;Nomenclature;339
22.6;References;339
23;18 Mathematical Optimization Techniques for Mass Integration;340
23.1;Problem Statement and Challenges;340
23.2;Synthesis of MSA-Induced interception networks;340
23.3;Developing Strategies for Segregation, Mixing, and Direct Recycle;349
23.4;Integration of Interception with Segregation, Mixing, and Recycle;352
23.5;Homework Problems;353
23.6;Nomenclature;357
23.7;References;357
24;19 Mathematical Techniques for the Synthesis of Heat-Exchange Networks;358
24.1;Targeting for Minimum Heating and Cooling Utilities;358
24.2;Stream Matching and HEN Synthesis;362
24.3;Handling Scheduling and Flexibility Issues in HEN Synthesis;366
24.4;Homework Problems;367
24.5;Nomenclature;369
24.6;References;369
25;20 Synthesis of Combined Heat and Reactive Mass-Exchange Networks;370
25.1;Synthesis of Combined Heat and Reactive Mass-Exchange Networks;370
25.2;Homework Problem;375
25.3;Nomenclature;375
25.4;References;376
26;21 Design of Integrated Biorefineries;378
26.1;Conceptual Design of a Biorefinery;378
26.2;Techno-Economic Assessment of a Biorefinery;380
26.3;References;385
27;22 Macroscopic Approaches of Process Integration;388
27.1;Eco-Industrial Parks;388
27.2;Material Flow Analysis and Reverse Problem Formulation for Watersheds;392
27.3;Process Integration as an Enabling Tool in Environmental Impact Assessment;399
27.4;Process Integration in Life Cycle Analysis;400
27.5;Nomenclature;403
27.6;References;404
28;23 Concluding Thoughts: Launching Successful Process-Integration Initiatives and Applications;406
28.1;Commercial Applicability;406
28.2;Pitfalls in Implementing Process Integration;406
28.3;Starting and Sustaining PI Initiatives and Projects;408
28.4;References;409
29;I. Conversion Relationships for Concentrations and Conversion Factors for Units;410
29.1;Basic relationships for Converting Concentrations;410
29.2;Key Conversion Factors for Different Sets of Units;411
30;II. Modeling of Mass-Exchange Units for Environmental Applications;414
30.1;What Is a Mass Exchanger?;414
30.2;Equilibrium;414
30.3;Interphase Mass Transfer;415
30.4;Types and Sizes of Mass Exchangers;415
30.5;Minimizing Cost of Mass-Exchange Systems;418
30.6;Homework Problems;423
30.7;References;426
31;Index;428

Leseproben

Preface

Mahmoud M. El-Halwagi, College Station, Texas

One of the most important challenges facing humanity is the need for a sustainable development that accommodates the escalating demands for natural resources while leaving future generations with the opportunities to realize their potential. This challenge is especially important for the chemical process industries that are characterized by the enormous usage of natural resources. To effectively address this challenge, it is inevitable for industry to embrace the concept of sustainable design, which involves process-design activities that lead to economic growth, environmental protection, and social progress for the current generation without compromising the potential of future generations to have an ecosystem that meets their needs. Consequently, a growing number of industries are launching sustainable-design initiatives that are geared toward enhancing the corporate stewardship of the environment. Although these initiatives are typically clear in their strategic goals, they are very difficult for technical managers and process engineers to transform into viable actions. A sustainable design should endeavor to conserve natural resources (mass and energy), recycle and reuse materials, prevent pollution, enhance yield, improve quality, advance inherent safety, and increase profitability. The question is how to achieve and reconcile these objectives? Processing facilities are complex systems of unit operations and streams. Designing these facilities or improving their performance typically entails the screening of numerous alternatives. Because of the enormous number of design alternatives, laborious conventional engineering approaches that are based on generating and testing case studies are unlikely to provide effective work processes or reach optimal solutions. Indeed, what is needed is a systematic framework and associated concepts and tools that methodically guide designers to the global insights of the process, identify root causes of the problems or key areas of opportunities, benchmark the performance of the process, and develop a set of design recommendations that can attain the true potential of the process.

Over the past three decades, significant advances have been made in treating chemical processes as integrated systems and developing systematic tools to determine practically achievable benchmarks. This framework is referred to as process integration and is defined as a holistic approach to design and operation that emphasizes the unity of the process. Process integration can be used to systematically enhance and reconcile various process objectives, such as cost effectiveness, yield enhancement, energy efficiency, and pollution prevention. Many archival papers have been published on different aspects of process integration. Because of the specialized nature of these papers, readership has been mostly confined to academic researchers in the field. On the other hand, many industrial projects have been successfully implemented on specific aspects of process integration. Because of the confidential nature of most of these projects, details have not been widely available in the public domain. This book was motivated by the need to reach out to a much wider base of readers who are interested in systematically developing sustainable designs through process integration. The book is appropriate for senior-level undergraduate or first-year graduate courses on process design, sustainability, or process synthesis and integration. It is also tailored to serve as a self-study textbook for process engineers and technical managers involved in process innovation, development, design and improvement, pollution prevention, and energy conservation. A key feature of the book is the emphasis on benchmarking the performance of a process or subprocess and then methodically detailing the steps needed to attain these performance targets in a cost-effective manner.

The approach of this book is to first explain the problem statement and scope of applications, followed by the generic concepts, procedures, and tools that can be used to solved the problem. Next, case studies and numerical examples are given to demonstrate the applicability of the tools and procedures. Chapter 1 introduces the key concepts of sustainability, sustainable design, and process integration. Motivating examples are given on the development and integration of sustainable design alternatives. The chapter also describes the learning outcomes of the books. Chapter 2 provides a detailed coverage of process economics including cost types and estimation, depreciation, break-even analysis, time value of money, and profitability analysis. Applications involve a broad range of conventional and contemporary problems in the process industries. Because of the extensive nature of the chapter, it can be used in senior-level process design and economics courses. Chapter 3 introduces the concept of overall benchmarking (targeting) and focuses on the identification of performance targets for the consumption of fresh materials, the discharge of waste materials, and the production of maximum yield. Chapters 4 through 9 present graphical techniques (pinch diagrams) for the targeting of direct-recycle systems, mass-exchange networks, overall processes, heat-exchange networks, combined heat and power systems, and property integration. Chapters 10 through 13 are based on algebraic procedures for the design of direct-recycle networks, mass-exchange networks, heat-induced separators, and membrane-separation networks. Chapter 14 covers the basic approaches to the formulation of optimization problems as mathematical programs and the different types of formulations. Examples are given on transforming tasks and concepts into optimization formulations. Also, the use of the software LINGO is described. Chapters 15 through 20 are devoted to the solution of sustainable design problems through optimization. Several classes of problems are addressed, including direct-recycle networks, mass-exchange networks, heat-exchange networks, and combined heat and reactive mass-exchange networks. Chapter 21 covers the conceptual design and techno-economic assessment of integrated biorefineries. The focus is on top-level and quick synthesis and screening of alternative designs. Macroscopic process integration approaches are addressed in Chapter 22, with several applications such as eco-industrial parks, material flow analysis, environmental impact assessment, and life cycle analysis. The book culminates in Chapter 23, which offers a discussion on commercial applicability of process integration for sustainable design, track record and pitfalls in implementing process integration, and starting and sustaining process integration initiatives and projects.

Various individuals have positively impacted my path of learning about and contributing to sustainable design through process integration. I very much appreciate the professional associates and leaders of the process systems engineering and the sustainability communities whose contributions have made a paradigm shift in the understanding and tackling of sustainable design problems. I am especially grateful to Dr. Dennis Spriggs (president of Matrix Process Integration) who has mentored me in numerous industrial applications and has consistently shown the power of the “science of the big picture” in tackling complex industrial challenges in a smooth and insightful manner. I am also thankful to the academic partners with whom I had the honor of collaborating. Specifically, I would like to thank the following professors and their students: Drs. Ahmed Abdel-Wahab (Texas A&M University-Qatar), Mert Atilhan (Qatar University), Mario Eden (Auburn University), Nimir Elbashir (Texas A&M University-Qatar), Amro El-Baz (Zagazig University), Fadwa Eljack (Qatar University), Xiao Feng (China University of Petroleum), Dominic C. Y. Foo (University of Nottingham, Malaysia Campus), Arturo Jiménez-Gutiérrez (Instituto Tecnológico de Celaya), Ken Hall (Texas A&M University), Mark lottzapple (Texas A&M University), Viatcheslav Kafarov (Universidad Industrial de Santander), B. J. Kim (Soongsil University), Patrick Linke (Texas A&M University-Qatar), Vladimir Mahalec (McMaster University), Sam Mannan (Texas A&M University), Pedro Medellín Milán (Universidad Autónoma de San Luis Potosí), Denny Ng (University of Nottingham, Malaysia Campus), Martín Picón-Núñez (Universidad de Guanajuato), José María Ponce-Ortega (Universidad Michoacana de San Nicolás de Hidalgo), Abeer Shoaib (Suez Canal University), Paul Stuart (Ecole Polytechnique de Montréal), and Raymond Tan (De La Salle University).

I am very grateful to the numerous undergraduate students at Texas A&M University and Auburn University as well as attendees of my industrial workshops, short courses, and seminars whose invaluable feedback and input was instrumental in developing and refining the book.

I am indebted to my former and current graduate students. I have learned much from this distinguished group of scholars, which includes: Nesreen Ahmed (Suez Canal University), Nasser Al-Azri (Sultan Qaboos University), Hassan Alfadala (Barwa), Eid Al-Mutairi (King Fahd University of Petroleum and Minerals), Abdul-Aziz Almutlaq (King Saud University), Meteab Al-Otaibi (SABIC), Saad Al-Sobhi (Qatar University), Musaed Al-Thubaiti (Aramco), Selma Atilhan (Texas A&M University-Qatar), Srinivas “B.K.” Bagepalli (Danaher), Buping Bao, Abdullah Bin Mahfouz (SABIC), Ian Bowling (Chevron), Ming-Hao Chiou, Benjamin Cormier (BP), Eric...