Introduction to Process Integration Tier I Integration has evolved from heat recovery methodology in the 80’s to become what a number of ... Process engineering principles and in-depth

Module 8 – Introduction to Process Integration 11

PIECENAMPProgram for North American Mobility in Higher EducationProgram for North American Mobility in Higher Education

NAMPNAMP

Introducing Process integration for Environmental Control in EngIntroducing Process integration for Environmental Control in Engineering Curriculaineering Curricula

Introduction to Process Introduction to Process IntegrationIntegration

Tier ITier I

Module 8Module 8

PIECEPIECE


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How to use this presentationHow to use this presentation

This presentation contains internal links to other slides and exThis presentation contains internal links to other slides and external links ternal links to websites:to websites:

Example of a linkExample of a link (text underlined in grey): link to a slide in the (text underlined in grey): link to a slide in the presentation or to a websitepresentation or to a website

: link to the tier table of contents: link to the tier table of contents

: link to the last slide viewed: link to the last slide viewed

: when the user has gone over the whole presentation,: when the user has gone over the whole presentation, some some multiple choice questions are given at the end of this tier. Thimultiple choice questions are given at the end of this tier. This icon takes s icon takes the user back to the question statement if a wrong answer has bethe user back to the question statement if a wrong answer has been givenen given


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Table of contentsTable of contentsProject SummaryProject Summary

Participating institutionsParticipating institutionsModule creatorsModule creators

Module Structure & PurposeModule Structure & PurposeTier ITier I

Statement of IntentStatement of IntentSectionsSections1.1 Introduction & Definition of Process Integration (PI)1.1 Introduction & Definition of Process Integration (PI)

Brief history of PIBrief history of PIModern context of PIModern context of PIIEA definition of PIIEA definition of PIM. ElM. El--Halwagi definition of PIHalwagi definition of PINick Nick HallaleHallale definition of PIdefinition of PINAMPNAMP--PIECE definition of PIPIECE definition of PI


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Table of contents (2)Table of contents (2)Tier ITier I

1.1 Introduction & Definition of Process Integration (PI)1.1 Introduction & Definition of Process Integration (PI)Possible objectives of PIPossible objectives of PISummary of PI elementsSummary of PI elementsConclusionConclusion

1.2 Overview of PI tools1.2 Overview of PI toolsOverview of PI toolsOverview of PI toolsProcess SimulationProcess SimulationData Treatment & ReconciliationData Treatment & ReconciliationPinch AnalysisPinch AnalysisOptimization by Mathematical ProgrammingOptimization by Mathematical ProgrammingStochastic Search MethodsStochastic Search MethodsLife Cycle AnalysisLife Cycle AnalysisDataData--driven Process Modelingdriven Process ModelingIntegrated Process Design & ControlIntegrated Process Design & Control


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Table of contents (3)Table of contents (3)Tier ITier I

1.2 Overview of PI tools1.2 Overview of PI toolsReal Time OptimizationReal Time OptimizationBusiness Model & Supply Chain ModelingBusiness Model & Supply Chain Modeling

1.3 Around1.3 Around--the world tour of PI practitionersthe world tour of PI practitionersInstitutions Institutions –– World MapWorld MapInstitutions Institutions –– North & South AmericaNorth & South AmericaInstitutions Institutions –– EuropeEuropeInstitutions Institutions –– Asia, Africa & OceaniaAsia, Africa & OceaniaCompaniesCompanies

QuizQuiz


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ObjectivesObjectivesCreate webCreate web--based modules to assist universities to address based modules to assist universities to address the introduction to Process Integration into engineering the introduction to Process Integration into engineering curriculacurriculaMake these modules widely available in each of the Make these modules widely available in each of the participating countriesparticipating countries

Participating institutionsParticipating institutionsTwo universities in each of the three countries (Canada, Two universities in each of the three countries (Canada, Mexico and the USA)Mexico and the USA)Two research institutes in different industry sectors: Two research institutes in different industry sectors: petroleum (Mexico) and pulp and paper (Canada)petroleum (Mexico) and pulp and paper (Canada)Each of the six universities has sponsored 7 exchange Each of the six universities has sponsored 7 exchange students during the period of the grant subsidised in part by students during the period of the grant subsidised in part by each of the three countrieseach of the three countries’’ governmentsgovernments

Project SummaryProject Summary


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Program for North American Mobility in Higher EducationProgram for North American Mobility in Higher Education NAMPNAMP

Process integration for Environmental Control in Engineering CurProcess integration for Environmental Control in Engineering Curricularicula PIECEPIECE

University of University of OttawaOttawa

ÉÉcole cole Polytechnique de Polytechnique de

MontrMontrééalal

InstitutoInstitutoMexicanoMexicano del del

PetrPetróóleoleo

PapricanPaprican

Universidad Universidad AutAutóónomanoma de San de San

Luis Luis PotosPotosíí

University of University of Texas A&MTexas A&M

Universidad de Universidad de GuanajuatoGuanajuato North Carolina North Carolina

State UniversityState University


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Module 8Module 8This module was created by:This module was created by:

Carlos Alberto Miranda AlvarezCarlos Alberto Miranda Alvarez

JeanJean--Martin BraultMartin Brault

Host InstitutionHost InstitutionFromFrom Host directorHost director

Paul StuartPaul Stuart

Martin Martin PiconPicon--NuNuññezez


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What is the structure of this module?What is the structure of this module?

All modules are divided into 3 tiers, each with a specific All modules are divided into 3 tiers, each with a specific goal:goal:

Tier I: Background InformationTier I: Background InformationTier II: Case Study ApplicationsTier II: Case Study ApplicationsTier III: OpenTier III: Open--Ended Design ProblemEnded Design Problem

These tiers are intended to be completed in that particular These tiers are intended to be completed in that particular order. Students are quizzed at various points to measure order. Students are quizzed at various points to measure their degree of understanding, before proceeding to the their degree of understanding, before proceeding to the next level. Each tier contains a statement of intent at the next level. Each tier contains a statement of intent at the beginning and a quiz at the end.beginning and a quiz at the end.

Structure of Module 8Structure of Module 8


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What is the purpose of this module?What is the purpose of this module?

It is the intent of this module to cover the basic aspects It is the intent of this module to cover the basic aspects of of Process Integration MethodsProcess Integration Methods and and ToolsTools, and to , and to place place Process IntegrationProcess Integration into a broad perspective. It into a broad perspective. It is identified as a preis identified as a pre--requisite for other modules related requisite for other modules related to the learning of to the learning of Process Integration.Process Integration.

Purpose of Module 8Purpose of Module 8


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Tier IBackground Information


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Tier I Statement of intentTier I Statement of intent

The goal of this tier is to provide a general overview of The goal of this tier is to provide a general overview of Process Integration tools, with focus on their link with Process Integration tools, with focus on their link with profitability analysis. At the end of Tier I, the student profitability analysis. At the end of Tier I, the student should be able to:should be able to:

Distinguish the key tools of Process IntegrationDistinguish the key tools of Process IntegrationUnderstand the scope of each Process Integration Understand the scope of each Process Integration tooltoolHave an overview of each Process Integration toolHave an overview of each Process Integration tool


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Tier I ContentsTier I Contents

Tier Tier II is broken down into three sectionsis broken down into three sections

1.1 Introduction and definition of Process 1.1 Introduction and definition of Process Integration (PI)Integration (PI)1.2 Overview of PI tools1.2 Overview of PI tools1.3 Around1.3 Around--thethe--world tour of PI practitioners world tour of PI practitioners which focuses on their expertisewhich focuses on their expertise

A short multipleA short multiple--choice quiz will follow at the end of this choice quiz will follow at the end of this tier.tier.


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1.1 Introduction and definition of Process Integration1.1 Introduction and definition of Process Integration

1.2 Overview of Process Integration tools 1.2 Overview of Process Integration tools

1.3 Around1.3 Around--thethe--world tour of PI practitioners which world tour of PI practitioners which focuses on their expertisefocuses on their expertise

Tier I OutlineTier I Outline





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1.1 Introduction and definition of Process Integration


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The president of your company probably does not know The president of your company probably does not know what Process Integration can do for the company.........what Process Integration can do for the company.........

.......... but he should. Let.......... but he should. Let’’s look at why...s look at why...

Introduction and Definition of Process IntegrationIntroduction and Definition of Process Integration


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19601960’’ss--19701970’’ss LinnhoffLinnhoff started the area of Pinch started the area of Pinch (bottleneck identification) at University of Manchester (bottleneck identification) at University of Manchester Institute of Science and Technology (UMIST), Institute of Science and Technology (UMIST), focusing on the area of Thermal Pinch. At about the focusing on the area of Thermal Pinch. At about the same time, the UMIST Department of Process same time, the UMIST Department of Process Integration was created, shortly after the consulting Integration was created, shortly after the consulting firm firm LinnhoffLinnhoff--March Inc. was formedMarch Inc. was formed19801980’’ss--19901990’’ss Concept expansion from energy to Concept expansion from energy to process designprocess design19901990’’ss--20002000’’ss Analogies used to derive Pinch Analogies used to derive Pinch concept from heat exchanger networks to mass concept from heat exchanger networks to mass transfer, water treatment and hydrogen systemstransfer, water treatment and hydrogen systems

PI is not really easy to definePI is not really easy to define……

A brief history of Process IntegrationA brief history of Process Integration



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1.1. Process Integration might be regarded as a set of early stage Process Integration might be regarded as a set of early stage process techniques for both new and retrofit designprocess techniques for both new and retrofit design

2.2. Business objectives drive the development of PI:Business objectives drive the development of PI:a)a) Emphasis is on Emphasis is on retrofitretrofit projects in the projects in the ““new economynew economy”” driven by driven by

Return on Capital Employed (ROCE)Return on Capital Employed (ROCE)b)b) PI is PI is finding value in data, finding value in data, especially as real time data systems especially as real time data systems

have been implementedhave been implemented3.3. Corporations wish to make more knowledgeable decisions:Corporations wish to make more knowledgeable decisions:

1.1. For operationsFor operations2.2. During the design processDuring the design process

4.4. A strong trend today is to move away from unit operations and A strong trend today is to move away from unit operations and focus on phenomena. We no longer look at integration focus on phenomena. We no longer look at integration betweenbetweenunits only, but also at integration units only, but also at integration withinwithin units (Process units (Process Integration Primer, IEA)Integration Primer, IEA)


Modern Process Integration contextModern Process Integration context


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The The International Energy Agency International Energy Agency (IEA) definition of Process (IEA) definition of Process Integration (1993):Integration (1993):

““Systematic and general methods for designing integrated productiSystematic and general methods for designing integrated production systems, ranging on systems, ranging from individual processes to total sites, with special emphasis from individual processes to total sites, with special emphasis on the efficient use of on the efficient use of energyenergy and reducing and reducing environmentalenvironmental effectseffects””

““Process Integration is the common term used for the application Process Integration is the common term used for the application of methodologies of methodologies developed for systemdeveloped for system--oriented and integrated approaches to industrial process plant doriented and integrated approaches to industrial process plant design esign for both new and retrofit applications.for both new and retrofit applications.””““Such methodologies can be mathematical, thermodynamic and economSuch methodologies can be mathematical, thermodynamic and economic models, methods ic models, methods and techniques. Examples of these methods include: Artificial Inand techniques. Examples of these methods include: Artificial Intelligence, Hierarchical telligence, Hierarchical Analysis, Pinch Analysis and Mathematical Programming. Process IAnalysis, Pinch Analysis and Mathematical Programming. Process Integration refers to ntegration refers to optimal design; examples of aspects are: capital investment, eneoptimal design; examples of aspects are: capital investment, energy efficiency, emissions, rgy efficiency, emissions, operability, flexibility, controllability, safety and yields. Properability, flexibility, controllability, safety and yields. Process Integration also refers to ocess Integration also refers to some aspects of operation and maintenancesome aspects of operation and maintenance””

Sustainable DevelopmentSustainable Development


Definition of Process IntegrationDefinition of Process Integration


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ElEl--Halwagi, M. M., Halwagi, M. M., Pollution Prevention through Process Pollution Prevention through Process Integration: Systematic Design ToolsIntegration: Systematic Design Tools. Academic Press, 1997. . Academic Press, 1997.

““A chemical process is an integrated system of interconnected uniA chemical process is an integrated system of interconnected units ts and streams, and it should be treated as such. Process Integratiand streams, and it should be treated as such. Process Integration on is a holistic approach to process design, retrofitting, and operis a holistic approach to process design, retrofitting, and operation ation which emphasizes the unity of the process. In light of the stronwhich emphasizes the unity of the process. In light of the strong g interaction among process units, streams, and objectives, Procesinteraction among process units, streams, and objectives, Process s

Integration offers a unique framework for fundamentally Integration offers a unique framework for fundamentally understanding the global insights of the process, methodically understanding the global insights of the process, methodically

determining its attainable performance targets, and systematicaldetermining its attainable performance targets, and systematically ly making decisions leading to the realization of these targets. Thmaking decisions leading to the realization of these targets. There ere

are three key components in any comprehensive Process are three key components in any comprehensive Process Integration methodology: synthesis, analysis, and optimization.Integration methodology: synthesis, analysis, and optimization.””




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Nick Nick HallaleHallale, , AspentechAspentech –– CEP July 2001 CEP July 2001 –– Burning Bright Burning Bright Trends in Process IntegrationTrends in Process Integration

““Process Integration is more than just Pinch technology and Heat Process Integration is more than just Pinch technology and Heat Exchanger Networks. Today, it has a far wider scope and touches Exchanger Networks. Today, it has a far wider scope and touches every area of process design. Switchedevery area of process design. Switched--on industries are making on industries are making more money from their raw materials and capital assets while more money from their raw materials and capital assets while

becoming cleaner and more sustainablebecoming cleaner and more sustainable””




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North American Mobility Program in Higher Education North American Mobility Program in Higher Education (NAMP)(NAMP)--January 2003January 2003

““Process Integration (PI) is the synthesis of process control, Process Integration (PI) is the synthesis of process control, process engineering and process modeling and simulation process engineering and process modeling and simulation

into tools that can deal with the large quantities of operating into tools that can deal with the large quantities of operating data now available from process information systems. It is data now available from process information systems. It is an emerging area, which offers the promise of improved an emerging area, which offers the promise of improved control and management of operating efficiencies, energy control and management of operating efficiencies, energy use, environmental impacts, capital effectiveness, process use, environmental impacts, capital effectiveness, process

design, and operations management.design, and operations management.””




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So What Happened?So What Happened?In addition to thermodynamics (the foundation of Pinch), other In addition to thermodynamics (the foundation of Pinch), other techniques are being drawn upon for holistic analysis, in partictechniques are being drawn upon for holistic analysis, in particular:ular:

Process modelingProcess modelingProcess statisticsProcess statisticsProcess optimizationProcess optimizationProcess economicsProcess economicsProcess controlProcess controlProcess designProcess design




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Here are some of the design activities that these techniques andHere are some of the design activities that these techniques and methods methods address today:address today:

ProcessProcess modelingmodeling and and simulationsimulation, and , and validationvalidation of the results in of the results in order to have accurate and reliable process information for bothorder to have accurate and reliable process information for both new and new and retrofit designretrofit designMinimizeMinimize total annual costtotal annual cost by optimal tradeby optimal trade--off between energy, off between energy, equipment and raw material. Within this tradeequipment and raw material. Within this trade--off: minimize off: minimize energyenergy, , improve improve rraw materialaw material usage and minimize usage and minimize capitalcapital costcostIncrease Increase production volumeproduction volume by by debottleneckingdebottleneckingReduce Reduce operatingoperating problems by problems by correctcorrect (rather than maximum) use of (rather than maximum) use of Process IntegrationProcess IntegrationIncrease plant Increase plant controllabilitycontrollability and and flexibilityflexibilityMinimize undesirable Minimize undesirable eemissions missions and promote and promote pollutionpollution preventionpreventionAdd to the joint efforts in the process industries and society fAdd to the joint efforts in the process industries and society for a or a sustainablesustainable developmentdevelopment



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–– Lower capital cost, for the same design objectiveLower capital cost, for the same design objective–– Incremental production increase, from the same Incremental production increase, from the same

asset baseasset base–– MarginallyMarginally--reduced unit production costs by process reduced unit production costs by process

optimizationoptimization–– Better energy/environmental performance, without Better energy/environmental performance, without

compromising competitive positioncompromising competitive position

ReducingReducing

COSTSCOSTS

POLLUTIONPOLLUTION

ENERGYENERGY

IncreasingIncreasing

THROUGHPUTTHROUGHPUT

YIELDYIELD

PROFITPROFIT


Possible objectivesPossible objectives


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Process knowledgeProcess knowledge(models)(models)

RealReal--Time Time Process DataProcess Data

PI systems PI systems & Tools& Tools

Improving overall plant facilities Improving overall plant facilities energy efficiency and energy efficiency and productivity requires a multiproductivity requires a multi--pronged analysis involving a pronged analysis involving a variety of technical skills and variety of technical skills and expertise, including: expertise, including:

Knowledge of both Knowledge of both conventional industry practice conventional industry practice and stateand state--ofof--thethe--art art technologies commercially technologies commercially availableavailableFamiliarity with industry Familiarity with industry issues and trendsissues and trendsMethodology for determining Methodology for determining correct marginal costscorrect marginal costsProcedures and tools for Procedures and tools for energy, water, and raw energy, water, and raw material conservation auditsmaterial conservation auditsProcess information systemsProcess information systems

Summary of Process Integration elementsSummary of Process Integration elementsIntroduction and Definition of Process IntegrationIntroduction and Definition of Process Integration


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Process Integration has evolved from heat recovery Process Integration has evolved from heat recovery methodology in the 80methodology in the 80’’s to become what a number of s to become what a number of leading industrial companies and research groups in the leading industrial companies and research groups in the 2020thth century regard as the century regard as the holistic analysis of processes, holistic analysis of processes, involving the following elements:involving the following elements:

Process dataProcess dataSystems and tools Systems and tools Process engineering principles and inProcess engineering principles and in--depth depth process sector knowledgeprocess sector knowledgeTargetingTargeting


ConclusionConclusion


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1.2 Overview of Process Integration tools1.2 Overview of Process Integration tools



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1.2 Overview of Process Integration Tools


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Process SimulationProcess Simulation

••SteadySteady--statestate

••DynamicDynamic

Pinch AnalysisPinch Analysis

Optimization by Optimization by Mathematical Mathematical ProgrammingProgramming

Stochastic Search Stochastic Search MethodsMethods

Life Cycle AnalysisLife Cycle Analysis

DataData--Driven Driven Process ModelProcess Modelinging

Business Model Business Model and Supplyand Supply Chain Chain MaManagementnagement

Integrated Process Integrated Process Design and ControlDesign and Control

Real Time OptimizationReal Time Optimization

Process DataProcess Data

DataData Treatment and Treatment and ReconciliationReconciliation

Overview of Process Integration ToolsOverview of Process Integration Tools


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Process SimulationProcess Simulation

••Steady stateSteady state

••DynamicDynamic


Optimization by Optimization by Mathematical Mathematical ProgrammingProgramming

Stochastic Search Stochastic Search MethodsMethods


DataData--Driven Driven Process ModelingProcess Modeling

Business Model Business Model ••Supply Chain Supply Chain ManagementManagement

Integrated Process Integrated Process Design and ControlDesign and Control



Data Treatment and Data Treatment and ReconciliatioReconciliationn

NEXTNEXT

Overview of Process Integration ToolsOverview of Process Integration Tools


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Process Simulation


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In the process industry, we find two levels of models: plant In the process industry, we find two levels of models: plant models, and models of unit operations such as reactors, columns,models, and models of unit operations such as reactors, columns,pumps, heat exchangers, tanks, etc.pumps, heat exchangers, tanks, etc.

A model does not A model does not include everything:include everything:

n>m and k>tn>m and k>t

“All models are wrong, some models are useful”

George Box, PhD, University of Wisconsin

PROCESSPROCESS

MODELMODELInputInput OutputOutput

InputInput OutputOutput

XX11, ..., , ..., XXnn

XX11, ..., , ..., XXmm

YY11, ..., , ..., YYkk

YY11, ..., , ..., YYtt

There are two types of simulation: steadyThere are two types of simulation: steady--state and dynamicstate and dynamic

Simulation: Simulation: ““what ifwhat if”” experimentation with a modelexperimentation with a modelSimulation involves performing a series of experiments with a Simulation involves performing a series of experiments with a

process modelprocess model

Figure 1

Process simulationProcess simulation


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What is a model used for?What is a model used for?

A model is an abstraction of a process operation used to A model is an abstraction of a process operation used to build, change, improve, control, and answer questions about build, change, improve, control, and answer questions about that processthat process

A model can be used for different basic problem A model can be used for different basic problem formulations: simulation, identification, estimation and designformulations: simulation, identification, estimation and design

A model can be used to solve problems in the areas of the A model can be used to solve problems in the areas of the process design, control and optimization, risk analysis, process design, control and optimization, risk analysis, operator training, risk assessment, and software engineering operator training, risk assessment, and software engineering for computer aided engineering environmentsfor computer aided engineering environments

Process Modeling is an understanding of the phenomena of a Process Modeling is an understanding of the phenomena of a given process and the transformation of this understanding into given process and the transformation of this understanding into a a model.model.

Process simulation Process simulation –– Process modelingProcess modeling


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Why is steadyWhy is steady--state simulation state simulation important?important?

Better understanding of the processBetter understanding of the processConsistent set of typical plant/facility Consistent set of typical plant/facility datadataObjective comparative evaluation of Objective comparative evaluation of options for Return On Investment options for Return On Investment (ROI) etc.(ROI) etc.Identification of bottlenecks, Identification of bottlenecks, instabilities, etc.instabilities, etc.Performs many experiments cheaply Performs many experiments cheaply once the model is builtonce the model is builtAvoids implementing ineffective Avoids implementing ineffective solutionssolutions

MODELMODELInputInput OutputOutput

XX11, ..., , ..., XXmm YY11, ..., , ..., YYtt

ADVANCEMENT of plant operations/ADVANCEMENT of plant operations/OPERATIONAL SUPPORTOPERATIONAL SUPPORT

OPTIMIZATIONOPTIMIZATION

OPTIMIZATION ofOPTIMIZATION ofplant operationsplant operations

Online Online systemsystem

EDUCATION, TRAINING EDUCATION, TRAINING CONTROL SYSTEMCONTROL SYSTEM

QuasiQuasi--onlineonlinesystemsystem

PROCESS DESIGN / ANALYSISPROCESS DESIGN / ANALYSISOffOff--line line systemsystem

Why is dynamic simulation Why is dynamic simulation important?important?

MODELMODEL(t)(t)

InputInput OutputOutput

X(t)X(t)11, ..., , ..., X(t)X(t)mm Y(t)Y(t)11, ..., , ..., Y(t)Y(t)tt

Next ToolFigure 3Figure 2

Process simulation Process simulation –– SteadySteady--state & Dynamicstate & Dynamic


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Data Treatment and Reconciliation


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Objectives of Data TreatmentObjectives of Data TreatmentProvide reliable information and knowledge of Provide reliable information and knowledge of complete data for complete data for validation of process simulation and analysisvalidation of process simulation and analysisPerform instrument maintenancePerform instrument maintenanceDetect operating problemsDetect operating problemsEstimate unmeasured valuesEstimate unmeasured valuesReduce random and gross errors in measurementsReduce random and gross errors in measurementsDetect steady statesDetect steady states

Objectives of Data ReconciliationObjectives of Data ReconciliationOptimally adjust measured values within given process constraintOptimally adjust measured values within given process constraintssImprove consistency of data to calibrate and validate process Improve consistency of data to calibrate and validate process simulationsimulationEstimate unmeasured process valuesEstimate unmeasured process valuesDetect gross errors to further investigate operation/instrument Detect gross errors to further investigate operation/instrument problemsproblems

Data Treatment & ReconciliationData Treatment & Reconciliation


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THERMODYNAMIC PROPERTIES

STATISTICALPRINCIPLES

ACCURATE and RELIABLE INFORMATION










Data ReconciliationData ReconciliationData Reconciliation is the validation of process data using knowData Reconciliation is the validation of process data using knowledge of ledge of plant structure and of the plant measurement systemplant structure and of the plant measurement system

Figure 4

Data Treatment & ReconciliationData Treatment & Reconciliation


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DATA RECONCILIATIONDATA RECONCILIATION

Measurement Errors?Measurement Errors? Gross Error DetectionGross Error Detection

Unclosed Balances?Unclosed Balances? Closed BalancesClosed Balances

Unidentified Losses?Unidentified Losses? Identified LossesIdentified Losses

Efficiency?Efficiency? Monitored EfficiencyMonitored Efficiency

Performance?Performance? Quantified PerformanceQuantified Performance

Next Tool

Data Treatment & Reconciliation Data Treatment & Reconciliation -- BenefitsBenefits


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Pinch Analysis


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In the process industries, the prime objective of Pinch AnalysisIn the process industries, the prime objective of Pinch Analysis is is to optimize the ways in which process utilities (particularly ento optimize the ways in which process utilities (particularly energy, ergy, mass, water, and hydrogen) are applied for a wide variety of mass, water, and hydrogen) are applied for a wide variety of purposespurposes

Pinch Analysis does this by creating an inventory of all producPinch Analysis does this by creating an inventory of all producers ers and consumers of these utilities and then systematically designiand consumers of these utilities and then systematically designing ng an optimal scheme of utility exchange between these producers an optimal scheme of utility exchange between these producers and consumers. Energy, mass, and water reand consumers. Energy, mass, and water re--use are at the heart of use are at the heart of Pinch Analysis activitiesPinch Analysis activities

With the application of Pinch Analysis, savings can be achievedWith the application of Pinch Analysis, savings can be achieved in in both capital investment and operating cost. Emissions can be both capital investment and operating cost. Emissions can be minimized and throughput maximizedminimized and throughput maximized

What is Pinch Analysis?What is Pinch Analysis?



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The basis of Pinch Analysis:The basis of Pinch Analysis:The use of thermodynamic principles (first and second law)The use of thermodynamic principles (first and second law)The use of design and economy heuristicsThe use of design and economy heuristics

Pinch Analysis is a technique to design:Pinch Analysis is a technique to design:Heat Exchanger Networks (HEN) & Mass Exchange Networks Heat Exchanger Networks (HEN) & Mass Exchange Networks

(MEN)(MEN)Utility NetworksUtility Networks

Pinch Analysis makes extensive use of various graphical Pinch Analysis makes extensive use of various graphical representationsrepresentations

In Pinch Analysis, the engineer controls the design procedure In Pinch Analysis, the engineer controls the design procedure (interactive method)(interactive method)

Pinch Analysis integrates economic parametersPinch Analysis integrates economic parameters

FeaturesFeatures



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Possible BenefitsPossible Benefits

One of the main advantages of One of the main advantages of Pinch Analysis over Pinch Analysis over conventional design methods is conventional design methods is the ability to set a target the ability to set a target energy consumption for an energy consumption for an individual process or for an individual process or for an entire production site before entire production site before designing the processesdesigning the processesPinch Analysis quickly identifies Pinch Analysis quickly identifies where energy, water, hydrogen where energy, water, hydrogen and other material savings are and other material savings are likely to be foundlikely to be foundReduction of emissionsReduction of emissionsPinch Analysis enables the Pinch Analysis enables the engineer to find the best way engineer to find the best way to change a process, if the to change a process, if the process allows itprocess allows it

In addition, Pinch Analysis allows you toIn addition, Pinch Analysis allows you to

Update or develop process flow diagramsUpdate or develop process flow diagramsIdentify process bottlenecksIdentify process bottlenecksRun both departmental and full plant Run both departmental and full plant facilities simulationsfacilities simulationsDetermine minimal heating (steam) and Determine minimal heating (steam) and cooling requirementscooling requirementsIdentify cogeneration opportunitiesIdentify cogeneration opportunitiesEstimate costs of projects to achieve Estimate costs of projects to achieve energy savingsenergy savingsEvaluate new equipment configurations Evaluate new equipment configurations for the most economical installationfor the most economical installationSubstitute past energy studies with a live Substitute past energy studies with a live study that can be easily updated using study that can be easily updated using simulationsimulation

Next Tool



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Optimization by Mathematical Programming


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A Mathematical Model of a system is a set of mathematical A Mathematical Model of a system is a set of mathematical relationships (e.g., equalities, inequalities, logical conditionrelationships (e.g., equalities, inequalities, logical conditions) s) which represents an abstraction of the real world system under which represents an abstraction of the real world system under considerationconsiderationA Mathematical Model can be developed using:A Mathematical Model can be developed using:

Fundamental approachesFundamental approachesEmpirical methodsEmpirical methodsMethods based on analogyMethods based on analogy

A Mathematical Model of a system consists of four key A Mathematical Model of a system consists of four key elements:elements:

VariablesVariablesParametersParametersConstraintsConstraintsMathematical relationsMathematical relations

Mathematical ModelMathematical Model

Optimization of Mathematical ProgrammingOptimization of Mathematical Programming


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What is Optimization?What is Optimization?

An An optimization problemoptimization problem is a mathematical model which in is a mathematical model which in addition to the key elements stated in the previous slide addition to the key elements stated in the previous slide contains one or more performance criteriacontains one or more performance criteriaThe The performance criteriaperformance criteria are represented by an are represented by an objective objective functionfunction. This function can be the . This function can be the minimizationminimization of costs, the of costs, the maximizationmaximization of profit or yield of a process, for exampleof profit or yield of a process, for exampleIf we have multiple performance criteria, the problem is then If we have multiple performance criteria, the problem is then classified as a multiclassified as a multi--objective optimization problemobjective optimization problemThere are different classes of optimization problems: There are different classes of optimization problems: linear and linear and nonnon--linearlinear programming,programming, LP LP andand NLP,NLP, mixedmixed--integer linear integer linear programming (MILP) programming (MILP) andand mixedmixed--integer noninteger non--linear programming linear programming (MINLP)(MINLP)

Whenever possible, linear programs (LP or MILP) are used becauseWhenever possible, linear programs (LP or MILP) are used becausethey guarantee global solutions. MINLP problems also feature they guarantee global solutions. MINLP problems also feature many applications in engineering.many applications in engineering.



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ApplicationsApplications

Process SynthesisProcess SynthesisHeat Exchanger Networks (HEN)Heat Exchanger Networks (HEN)Mass Exchanger Networks (MEN)Mass Exchanger Networks (MEN)Distillation sequencingDistillation sequencingReactorReactor--based systemsbased systemsUtility systemsUtility systemsTotal process systemsTotal process systems

Design, scheduling, and planning of processDesign, scheduling, and planning of processDesign and retrofit of Design and retrofit of multiproductmultiproduct plantsplantsDesign and scheduling of Design and scheduling of multiproductmultiproduct plantsplants

Interaction of design and controlInteraction of design and controlMolecular product designMolecular product designFacility location and allocationFacility location and allocationFacility planning and schedulingFacility planning and schedulingTopology of transport networksTopology of transport networks

Next Tool



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Stochastic Search Methods


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Why Stochastic Search Methods?Why Stochastic Search Methods?

All of the model formulations that you have encountered thus farAll of the model formulations that you have encountered thus farin the Optimization section have assumed that the data for the in the Optimization section have assumed that the data for the given problem are known accurately. However, for many actual given problem are known accurately. However, for many actual problems, the problem data cannot be known accurately for a problems, the problem data cannot be known accurately for a variety of reasons. The first reason is due to simple measuremenvariety of reasons. The first reason is due to simple measurement t error. The second and more fundamental reason is that some data error. The second and more fundamental reason is that some data represent information about the future (e.g., product demand or represent information about the future (e.g., product demand or price for a future time period) and simply cannot be known with price for a future time period) and simply cannot be known with certainty. certainty.

Stochastic Search MethodsStochastic Search Methods


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There are different types of stochastic algorithmsThere are different types of stochastic algorithmsSimulated Annealing (SA)Simulated Annealing (SA)Genetic Algorithms (Genetic Algorithms (GAsGAs))TabuTabu SearchSearch

These algorithms are suitable for problems that deal with These algorithms are suitable for problems that deal with uncertainty. These computer algorithms or procedure uncertainty. These computer algorithms or procedure models do not guarantee global optima but are successful models do not guarantee global optima but are successful and widely known to come very close to the global optimal and widely known to come very close to the global optimal solution.solution.

SA takes one solution and efficiently moves it around in SA takes one solution and efficiently moves it around in the search space, avoiding local optimathe search space, avoiding local optimaGAsGAs have the capability of collectively searching for have the capability of collectively searching for multiple optimal solutions for the same optimal costmultiple optimal solutions for the same optimal costTabuTabu Search is an iterative procedure that explores the Search is an iterative procedure that explores the search space of all feasible solutions by a sequence of search space of all feasible solutions by a sequence of movesmoves

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Stochastic Search MethodsStochastic Search Methods


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Life Cycle Analysis (LCA)


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Technique for assessing the environmental Technique for assessing the environmental aspects and potential impacts associated with a aspects and potential impacts associated with a product by:product by:

–– Establishing an inventory of relevant inputs and outputs of a Establishing an inventory of relevant inputs and outputs of a systemsystem

–– Evaluating the potential environmental impacts associated with Evaluating the potential environmental impacts associated with those inputs and outputsthose inputs and outputs

–– Interpreting the results of the inventory and impact phases in Interpreting the results of the inventory and impact phases in relation with the objectives of the studyrelation with the objectives of the study

–– Evaluation of some aspects of a product system Evaluation of some aspects of a product system through all stages of its life cyclethrough all stages of its life cycle

What is Life Cycle Analysis?What is Life Cycle Analysis?



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Recycling and Disposal as Waste

at the end of its useful life

Extraction and Processing of Raw

Materials

Manufacturing

Packaging

Marketing

Use, Reuse and Maintenance of the

product

Figure 5



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Improves overall environmental performance and Improves overall environmental performance and compliancecomplianceProvides a framework for using pollution Provides a framework for using pollution prevention practices to meet LCA objectivesprevention practices to meet LCA objectivesIncreases efficiency and potential cost savings Increases efficiency and potential cost savings when managing environmental obligationswhen managing environmental obligationsPromotes predictability and consistency in Promotes predictability and consistency in managing environmental obligationsmanaging environmental obligationsMeasures scarce environmental resources more Measures scarce environmental resources more effectivelyeffectively

Possible BenefitsPossible Benefits

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Data-Driven Process Modeling


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Drowning in data!Drowning in data!

Interesting, useful patterns and relationships Interesting, useful patterns and relationships not intuitively not intuitively obviousobvious lie hidden inside enormous, unwieldy databases. lie hidden inside enormous, unwieldy databases. Also, many variables are Also, many variables are correlatedcorrelatedData mining techniques: Neural Networks, Multiple Data mining techniques: Neural Networks, Multiple Regression, Decision Trees, Genetic Algorithms, Clustering, Regression, Decision Trees, Genetic Algorithms, Clustering, MVA, etc.MVA, etc.

DataData--Rich but KnowledgeRich but Knowledge--PoorPoor

DataData--Driven Process ModelingDriven Process Modeling

Process Integration challengeMake sense of masses of dataNecessity to work on bigger samples if full advantage is to be taken of all accessible information


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Theoretical model Theoretical model uses First Principles to mimic the inner uses First Principles to mimic the inner workings of a processworkings of a processEmpirical model Empirical model uses the plant process data directly to uses the plant process data directly to establish mathematical correlationsestablish mathematical correlationsUnlike the theoretical models, empirical models do NOT take the Unlike the theoretical models, empirical models do NOT take the process fundamentals into account. They only use pure process fundamentals into account. They only use pure mathematical and statistical techniques. Multivariate Analysis mathematical and statistical techniques. Multivariate Analysis (MVA) is one such method, because it reveals patterns and (MVA) is one such method, because it reveals patterns and correlations between variables independently of any precorrelations between variables independently of any pre--conceived notionsconceived notions

Theoretical vs. Empirical ModelTheoretical vs. Empirical Model



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MMultiultivvariate ariate AAnalysisnalysis”” ((> 5 variables)> 5 variables)MVA uses ALL available data to capture information as much MVA uses ALL available data to capture information as much as possibleas possiblePrinciple: boil down hundreds of variables down to aPrinciple: boil down hundreds of variables down to a mere mere handfulhandful

What is MVA?What is MVA?

MVAMVA

Explore interExplore inter--relationshipsrelationships«« WhatWhat--ifif »» exercisesexercisesSoftware sensorsSoftware sensorsFeedFeed--forward controlforward control

BenefitsBenefits

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Integrated Process Design & Control


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Safety issues, energy costs, environmental concerns have Safety issues, energy costs, environmental concerns have increased complexity and sensitivity of processesincreased complexity and sensitivity of processesPlants become highly integrated in terms of mass and energy Plants become highly integrated in terms of mass and energy and therefore, process dynamics are often difficult to controland therefore, process dynamics are often difficult to control

ObjectivesObjectives

Product specifications variability should be kept at a minimum Product specifications variability should be kept at a minimum process variability (to control product quality)process variability (to control product quality)

Control is essential to operate a process in the best conditionsControl is essential to operate a process in the best conditions

ContextContext

Integrated Process Control & ControlIntegrated Process Control & Control


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Controllability is the Controllability is the property of a processproperty of a process that that accounts for the accounts for the ease ease with which a continuous with which a continuous plant can be held at a specified operating plant can be held at a specified operating regimeregime despite bounded external disturbances despite bounded external disturbances and uncertainties and and uncertainties and regardless of the control regardless of the control systemsystem imposed on such a processimposed on such a process

ControllabilityControllability



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Stability and better Stability and better performance of control loops performance of control loops and structures and structures System relatively insensitive to System relatively insensitive to perturbationsperturbationsEfficient management of Efficient management of interacting networksinteracting networks

Improvement of current dynamics

Flexibility

Why is Controllability important?Why is Controllability important?

Smoother operation of process Smoother operation of process closer to operating limitscloser to operating limits

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Real-Time Optimization (RTO)


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The process industries are increasingly compelled to The process industries are increasingly compelled to operate profitably in a very dynamic and global market. operate profitably in a very dynamic and global market. The increasing competition in the international area and The increasing competition in the international area and stringent product requirements mean decreasing profit stringent product requirements mean decreasing profit margins unless plant operations are optimized margins unless plant operations are optimized dynamically to adapt to the changing market conditions dynamically to adapt to the changing market conditions and to reduce the operating cost.and to reduce the operating cost.

ContextContext

Importance of Importance of realreal--time or ontime or on--line optimizationline optimization!!



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RealReal--Time Optimization is a modelTime Optimization is a model--based steadybased steady--state technology that determines the economically state technology that determines the economically optimal operating regime for a process in the near optimal operating regime for a process in the near termtermThe system optimizes a process simulation, not the The system optimizes a process simulation, not the process directlyprocess directlyPerformance measured in terms of economic benefitPerformance measured in terms of economic benefitIs an active field of research Is an active field of research mmodel accuracy, odel accuracy, error transmission, performance evaluationerror transmission, performance evaluation

What is RealWhat is Real--Time Optimization (RTO)?Time Optimization (RTO)?



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ReconciliationReconciliation

& gross error& gross error

detectiondetection

Updating process modelUpdating process model

(Steady(Steady--statestate→→dynamicdynamic

simulation)simulation)

SteadySteady--state detectionstate detectionOptimizationOptimization

(objective functions)(objective functions)

Business objectives;Business objectives;

Economic data;Economic data;

Product specificationProduct specification

Cost, process,Cost, process,

Environmental &Environmental &

product Dataproduct Data

Plant facilityPlant facility

RTO RTO -- SchematicallySchematically

Next ToolFigure 6



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Business Model and Supply Chain Modeling

(BM-SCM)


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Integrated Business &Process Model

Cost, Process, Cost, Process, Environmental &Environmental &

Product DataProduct Data

Cost, Process,Cost, Process,Environmental & Environmental &

Product OutcomesProduct Outcomes

ProcessProcessDesignDesign

AnalysisAnalysisAnd And

SynthesisSynthesis

ProcessProcessOperationOperationAnalysis Analysis

and and OptimizationOptimization

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Business Model and Supply Chain Modeling (BMBusiness Model and Supply Chain Modeling (BM--SCM)SCM)


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The double arrows mean that the The double arrows mean that the data set is consistent throughout the data set is consistent throughout the

plant facilitiesplant facilities

Plant Facilities

Integrated Business & Process Model

Process (P) & Environmental

(E) Data

Accounting Data

Product Data

MarketData

Data Processing

ProcessedP&E Data

Data Reconciliation

ReconciledP&E Data

Data Validation & Data Validation &

ReconciliationReconciliation

Once the model is built, it Once the model is built, it can be used to validate and can be used to validate and

reconcile datareconcile data

Cost, Process, Environmental Cost, Process, Environmental

and Product Dataand Product Data

BMBM--SCM SCM –– Cost, Process, Environmental & Product DataCost, Process, Environmental & Product Data


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1st PrinciplesModels

Cost

Acc

ount

ing

Mod

elSupply Chain(SC) and

Env. SC Models

Cost

acc

ount

ing

mod

el

Model that deals with the classification, recording, allocation, and summarization of data for the purpose of management decision making and financial reporting

Cost, Process, E & P Data

Environmental DataEnvironmental Data

Market DataMarket Data

Accounting DataAccounting Data


Product DataProduct Data

Supply Chain (SC) and

Env. SC models

Click hereClick here

Data Driven Models

ProcessSimulation

Models

Integrated Business Integrated Business

and and

Process ModelProcess Model

BMBM--SCM SCM –– Integrated Business & Process ModelIntegrated Business & Process Model


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Supply Manufacturing Retail

Distribution Consumer

Supply ManufacturingManufacturing Retail

Distribution

Retail

Distribution ConsumerConsumer

Supply Chain (SC)Supply Chain (SC) is a network of organizations that are involved, is a network of organizations that are involved, through upstream and downstream linkages, in the different through upstream and downstream linkages, in the different processes and activities that produce value in the form of processes and activities that produce value in the form of products and services in the hands of the ultimate customerproducts and services in the hands of the ultimate customer

Supply Manufacturing Retail

Distribution Consumer

W

Recycling

W

Collection

RemanufacturingReuse

W

W W

W W

W

Supply ManufacturingManufacturing Retail

Distribution

Retail

Distribution ConsumerConsumer

W

Recycling

W

Collection


W

W W

W W

W

WW

RecyclingRecycling

WWW

CollectionCollection



WW

WW WW

WW WW

WW

(Waste)(Waste)

Environmental Supply Chain (ESC)Environmental Supply Chain (ESC) holds all the elements a holds all the elements a traditional Supply Chain has, but is extended to a semitraditional Supply Chain has, but is extended to a semi--closed closed loop in order to also account for the environmental impact of loop in order to also account for the environmental impact of the Supply Chain and for recycling, rethe Supply Chain and for recycling, re--use and collection of used use and collection of used material (material (BeamonBeamon 19991999) )

BMBM--SCM SCM –– Supply Chain & Environmental Supply ChainSupply Chain & Environmental Supply Chain


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Objectives of the SC and ESC modelsObjectives of the SC and ESC models

To integrate interTo integrate inter--organizational units along a SC and organizational units along a SC and coordinate materials, information and financial flows in order tcoordinate materials, information and financial flows in order to o fulfill customer demands and to improve SC profitability and fulfill customer demands and to improve SC profitability and responsivenessresponsivenessTo gain insight on the total environmental impact of the To gain insight on the total environmental impact of the production process (from supplier to customer and back to the production process (from supplier to customer and back to the facility by recycling) and all the products that are manufacturefacility by recycling) and all the products that are manufactured d (closely linked to LCA)(closely linked to LCA)

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BM-SCM

BMBM--SCM SCM –– Supply Chain & Environmental Supply ChainSupply Chain & Environmental Supply Chain


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1.3 Around-the-world tour of PI practitioners which focuses on

their expertise


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Courtesy mainly of the World Wide Web Courtesy mainly of the World Wide Web to to capture the flavour of the evolution of Process capture the flavour of the evolution of Process IntegrationIntegrationPI is relatively newPI is relatively new

Researchers build on their strengthsResearchers build on their strengthsMany of the groundMany of the ground--breaking techniques are breaking techniques are coming from universitiescoming from universitiesWhen techniques become practical, the private When techniques become practical, the private sector generally capitalizes and techniques sector generally capitalizes and techniques advance more rapidlyadvance more rapidly

Institutions CompaniesEND

AroundAround--thethe--world tour of PI Practitionersworld tour of PI Practitioners


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InstitutionsInstitutions

Click on a continent to view institutions from that continentClick on a continent to view institutions from that continent

North and South America

Europe

Africa, Middle-East, Asia and Oceania



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InstitutionsInstitutions--North and South AmericaNorth and South America

CanadaCanada (2)(2)

USAUSA (8)(8)

BrazilBrazil (1)(1)

MexicoMexico (1)(1)


To view institutions from a To view institutions from a particular country, click on the flag particular country, click on the flag of the country of choiceof the country of choice

Back to World Map


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InstitutionsInstitutions--EuropeEurope

BelgiumBelgium (1)(1)

DenmarkDenmark (1)(1)

FinlandFinland (3)(3)

FranceFrance (1)(1)

GermanyGermany (2)(2)

UKUK (5)(5)

HungaryHungary (1)(1)

GreeceGreece (1)(1)

NorwayNorway (1)(1)

PortugalPortugal (2)(2)

SloveniaSlovenia (1)(1)

Spain Spain (1)(1)

SwedenSweden (1)(1)

SwitzerlandSwitzerland (1)(1)



Back to World Map


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InstitutionsInstitutions--Africa, MiddleAfrica, Middle--East, Asia and OceaniaEast, Asia and Oceania

India India (1)(1)

Israel Israel (1)(1)

South Africa South Africa (1)(1)

Australia Australia (3)(3)



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CanadaCanadaÉÉcole Polytechnique de Montrcole Polytechnique de Montrééal, Department of Chemical al, Department of Chemical Engineering, MontrEngineering, Montrééalal

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Major Contact:Major Contact: Professor Paul StuartProfessor Paul Stuart

Web:Web: http://www.pulphttp://www.pulp--paper.capaper.ca

Research areasResearch areas:: the application of Process Integration in the pulp the application of Process Integration in the pulp and paper industry, with emphasis on pollution prevention techniand paper industry, with emphasis on pollution prevention techniques ques and profitability analysis, the efficient use of energy and raw and profitability analysis, the efficient use of energy and raw materials materials (including water), process control, and plant sustainability(including water), process control, and plant sustainability

Consortium:Consortium: "Process "Process Integration in the Pulp and Integration in the Pulp and Paper Industry Research Paper Industry Research Consortium" with 13 Consortium" with 13 members (2003) including members (2003) including operating companies, operating companies, engineering & contracting engineering & contracting companies, consulting companies, consulting companies and software companies and software vendors in pulp and paper vendors in pulp and paper industryindustry

Current research in Process IntegrationCurrent research in Process Integration

Process SimulationProcess SimulationData ReconciliationData ReconciliationProcess ControlProcess ControlNetworks Analysis (HEN and MEN)Networks Analysis (HEN and MEN)Environmental technologies (e.g. LCA)Environmental technologies (e.g. LCA)Business modelBusiness modelDateDate--Driven ModelingDriven Modeling


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CanadaCanadaUniversity of Ottawa, Department of Chemical University of Ottawa, Department of Chemical Engineering, OttawaEngineering, Ottawa

Major Contact:Major Contact: Professor Jules Professor Jules ThibaultThibault

Web:Web: http://http://www.genie.uottawa.cawww.genie.uottawa.ca/chg/eng//chg/eng/

BrazilBrazilUniversidadeUniversidade Federal do Rio de Janeiro, Rio de JaneiroFederal do Rio de Janeiro, Rio de JaneiroMajor Contact:Major Contact: Professor Eduardo Mach Professor Eduardo Mach QueirozQueiroz

Web:Web: http://http://www.poli.ufrj.brwww.poli.ufrj.br//




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MexicoMexicoUniversidad de Guanajuato, Department of Chemical Universidad de Guanajuato, Department of Chemical Engineering, GuanajuatoEngineering, Guanajuato

Major Contact:Major Contact: Dr MartDr Martíínn--PicPicóónn--NNúñúñezez

Web:Web: http://www.ugto.mx

Research areas:Research areas: hosts the only course hosts the only course Masters Program in Process Integration in North Masters Program in Process Integration in North America. America. Analysis of processes, Power Systems, Analysis of processes, Power Systems, and development of environmentally benign and development of environmentally benign technologytechnology

Current research in Process IntegrationCurrent research in Process IntegrationSynthesis of processes; modeling, simulation, control Synthesis of processes; modeling, simulation, control

and optimization of processes; new processes and and optimization of processes; new processes and materialsmaterials

Heat rHeat recovery systems; renewable sources of ecovery systems; renewable sources of energy; thermodynamic optimizationenergy; thermodynamic optimization

Contaminated atmosphere rehabilitation; treatment Contaminated atmosphere rehabilitation; treatment of effluents; environmental processesof effluents; environmental processes




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USAUSACarnegie Mellon University, Department of Chemical Carnegie Mellon University, Department of Chemical Engineering, PittsburghEngineering, Pittsburgh

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Major Contact:Major Contact: Professor Ignacio E. GrossmannProfessor Ignacio E. Grossmann

Web:Web: http://http://capd.cheme.cmu.educapd.cheme.cmu.edu//

Research areas:Research areas: recognized as one of the major research groups in the area of Corecognized as one of the major research groups in the area of Computer Aided mputer Aided Process Design. In Process Integration, the group is recognized Process Design. In Process Integration, the group is recognized for its work in Mathematical for its work in Mathematical Programming, Optimization, reactor systems, separation systems (Programming, Optimization, reactor systems, separation systems (especially distillation), Heat especially distillation), Heat Exchanger Networks, operability and the synthesis of operating pExchanger Networks, operability and the synthesis of operating proceduresrocedures

Consortium: Consortium: CAPD (Centre for (Centre for Advanced Process DecisionAdvanced Process Decision--making, making, founded 1986, 20 members (2001)) founded 1986, 20 members (2001)) including operating companies, including operating companies, engineering & contracting engineering & contracting companies, consulting companies companies, consulting companies and software vendorsand software vendors


Insights to aid and automate synthesis (invention)Insights to aid and automate synthesis (invention)Structural optimization of process Structural optimization of process flowsheetsflowsheetsSynthesis of reactor systems and separation systemsSynthesis of reactor systems and separation systemsSynthesis of Heat Exchanger NetworksSynthesis of Heat Exchanger NetworksGlobal optimization techniques relevant to Process Global optimization techniques relevant to Process

IntegrationIntegrationIntegrated Design and Scheduling of batch plantsIntegrated Design and Scheduling of batch plantsSupply chain dynamics and optimizationSupply chain dynamics and optimization




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USAUSATexas A&M University, Department of Chemical Engineering, Texas A&M University, Department of Chemical Engineering, College StationCollege Station

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Major Contact:Major Contact: Professor Professor MahmoudMahmoud M. ElM. El--HalwagiHalwagi

Web:Web: http://processhttp://process--integration.tamu.eduintegration.tamu.edu/ / and and http://wwwhttp://www--che.tamu.edu/cpipeche.tamu.edu/cpipe//

Research areasResearch areas::Recognized as a leading Recognized as a leading research group in the research group in the areas of Mass areas of Mass Integration and Integration and Pollution Prevention Pollution Prevention through Process through Process IntegrationIntegration


Global allocation of mass and energyGlobal allocation of mass and energySynthesis of waste allocation and species Synthesis of waste allocation and species

interception networksinterception networksPhysical and reactive Mass Pinch AnalysisPhysical and reactive Mass Pinch AnalysisSynthesis of HeatSynthesis of Heat--Induced NetworksInduced NetworksDesign of membraneDesign of membrane--hybrid systemshybrid systemsDesign of environmentally acceptable reactionsDesign of environmentally acceptable reactionsIntegration of reaction and separation systemsIntegration of reaction and separation systemsFlexibility and scheduling systemsFlexibility and scheduling systemsSimultaneous design and controlSimultaneous design and controlGlobal optimization via interval analysisGlobal optimization via interval analysis




PIECENAMP


USAUSAAuburn University, AuburnAuburn University, Auburn

Massachusetts Institute of Technology (MIT), Massachusetts Institute of Technology (MIT), Department of Chemical Engineering, CambridgeDepartment of Chemical Engineering, Cambridge

NEXT

Major Contact:Major Contact: Professor Christopher RobertsProfessor Christopher Roberts

Web:Web: http://http://www.eng.auburn.edu/department/chewww.eng.auburn.edu/department/che//

Major Contact:Major Contact: Professor George StephanopoulosProfessor George Stephanopoulos

Web:Web: http://http://web.mit.edu/cheme/index.htmlweb.mit.edu/cheme/index.html



PIECENAMP

USAUSAPrinceton University, PrincetonPrinceton University, Princeton

Purdue University, West LafayettePurdue University, West Lafayette

NEXT

Major Contact:Major Contact: Professor Professor ChristodoulosChristodoulos A. A. FloudasFloudas

Web:Web: http://http://chemeng.princeton.edu/html/home.shtmlchemeng.princeton.edu/html/home.shtml

Major Contact:Major Contact: Professor G.V. Rex Professor G.V. Rex ReklaitisReklaitis

Web:Web: https://https://engineering.purdue.edu/ChE/index.htmlengineering.purdue.edu/ChE/index.html andandhttps://https://engineering.purdue.eduengineering.purdue.edu/ECN//ECN/




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USAUSAUniversity of Massachusetts, AmherstUniversity of Massachusetts, Amherst

University of Pennsylvania, PhiladelphiaUniversity of Pennsylvania, Philadelphia

Major Contact:Major Contact: Professor J. M. DouglasProfessor J. M. Douglas

Web:Web: http://http://www.ecs.umass.edu/chewww.ecs.umass.edu/che//

Major Contact:Major Contact: Professor Warren D. Professor Warren D. SeiderSeider

Web:Web: http://http://www.seas.upenn.edu/cbe/chehome.htmlwww.seas.upenn.edu/cbe/chehome.html




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BelgiumBelgiumUniversitUniversitéé de de LiLièègege, , Laboratory for Analysis and Laboratory for Analysis and Synthesis of Chemical Systems (LASSC),Synthesis of Chemical Systems (LASSC), LiLièègege

DenmarkDenmarkTechnical University of Denmark, Technical University of Denmark, LyngbyLyngby

Major Contact:Major Contact: Professor Boris Professor Boris KalitventzeffKalitventzeff

Web:Web: http://http://www.ulg.ac.be/lasscwww.ulg.ac.be/lassc//

Major Contact:Major Contact: Professor Professor BjBjøørnrn QvaleQvale

Web:Web: http://http://www.et.dtu.dkwww.et.dtu.dk//


Back to Europe Institutions


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FinlandFinland

ÅÅbobo AkademiAkademi University, Process Design Laboratory, University, Process Design Laboratory, ÅÅbobo

LappeenrantaLappeenranta University of Technology, University of Technology, LappeenrantaLappeenranta

Helsinki University of Technology, Laboratory of Energy Helsinki University of Technology, Laboratory of Energy Engineering and Environmental Protection, HelsinkiEngineering and Environmental Protection, Helsinki

Major Contact:Major Contact: Professor Professor TapioTapio WesterlundWesterlund

Web:Web: http://http://www.abo.fi/fak/ktf/atwww.abo.fi/fak/ktf/at//

Major Contact:Major Contact: Professor Lars Professor Lars NystrNyströömm

Web:Web: http://www2.lut.fi/kete/laboratories/Process_Engineering/mainpaghttp://www2.lut.fi/kete/laboratories/Process_Engineering/mainpage.htme.htm

Major Contact:Major Contact: Professor CarlProfessor Carl--Johan Johan FogelholmFogelholm

Web: Web: http://http://eny.hut.fieny.hut.fi//




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FranceFranceINPTINPT--ENSIGC, Chemical Engineering Laboratory, ENSIGC, Chemical Engineering Laboratory, ToulouseToulouse

GreeceGreeceChemical Process Engineering Research Institute, HellasChemical Process Engineering Research Institute, Hellas

Major Contact:Major Contact: Professor Xavier Professor Xavier JouliaJoulia

Web:Web: http://www.ensiacet.fr/ENSIA7_FR/FORMATION/INGENIEUR/GPI/gpi.shthttp://www.ensiacet.fr/ENSIA7_FR/FORMATION/INGENIEUR/GPI/gpi.shtmlml

Major Contact:Major Contact: Professor I. Professor I. VasalosVasalos

Web:Web: http://http://www.cperi.forth.grwww.cperi.forth.gr




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GermanyGermanyUniversitUniversitäätt Dortmund, DortmundDortmund, Dortmund

TechnischeTechnische UniversitUniversitäätt Hamburg, Hamburg, HarburgHarburg

Major Contact:Major Contact: Professor A. BehrProfessor A. Behr

Web:Web: http://www.bci.unihttp://www.bci.uni--dortmund.de/tca/web/en/index.htmldortmund.de/tca/web/en/index.html

Major Contact:Major Contact: Professor GProfessor Güünter nter GruhnGruhn

Web:Web: http://www.tuhttp://www.tu--harburg.de/vt3/harburg.de/vt3/




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NorwayNorwayNorwegian University of Science and Technology, Process Norwegian University of Science and Technology, Process Systems Engineering in Systems Engineering in TrondheimTrondheim (PROST), (PROST), TrondheimTrondheim

HungaryHungaryBudapest University of Technology and Economics, Budapest University of Technology and Economics, BudapestBudapest

Major Contact:Major Contact: Professor Professor ZsoltZsolt FonyoFonyo

Web:Web: http://http://www.bme.huwww.bme.hu/en/organization/faculties/chemical//en/organization/faculties/chemical/

Major Contact:Major Contact: Professor Professor SigurdSigurd SkogestadSkogestad

Web:Web: http://http://kikp.chembio.ntnu.nokikp.chembio.ntnu.no/research/PROST//research/PROST/




PIECENAMP


PortugalPortugalUniversidadeUniversidade do Porto, Portodo Porto, Porto

InstitutoInstituto Superior Superior TTéécnicocnico, , LisboaLisboa

Major Contact:Major Contact: Professor Manuel A.N. CoelhoProfessor Manuel A.N. Coelho

Web:Web: http://http://www.fe.up.ptwww.fe.up.pt//

Major Contact:Major Contact: Professor Professor ClementeClemente Pedro Pedro NunesNunes

Web:Web: http://http://dequim.ist.utl.pt/englishdequim.ist.utl.pt/english//



PIECENAMP

SloveniaSloveniaUniversity of University of MariborMaribor, , MariborMaribor

SwitzerlandSwitzerlandSwiss Federal Institute of Technology, LausanneSwiss Federal Institute of Technology, Lausanne

Major Contact:Major Contact: Professor Peter Professor Peter GlaviGlavičč

Web:Web: http://www.unihttp://www.uni--mb.simb.si//

Major Contact:Major Contact: Professor Daniel Professor Daniel FavratFavrat

Web:Web: http://http://leniwww.epfl.chleniwww.epfl.ch//




PIECENAMP


SpainSpainUniversitatUniversitat PolitPolitèècnicacnica de de CatalunyaCatalunya, Chemical Engineering , Chemical Engineering Department, BarcelonaDepartment, BarcelonaMajor Contact:Major Contact: Professor Luis Professor Luis PuigjanerPuigjaner

Web:Web: http://http://tqg.upc.estqg.upc.es//

Research areas:Research areas: pioneering work in Computer Aided Process Operations. In Procespioneering work in Computer Aided Process Operations. In Process Integration, the s Integration, the group is recognized for its contributions in timegroup is recognized for its contributions in time--dependent processes, such as Combined Heat and dependent processes, such as Combined Heat and Power, Combined EnergyPower, Combined Energy--Waste and Waste Minimization, Integrated Process Monitoring, DiaWaste and Waste Minimization, Integrated Process Monitoring, Diagnosis and gnosis and Control and Process UncertaintyControl and Process Uncertainty

Consortium:Consortium: "Manufacturing "Manufacturing Reference Centre" with 12 members Reference Centre" with 12 members (1966) including (1966) including ConselleriaConselleria d'Indd'Indúústriastriaand associated operating companies, and associated operating companies, engineering and contracting companies, engineering and contracting companies, consultants and software vendors. Also consultants and software vendors. Also the TQG (General Chemical Technology) the TQG (General Chemical Technology) research group has grown steadily with research group has grown steadily with research related to kinetics, process research related to kinetics, process design and operationdesign and operation

Current research in Process IntegrationCurrent research in Process IntegrationEvolutionary modeling and optimizationEvolutionary modeling and optimizationMultiMulti--objective optimization in timeobjective optimization in time--dependent dependent

systemssystemsCombined energy and water use minimizationCombined energy and water use minimizationIntegration of thermally coupled distillation columnsIntegration of thermally coupled distillation columnsHotHot--gas recovery and cleaning systemsgas recovery and cleaning systems



PIECENAMP

SwedenSwedenChalmers University of Technology, Department of Heat Chalmers University of Technology, Department of Heat and Power, and Power, GGööteborgteborg

Major Contact:Major Contact: ThoreThore BerntssonBerntsson

Web: Web: http://http://www.hpt.chalmers.sewww.hpt.chalmers.se//

Research areas:Research areas: methodology development and applied research based on Pinch methodology development and applied research based on Pinch Technology. Emphasis on new retrofit methods including realisticTechnology. Emphasis on new retrofit methods including realistic treatment of treatment of geographical distances, pressure drops, varying fixed costs, etcgeographical distances, pressure drops, varying fixed costs, etc. Important new . Important new concepts include the Cost Matrix for Retrofit Screening and new concepts include the Cost Matrix for Retrofit Screening and new Grand Composite Grand Composite thermodynamic diagrams for heat and power applications (includinthermodynamic diagrams for heat and power applications (including gas turbines and g gas turbines and heat pumps). Research in pulp and paper with focus on energy andheat pumps). Research in pulp and paper with focus on energy and environmentenvironment

Industry:Industry: Close Close cooperation with cooperation with some of the major some of the major pulp and paper pulp and paper industry groups, industry groups, including training including training courses and courses and consultingconsulting


Retrofit design of Heat Exchanger NetworksRetrofit design of Heat Exchanger NetworksProcess Integration of heat pumps in grassroots and retrofitsProcess Integration of heat pumps in grassroots and retrofitsGas turbine based CHP plants in retrofit situationsGas turbine based CHP plants in retrofit situationsApplied research in pulp and paper industry, such as black liquApplied research in pulp and paper industry, such as black liquor or

gasification and closing the bleaching plantgasification and closing the bleaching plantEnvironmental aspects of Process Integration, especially Environmental aspects of Process Integration, especially

greenhouse gas emissionsgreenhouse gas emissions




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UKUKImperial College, Centre for Process Systems Engineering, Imperial College, Centre for Process Systems Engineering, LondonLondon

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Major Contact:Major Contact: Professor Professor EfstratiosEfstratios N. N. PistikopoulosPistikopoulos

Web:Web: http://http://www.ps.ic.ac.ukwww.ps.ic.ac.uk// andand http://http://www.psenterprise.comwww.psenterprise.com

Research areas:Research areas: recognized as the largest research group in the area of Process recognized as the largest research group in the area of Process Systems Systems Engineering (PSE), which includes Synthesis/Design, Operations, Engineering (PSE), which includes Synthesis/Design, Operations, Control and Modeling. The group is Control and Modeling. The group is recognized as a worldrecognized as a world--wide centre of excellence in Process Modeling, Numerical wide centre of excellence in Process Modeling, Numerical Techniques/Optimization and Integrated Process Design (includes Techniques/Optimization and Integrated Process Design (includes simultaneous consideration of Process simultaneous consideration of Process Integration and Control). The Centre is also an important contriIntegration and Control). The Centre is also an important contributor in the area of integration and butor in the area of integration and operation of batch processesoperation of batch processes

Consortium:Consortium: Process Process Systems Engineering (PSE) Systems Engineering (PSE) with 17 members (2003) with 17 members (2003) including operating, including operating, engineering & contracting engineering & contracting companies, software vendorscompanies, software vendors


Integrated batch processingIntegrated batch processingDesign and management of integrated Supply Chain Design and management of integrated Supply Chain

processesprocessesUncertainty and operability in process designUncertainty and operability in process designFormulation of mathematical programming models to Formulation of mathematical programming models to

address problems in process synthesis and integrationaddress problems in process synthesis and integration




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Institutions

UKUKUMIST, Department of Process Integration, ManchesterUMIST, Department of Process Integration, Manchester

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Major Contact:Major Contact: Professor Robin SmithProfessor Robin Smith

Web:Web: http://http://www.cpi.umist.ac.ukwww.cpi.umist.ac.uk//

Research areas:Research areas: recognized as the pioneering and major research recognized as the pioneering and major research group in the area of Pinch Analysis. Previous research includes group in the area of Pinch Analysis. Previous research includes targets and targets and design methods for Heat Exchanger Networks (grassroots and retrodesign methods for Heat Exchanger Networks (grassroots and retrofits), fits), Heat and Power systems, Heat driven Separation Systems, FlexibilHeat and Power systems, Heat driven Separation Systems, Flexibility, Total ity, Total Sites, Pressure Drop considerations, Batch Process Integration, Sites, Pressure Drop considerations, Batch Process Integration, Water and Water and Waste Minimization and Distributed Effluent TreatmentWaste Minimization and Distributed Effluent Treatment

Industry:Industry: Research Research Consortium in Process Consortium in Process IntegrationIntegration created in created in 1984 and now formed 1984 and now formed by 26 major by 26 major companies companies representing different representing different aspects of the process aspects of the process and utility industriesand utility industries


Efficient use of raw materials (including water)Efficient use of raw materials (including water)Energy efficiencyEnergy efficiencyEmissions reductionEmissions reductionEEfficient use of capitalfficient use of capital



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UKUKUniversity of Edinburgh, EdinburghUniversity of Edinburgh, Edinburgh

University College, LondonUniversity College, London

University of Ulster, University of Ulster, ColeraineColeraine

Major Contact:Major Contact: Dr. David Dr. David BogleBogle

Web:Web: http://http://www.chemeng.ucl.ac.ukwww.chemeng.ucl.ac.uk//

Major Contact:Major Contact: Professor Jack W. Professor Jack W. PontonPonton

Web:Web: http://http://www.chemeng.ed.ac.ukwww.chemeng.ed.ac.uk//

Major Contact:Major Contact: Professor J.T. McMullanProfessor J.T. McMullan

Web:Web: http://http://www.engineering.ulster.ac.ukwww.engineering.ulster.ac.uk//




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IsraelIsraelTechnionTechnion, Israel Institute of Technology, Haifa, Israel Institute of Technology, Haifa

Major Contact:Major Contact: Professor Daniel R. Professor Daniel R. LewinLewin

Web:Web: http://www.technion.ac.il/technion/chemhttp://www.technion.ac.il/technion/chem--eng/index_explorer.htmeng/index_explorer.htm

IndiaIndiaIndian Institute of Technology, BombayIndian Institute of Technology, BombayMajor Contact:Major Contact: Dr. Dr. UdayUday V. V. ShenoyShenoy

Web:Web: http://http://www.che.iitb.ac.inwww.che.iitb.ac.in//


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South AfricaSouth AfricaUniversity of the Witwatersrand, Process & Materials University of the Witwatersrand, Process & Materials Engineering, JohannesburgEngineering, JohannesburgMajor Contact:Major Contact: Professor David Professor David GlasserGlasser

Web:Web: http://http://www.procmat.wits.ac.zawww.procmat.wits.ac.za//

Research areas:Research areas: recognized as the major research group in the development of threcognized as the major research group in the development of the Attainable e Attainable Region (AR) method for Reactor and Process Synthesis. The AttainRegion (AR) method for Reactor and Process Synthesis. The Attainable Region concept has been able Region concept has been expanded to systems where mass transfer, heat transfer and separexpanded to systems where mass transfer, heat transfer and separation take place. In its generalized ation take place. In its generalized form (reaction, mixing, separation, heat transfer and mass transform (reaction, mixing, separation, heat transfer and mass transfer), the Attainable Region concept fer), the Attainable Region concept provides a Synthesis tool that will provide targets for "optimalprovides a Synthesis tool that will provide targets for "optimal" designs against which more practical " designs against which more practical solutions can be judgedsolutions can be judged

Has founded its own Has founded its own consultancy enterprise called consultancy enterprise called WWits Enterprise its Enterprise http://http://www.enterprise.wits.www.enterprise.wits.ac.zaac.za//


Systems involving reaction, mixing and separation Systems involving reaction, mixing and separation (e.g. reactive distillation)(e.g. reactive distillation)

NonNon--isothermal chemical reactor systemsisothermal chemical reactor systemsOptimization of dynamic systemsOptimization of dynamic systems


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AustraliaAustraliaUniversity of Adelaide, AdelaideUniversity of Adelaide, Adelaide

Murdoch University, RockinghamMurdoch University, Rockingham

University of Queensland, BrisbaneUniversity of Queensland, Brisbane

Major Contact:Major Contact: Dr. B.K. O'NeillDr. B.K. O'Neill

Web:Web: http://http://www.chemeng.adelaide.edu.auwww.chemeng.adelaide.edu.au//

Major Contact:Major Contact: Professor Peter LeeProfessor Peter Lee

Web:Web: http://http://wwweng.murdoch.edu.au/engindex.htmlwwweng.murdoch.edu.au/engindex.html

Major Contact:Major Contact: Professor Ian CameronProfessor Ian Cameron

Web:Web: http://http://www.cheque.uq.edu.auwww.cheque.uq.edu.au//


Back to Oceania Institutions


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CompaniesCompaniesLinnhoffLinnhoff March Limited, March Limited, NorthwichNorthwich, Cheshire, UK, Cheshire, UK

Web:Web: http://http://www.linnhoffmarch.comwww.linnhoffmarch.com// and and http://http://www.kbcat.comwww.kbcat.com//

List of Services in the area of Process List of Services in the area of Process IntegrationIntegration

Project execution and consultingProject execution and consultingSoftware development and supportSoftware development and supportTraining assistanceTraining assistanceTypical Projects: Typical Projects: 1200 assignments over 18 years1200 assignments over 18 years

PI TechnologiesPI Technologies

Pinch Technology (analysis and HEN Pinch Technology (analysis and HEN Design,Total Site Analysis)Design,Total Site Analysis)

Water PinchWater Pinch™™ for wastewater for wastewater minimizationminimization

Combined thermal and hydraulic Combined thermal and hydraulic analysis of distillation columns PI analysis of distillation columns PI software: extensively proven statesoftware: extensively proven state--ofof--thethe--art software including art software including SuperTargetSuperTarget, , PinchExpressPinchExpress, , WaterTargetWaterTarget and and Steam97Steam97

LinnhoffLinnhoff MarchMarch is the pioneering company of Pinch Technology and is now a is the pioneering company of Pinch Technology and is now a division of KBC Process Technology Limited since 2002.division of KBC Process Technology Limited since 2002. KKBC Advanced BC Advanced Technologies is the leading independent process engineering consTechnologies is the leading independent process engineering consultancy, ultancy, improving operational efficiency and profitability in the hydrocimproving operational efficiency and profitability in the hydrocarbon processing arbon processing industry worldwideindustry worldwide

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CompaniesCompanies

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Process Systems Enterprise Limited, London, UKProcess Systems Enterprise Limited, London, UK

Web:Web: http://http://www.psenterprise.comwww.psenterprise.com


Dynamic process modelingDynamic process modelingDynamic optimizationDynamic optimizationEnterprise modelingEnterprise modelingExtensive training for all its productsExtensive training for all its products


gPROMSgPROMS®®, for , for ggeneral eneral PROPROcesscessMModeling odeling SSystem ystem SteadySteady--state and state and dynamic process simulation, dynamic process simulation, optimization (MINLP) and parameter optimization (MINLP) and parameter estimation software, packaged for estimation software, packaged for different usersdifferent users

Model EnterpriseModel Enterprise®® supply chain supply chain modeling and execution environmentmodeling and execution environment

Model CareModel Care®® business modelbusiness model

““Process Systems Enterprise Limited (PSE) is a provider of advancProcess Systems Enterprise Limited (PSE) is a provider of advanced modeled model--based based technology and services to the process industries. These technoltechnology and services to the process industries. These technologies address ogies address pressing needs in fastpressing needs in fast--growing engineering and automation market segments of growing engineering and automation market segments of the chemicals, petrochemicals, oil & gas, pulp & paper, power, fthe chemicals, petrochemicals, oil & gas, pulp & paper, power, fine chemicals, ine chemicals, food, pharmaceuticals and biotech industriesfood, pharmaceuticals and biotech industries..””


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CompaniesCompaniesIndustrial and Power AssociationIndustrial and Power Association--National Engineering National Engineering Laboratory (NEL), UKLaboratory (NEL), UK

Web:Web: http://www.ipahttp://www.ipa--scotland.org.uk/home.aspscotland.org.uk/home.asp

QuantiSciQuantiSci Limited, UKLimited, UK

Web:Web: http://http://www.quantisci.co.ukwww.quantisci.co.uk//

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CompaniesCompaniesAmerican Process Inc., AtlantaAmerican Process Inc., Atlanta, , USAUSA

Web:Web: http://http://www.americanprocess.comwww.americanprocess.com


EEnergy Targeting Using Pinch Analysinergy Targeting Using Pinch AnalysissSimulation modelingSimulation modelingLinear optimizationLinear optimizationOver 150 studies completedOver 150 studies completed


PARISPARIS™™ ((PProductionroduction AAnalysis fornalysis forRRate andate and IInventoriesnventories SStrategies)trategies)DecisionDecision--Making tool for optimizing pulp Making tool for optimizing pulp and paper mill operationsand paper mill operations))

OO--PinchPinch™™ ((OOperational perational PinchPinch))SPARTASPARTA™™ realreal--time steam and time steam and

power cost optimizerpower cost optimizerWater CloseWater Close™™ water pinchwater pinch

““Founded in 1994, American Process Inc is the premier consulting Founded in 1994, American Process Inc is the premier consulting engineering engineering specialist firm dedicated to energy cost minimization in pulp anspecialist firm dedicated to energy cost minimization in pulp and paper and other d paper and other industries. Our success is largely due to offering custom tailorindustries. Our success is largely due to offering custom tailored solutions for our ed solutions for our customers, understanding that each mill is a unique operation, tcustomers, understanding that each mill is a unique operation, thereby optimizing hereby optimizing the potential for savingsthe potential for savings””

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CompaniesCompaniesAdvanced Process Advanced Process CombinatoricsCombinatorics (APC), USA(APC), USA

Web:Web: http://http://www.combination.comwww.combination.com

Aspen Technology Inc. (Aspen Technology Inc. (AspenTechAspenTech), USA), USA

Web:Web: http://http://www.aspentech.comwww.aspentech.com and and http://http://www.hyprotech.comwww.hyprotech.com


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This is the end of Tier I. At this point, we assume that you havThis is the end of Tier I. At this point, we assume that you have e done all the reading. Some of this information might still seem done all the reading. Some of this information might still seem confusing but remember that we are still trying to set all the pconfusing but remember that we are still trying to set all the pieces ieces in the Process Integration puzzle. in the Process Integration puzzle.

Prior to advancing to Tier II, a short multiple choice quiz willPrior to advancing to Tier II, a short multiple choice quiz willfollow.follow.

End of Tier I


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QUIZ


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Where was the concept of Process Integration first developed?Where was the concept of Process Integration first developed?

Atlanta, USAAtlanta, USA

Montreal, CanadaMontreal, Canada

Guanajuato, MexicoGuanajuato, Mexico

Manchester, UKManchester, UK

Question 1Question 1

Tier I Tier I -- QuizQuiz


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1. Costs1. Costs 2. Pollution2. Pollution 3. Throughput3. Throughput

4. Energy Use4. Energy Use 5. Yield5. Yield 6. Profit6. Profit

7. Data Use7. Data Use 8. Production Volume8. Production Volume 9. Water Use9. Water Use

10. Operating Problems10. Operating Problems

1,4,6,7 and 9 ; 1,4,6,7 and 9 ; 2,3,5,8 and 102,3,5,8 and 10

3,4,5,7 and 8 ; 3,4,5,7 and 8 ; 1,2,6,9 and 101,2,6,9 and 10

2,3,6,8 and 10 ; 2,3,6,8 and 10 ; 1,4,5,7 and 91,4,5,7 and 9

1,2,4,9 and 10 ; 1,2,4,9 and 10 ; 3,5,6,7 and 83,5,6,7 and 8

Using PI techniques and methods allows you to observe different Using PI techniques and methods allows you to observe different variations variations in a process, a plant or a company. Use each one of the followinin a process, a plant or a company. Use each one of the following and g and indicate if they would be reduced or increased in a Process Inteindicate if they would be reduced or increased in a Process Integration gration context.context.



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Question 3Question 3Which of the following statements are false?Which of the following statements are false?

1.1. SteadySteady--state simulations enable the process engineer to study state simulations enable the process engineer to study strategies for startstrategies for start--up and shut downup and shut down

2.2. In the process industry, we find two levels of models: models ofIn the process industry, we find two levels of models: models of unit unit operations and plant modelsoperations and plant models

3.3. A model can represent exactly what goes on in a processA model can represent exactly what goes on in a process

4.4. Generally, dynamic simulations are used to estimate the sizes anGenerally, dynamic simulations are used to estimate the sizes and costs d costs of process unitsof process units

1 and 21 and 2

1,2 and 31,2 and 3

1 and 31 and 3

2 and 42 and 4

2 and 32 and 3

All of the aboveAll of the above

3 and 43 and 4

1,3 and 41,3 and 4



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Question 4Question 4What are plant measurements usually corrupted by?What are plant measurements usually corrupted by?

1.1. Random power supply fluctuations Random power supply fluctuations

2.2. Ambient conditionsAmbient conditions

3.3. Sensor Sensor miscalibrationmiscalibration

4.4. Computer calculation capacity and speedComputer calculation capacity and speed

5.5. Hostile process environmentHostile process environment

6.6. Sampling frequencySampling frequency

1,2 and 31,2 and 3

1,2,3 and 51,2,3 and 5

1,2 and 51,2 and 5

2 and 42 and 4

1,3 and 61,3 and 6


2,3,5 and 62,3,5 and 6

1,2,3 and 41,2,3 and 4



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Question 5Question 5What was Pinch Analysis originally conceived for?What was Pinch Analysis originally conceived for?

1.1. Oil refinery emissions reduction Oil refinery emissions reduction

2.2. Capital investment and operating costs savingsCapital investment and operating costs savings

3.3. Heat Exchanger Network designHeat Exchanger Network design

4.4. Better use of hydrogen in refineriesBetter use of hydrogen in refineries

5.5. Utility Network designUtility Network design

2 and 32 and 3

1,2,3 and 51,2,3 and 5

11

22

3 and 43 and 4


33

1,2,3 and 41,2,3 and 4



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Question 6Question 6What does an objective function represent in an optimization proWhat does an objective function represent in an optimization problem?blem?

1.1. Interactions among variables Interactions among variables

2.2. Performance criteriaPerformance criteria

3.3. ParametersParameters

4.4. Mass and energy balancesMass and energy balances

5.5. Equalities or inequalitiesEqualities or inequalities

2 and 32 and 3

1,2,3 and 51,2,3 and 5

11

22

3 and 43 and 4


33

1,2,3 and 41,2,3 and 4



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1.1. Solve problems over a long period of time, through processes sucSolve problems over a long period of time, through processes such as h as reproduction, mutation, and natural selectionreproduction, mutation, and natural selection

2.2. Each generation of the program improves upon the quality of the Each generation of the program improves upon the quality of the solution (each new generation is better than the previous one)solution (each new generation is better than the previous one)

3.3. Generate and evaluate thousands of generations in secondsGenerate and evaluate thousands of generations in seconds

2 and 32 and 3

1,2 and 31,2 and 3

11

22

1 and 21 and 2

33

The entire research area of Genetic Algorithms was inspired by DThe entire research area of Genetic Algorithms was inspired by Darwin's arwin's theory of natural selection and survival of the fittest. theory of natural selection and survival of the fittest. Unlike natural Unlike natural evolution, a Genetic Algorithm program is usually able to doevolution, a Genetic Algorithm program is usually able to do whatwhat??



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Question 8Question 8Which of the following statements are false?Which of the following statements are false?

1.1. The need for capital investment savings has led to the creation The need for capital investment savings has led to the creation of dataof data--mining techniquesmining techniques

2.2. A A ““blackblack--boxbox”” model using the plant process data directly takes the model using the plant process data directly takes the process fundamentals into account process fundamentals into account

3.3. Multivariate analysis is defined as the simultaneous analysis ofMultivariate analysis is defined as the simultaneous analysis of more more than five variablesthan five variables

4.4. Multivariate Analysis methods are used to replace the physical aMultivariate Analysis methods are used to replace the physical analysis nalysis of a process of a process

1,2 and 31,2 and 3

11

1,2 and 41,2 and 4


44

1,3 and 41,3 and 4



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Question 9Question 9With a RealWith a Real--Time Optimization system:Time Optimization system:

1.1. The process is optimized directlyThe process is optimized directly

2.2. UpUp--to date decisions on plant operations and maintenance to maximizto date decisions on plant operations and maintenance to maximize e plant profitabilityplant profitability can be madecan be made

3.3. Decisions can be made before complete information about the dataDecisions can be made before complete information about the data is is available available

4.4. It is possible to determine the economically optimal operating rIt is possible to determine the economically optimal operating regime egime for a process in the near term for a process in the near term

1,2 and 31,2 and 3

11

2,3 and 42,3 and 4


1 and 31 and 3

1,3 and 41,3 and 4



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AnswersAnswersQuestion 1Question 1 Manchester, UKManchester, UK

Question 2Question 2 1,2,4,9 and 10 ; 1,2,4,9 and 10 ; 3,5,6,7 and 83,5,6,7 and 8

Question 3Question 3 1,3 and 41,3 and 4

Question 4Question 4 1,2,3 and 51,2,3 and 5

Question 5Question 5 33






Documents

Introduction to Process Integration Tier I Integration has evolved from heat recovery methodology in the 80’s to become what a number of ... Process engineering principles and in-depth