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Role of PI for Resource Conservation Role of PI for Resource Conservation Role of PI for Resource Conservation Role of PI for Resource Conservation & Production Planning& Production Planning& Production Planning& Production Planning
Dominic C. Y. FOO, PhD, PEngProfessor of Process Design & Integration
Director, Centre of Excellence for Green TechnologiesUniversity of Nottingham Malaysia
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 2
Talk outlineTalk outlineTalk outlineTalk outline
� Process Integration (PI) for resource conservation – a historical perspective
� Some established areas for resource conservation network (RCN):�Water minimisation �Hydrogen integration�Property integration
� PI for production planning
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 3
MassMassMassMass----energy matrix of a processenergy matrix of a processenergy matrix of a processenergy matrix of a process
PROCESSING
UNITS
Feedstock
Material Utilities
(e.g. Fresh Water for
Steam, Cooling Water,
Quenching, Coal for
Power Generation, etc.)
Solvents
CatalystsMass
Products
By-Products
Effluents
Spent Materials
Mass
Heating/Cooling
PressurePower
Heating/Cooling
PressurePower
Energy
Energy
Classical textbooks for PIClassical textbooks for PIClassical textbooks for PIClassical textbooks for PI
� Smith, R. (2005). Chemical Process Design and Integration. New York: John Wiley & Sons.
� Linnhoff, B., Townsend, D. W., Boland, D., Hewitt, G. F., Thomas, B. E. A., Guy, A. R., & Marshall, R. H. (1982). A User Guide on Process Integration for the Efficient Use of Energy. Rugby: IChemE (latest edition by Ian Kemp).
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 4
Other textbooks with PI elementsOther textbooks with PI elementsOther textbooks with PI elementsOther textbooks with PI elements
� W. D. Seader, J. D. Seider & Lewin, D. R. (2003). Product & Process Design Principles, New York: John Wiley & Sons.
� Biegler, L.T., Grossman, E. I. and Westerberg, A. W. (1997). Systematic Methods of Chemical Engineering and Process Design, Prentice Hall, New Jersey.
� Sinnott, R. K. (2005). Chemical Engineering Design, Oxford: Elsevier Butterworth-Heinemann (Coulson & Richardson’s Chemical Engineering, Vol. 6).
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 5
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 6
Some important milestonesSome important milestonesSome important milestonesSome important milestones
1970s Synthesis of heat exchanger network (HEN)
1996 Hydrogen integration (hydrogen pinch)
1994 Water minimisation (water pinch)
2002 Property integration (propertypinch)
2007 Energy planning (carbon pinch)
1989 Synthesis of mass exchange network (MEN)
PI for resource conservation PI for resource conservation PI for resource conservation PI for resource conservation & waste minimisation & waste minimisation & waste minimisation & waste minimisation
Phase 1 Phase 1 Phase 1 Phase 1 –––– mass transfermass transfermass transfermass transfer----basedbasedbasedbased
Process-to-process
mass transfer
y
Excess capacity of process MSAs
Load for external MSAs
Rich composite curve
Lean composite curve
x1x2
Mass transfer pinch
∆m (kg/s)
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 8
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 9
Various water recovery schemesVarious water recovery schemesVarious water recovery schemesVarious water recovery schemes
Process 1
Process 2
Process 1
Process 2
Regeneration
Process 1
Process 2
Regeneration
Reuse
Regeneration-reuse
Regeneration-recycling
(Wang & Smith, 1994, 1995)
Process 1
Recycle
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 10
Mass transferMass transferMass transferMass transfer----based operationbased operationbased operationbased operation
Water for vessel
washing
Wastewater generated from
washing process
Vessel
Washing
Sour gas
Water
Sour water for regeneration
Sweet gasAbsorption
(Foo et al., 2006)
Fixed load problemFixed load problemFixed load problemFixed load problem
PROCESS
CPROC, in CPROC, out
CW ,out CW, in
Process
Water
F (kg)
CPROC, in
CPROC, out
CW, in
CW, out
C (ppm)Process
Water
Limiting water profile
∆m (kg/hr)
(Wang & Smith, 1994)
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 11
Limiting composite curveLimiting composite curveLimiting composite curveLimiting composite curve
2 7 37 41
C (ppm)
∆m (kg/h)
100
400
800
50
456
Process 3
Process 1
Process 2
Process 4
(Wang & Smith, 1994)18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 12
Targeting for regenerationTargeting for regenerationTargeting for regenerationTargeting for regeneration
C
Fresh water
∆m
Pinch
CPINCH = CRin
CRout
C
Fresh water
∆m
Pinch
CPINCH = CRin
CRout
Regenerated
water
Composite water
supply line
Composite water
supply line
Regenerated
water
Regeneration-reuse Regeneration-recycle
(Wang& Smith, 1994)
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 13
Targeting for regenerationTargeting for regenerationTargeting for regenerationTargeting for regenerationC
∆m
CPINCH
Composite water
supply line
Limiting composite
curve
Pinch
CRin
CRout
Fresh water
C
∆m
Limiting composite
curve
CPINCH
CRout
Composite
water supply
lineCRin
Fresh water Pinch
Regenerated
water
Regenerated
water
Final
discharge
Final
discharge
(Feng et al., 2007)
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 14
Total water networkTotal water networkTotal water networkTotal water networkWater Inflow
Water using
processes
Regeneration Effluent
Treatment
Reuse/
recycle
Plant boundary
Discharge
Reuse/recycle
(Kuo & Smith, 1998)
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 15
ProcessResourceResource in
outlet stream
j = 1 i = 1
SOURCESINK
Phase 2 Phase 2 Phase 2 Phase 2 –––– nonnonnonnon----mass transfer mass transfer mass transfer mass transfer processesprocessesprocessesprocesses
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 16
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 17
Some examples for waterSome examples for waterSome examples for waterSome examples for water----using processesusing processesusing processesusing processes
Boiler blowdownBoiler
Cooling tower make-
up waterCooling
tower
Utility make-up & blowdown
O2
NH3
C3H6
AN + H2O
C6H5NO2
Fe
H2O
C6H5NH2 +
Fe3O4
Reactant & by-product formation
Aniline production Acrylonitrile production
(Foo et al., 2006)
Refinery HRefinery HRefinery HRefinery H2222 networknetworknetworknetwork
Purge (FP, CP)Recycle (FR, CR) Fresh H2 makeup
(FM, CM)
Amine
unit
High pressure
flash separator
Liquid
hydrocarbon
feedReactor
H2S
Liquid product
Hydrogen sink
(FSK, CSK)
Hydrogen
source
(FSR, CSR)
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 18
(Alves & Towler, 2002)
Sink/source representationSink/source representationSink/source representationSink/source representation
i = 1
i = 2
i = 3
i = NSR
SOURCE
j = 1
j = 2
j = 3
j = NSK
SINK
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 19
Water source & water demand Water source & water demand Water source & water demand Water source & water demand composite curvescomposite curvescomposite curvescomposite curves
Water demands
composite
Water sources
composite
Pinch
composition
Water flowrate (kg/hr)
Composition
(ppm)
New pinch
composition
Water flowrate (kg/hr)
Composition
(ppm)
Wastewater
Minimum
fresh waterReduced
fresh water
Reduced
wastewater
Mixing of water
sources
(Dhole et al., 1996; Buehner & Rossiter, 1996)
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 20
Water surplus diagramWater surplus diagramWater surplus diagramWater surplus diagram
0.999
0.9991
0.9992
0.9993
0.9994
0.9995
0.9996
0.9997
0.9998
0.9999
1
0 50 100 150 200 250 300 350
Flowrate (t/h)
Wate
r puri
ty (
-)
Source
Demand
0.999
0.9991
0.9992
0.9993
0.9994
0.9995
0.9996
0.9997
0.9998
0.9999
1
-0.003 -0.002 -0.001 0 0.001 0.002 0.003 0.004 0.005
Water flowrate (t/h)
Wa
ter
pu
rity
(-)
5049
Water Pinch:
Purity = 0.99985 (150
ppm)
(Hallale, 2002)
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 21
Material recovery pinch diagramMaterial recovery pinch diagramMaterial recovery pinch diagramMaterial recovery pinch diagram
Impurity load
Flowrate
Minimum
waste
Maximum
recycle
Pinch
point
Sink
composite
Source
composite
Minimum
fresh
Impurity load
Flowrate
Minimum
waste
Maximum
recycle
Pinch
point
Sink
composite
Source
composite
Minimum
fresh
Impure fresh
locus
(El-Halwagi et al., 2003; Prakash & Shenoy, 2005)
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 22
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 23
An Acrylonitrile “AN” PlantAn Acrylonitrile “AN” PlantAn Acrylonitrile “AN” PlantAn Acrylonitrile “AN” Plant
Reactor
Decanter
Distillation
Column
O2
Aqueous
layer
ScrubberNH3
C3H6
Steam-jet Ejector
Steam
Wastewater to Biotreatment
Off-Gas
Condensate
Condensate
Bottoms
Water
AN to sales
6.0 kg H2O/s5.0 kg AN/s
5.1 kg H2O/s
+ Gases Tail gases to
disposal
Boiler
BFW
1.2 kg H2O/s
14 ppm NH3
0.4 kg AN/s
4.6 kg H2O/s
18 ppm NH3
4.6 kg AN/s
6.5 kg H2O/s10 ppm NH3
4.2 kg AN/s
1.0 kg H2O/s
25 ppm NH3
0.4 kg AN/s
5.5 kg H2O/s
0 ppm NH3
0.1 kg AN/s
0.7 kg H2O/s
1 ppm NH3
3.9 kg AN/s
0.3 kg H2O/s
34 ppm NH3
0.2 kg AN/s
1.2 kg H2O/s
20 ppm NH3
1.1 kg AN/s
12.0 kg H2O/s
Sink composite curveSink composite curveSink composite curveSink composite curve
Sink, SKj Fj (kg/s) Cj (ppm) mj (mg/s)
SK1 1.2 0 0SK2 5.8 10 58ΣΣΣΣj 7.0 58
Lim
itin
g m
ass
load
(mg/
s)
Flowrate (kg/s)5 10 15
50
100
150
200
250
300
SK1
SK2
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 24
Source composite curveSource composite curveSource composite curveSource composite curveSource Fi (kg/s) Ci (ppm) mi (mg/s)
SR1 0.8 0 0SR2 5.0 14 70.0SR3 5.9 25 147.5SR4 1.4 34 47.6ΣΣΣΣi 13.1 265.1
Lim
itin
g m
ass
load
(mg/
s)
Flowrate (kg/s)5 10 15
50
100
150
200
250
300
SR1
SR2
SR3
SR4
FFW = 2.1 FWW = 8.2
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 25
Refinery HRefinery HRefinery HRefinery H2222 network network network network
Fresh H2
source
Unit A
Unit B
Fuel
Recycle
310 (91%)
Recycle
490 (85%)
Purge
40 (91%)
Purge
10 (85%)
90 (99%)
110 (99%)
200 (99%)
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 26
20
40
60
0
80
100
120
200 400 600 800 1000 1200
Flowrate (MMscfd)
Impuri
ty lo
ad (M
Msc
fd)
Sink composite
curve
Pinch
1033
Fresh locus
FH = 183
FLQR = FP = 33
FREC = 817
FHQR= 467
12.0
Hydrogen pinchHydrogen pinchHydrogen pinchHydrogen pinch
SK1
SK2Source
composite curve
SR2
SR1
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 27
Property of mixture Mixing rule Operator Reference
Density,Shelley and El-Halwagi (2000)
Reid Vapor Pressure,Shelley and El-Halwagi (2000)
Material content,
Shelley and El-Halwagi (2000); El-Halwagi et al.
(2002)
Electric resistivity,Kazantzi and El-Halwagi (2004)
Viscosity, Qin et al. (2004)
Paper reflectivity,El-Halwagi et al.
(2002)
∑=i i
ix
ρρ
1
∑=i
ii RVPxRVP44.1
∑=i
ii MxM
∑=i i
i
R
x
R
1
)log()log(1
∑=
=sN
i
iix µµ
∑ ∞∞ =i
ii RxR92.5
,
( )i
iρ
ρψ1
=
( ) 44.1
iiRVPRVP =ψ
( )ii MM =ψ
( )i
iR
R1
=ψ
)log()( ii µµψ =
( ) ∑ ∞∞ =i
iii RxR92.5
,,ψ
ρ
RVP
M
R
µ
∞R
Property integrationProperty integrationProperty integrationProperty integration
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 28
Metal degreasing exampleMetal degreasing exampleMetal degreasing exampleMetal degreasing example
(Shelley & El-Halwagi, 2002)
Thermal processing, solvent
regeneration and makeup Degreasing unit Metal
finishing
To flare
To flare
Organic
additives
Degreased
metal
Absorber bottoms
(to boiler fuel)
5.0 kg/s
2.0 kg/s
Metal
Regenerated solvent
Offgas
Condensate I
(to waste disposal)
4.0 kg/s, 6 atm
Ab
sorp
tion
un
it
Condensate II
(to waste disposal)
3.0 kg/s, 2.5 atm
Fresh solvent
2.0 atm
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 29
10
0
20
30
40
50
60
70
80
2 4 6 8 10
Pro
per
ty lo
ad (k
g.at
m1.
44/s)
Flowrate (kg/s)
1 3 5 7 9FFS = 2.4
Fresh locus
9.4
FWS = 2.4
Pinch
Source composite
curve
Sink composite
curve
SR2SK1
SK2
SR1
27.1
6.5
17.7
70.5
Property pinch analysisProperty pinch analysisProperty pinch analysisProperty pinch analysis
5.418 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 30
Material regenerationMaterial regenerationMaterial regenerationMaterial regeneration
i = 1
i = 2
i = 3
SOURCE
j = 1
j = 2
j = 3
j = NSK
SINK
Interception
i = NSR
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 31
Material recovery pinch diagramMaterial recovery pinch diagramMaterial recovery pinch diagramMaterial recovery pinch diagramImpurity load
Flowrate
Minimum
waste
Maximum
recycle
Pinch
point
Sink
composite
Source
composite
Minimum
fresh
Impure fresh
locus
FR
FRRegeneration
(El-Halwagi, 2006)
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 32
Water source compositeWater source compositeWater source compositeWater source composite
Bandyopadhyay & Cormos (2008)
∆∆∆∆m (kg/h)
C (ppm)
Source composite
curve
Wastewater
line
Treatment
pinch point
Pivot
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 33
Ultimate flowrate Ultimate flowrate Ultimate flowrate Ultimate flowrate targetingtargetingtargetingtargeting
Assumptions: Fixed outlet concentration (Cout)
Source(s) is shifted to the FWR from highest
Cj until ΣjFj = ΣiFi in the RWR
Set regeneration concentration, Cout
Preliminary allocation – water sinks/sources are separated
into FWR (Ci ,Cj < Cout) and RWR (Ci ,Cj > Cout)
RWR
ΣjFj > ΣiFi
NO
YES
Sink(s) is shifted to the FWR from lowest Cj until
ΣjFj = ΣiFi in the RWR
Additional sink (Fj, A) and source flowrate (Fi, A) are
shifted to the FWR, calculated based on:
Fj Cj = Fi, A (Ci, A – Cj, A)
Ultimate flowrate targets
START
All SKj in the FWR with
Cj = 0 ppm?
YES
NO
END
Determine FFW and FWW in FWR
Total FRW = FRW, FWR + FRW, RWR
FRW, FWR is added at Cout in FWR
Calculate FRW, FWR = ((Fj × Cj)/ CF)
ΣiFi (with Ci higher than
Cout) ≤ FRW, FWR
(Ng et al., 2007a)
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 34
Fresh resource
Resource-
consuming
processes
Interception Waste
treatment
Direct
reuse/
recycle
Plant boundary
Waste discharge
Reuse/recycle
Total material networkTotal material networkTotal material networkTotal material network
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 35
Total material networkTotal material networkTotal material networkTotal material network
18 - 20 March 2013 International PI Jubilee Conference, Sweden Water pinch
NO
YES
Targeting for wastewater treatment
END
Targeting for water
regeneration
Targeting for water
reuse/recycle
Identification of wastewater streams
START
Further flowrate reduction?
(Ng et al., 2007c)
Distribution of papersDistribution of papersDistribution of papersDistribution of papers
(Foo, 2009)
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 37
Main approaches in PIMain approaches in PIMain approaches in PIMain approaches in PI
PROCESS
INTEGRATION (PI)1970s
Insight-based
(pinch analysis)
Mathematic
programming
Combined thermodynamic & mathematical
programming methods1990s
1980s
(Smith, 2000)
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 38
Material cascade Load cascade
δ0 = FR
ε1 = 0q1 Σi FSRi, 1 k = 1 Σj FSKj, 1
δ1 k = 1q2 Σi FSRi, 2 k = 2 Σj FSKj, 2 ε2
δ2 k = 2
ε3
δk-1
qk Σi FSRi, k k Σj FSKj, k εk
δk k
qk+1 Σi FSRi, k+1 k + 1 Σj FSKj, k+1 εk+1
δk+1
δn-2
qn-1 Σi FSRi, n-1 k = n–1 Σj FSKj, n-1 εn-1
k = n–1qn δn-1 = FD εn
Automated targeting model (ATM)Automated targeting model (ATM)Automated targeting model (ATM)Automated targeting model (ATM)for reuse/recyclefor reuse/recyclefor reuse/recyclefor reuse/recycle
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 39
(Ng et al., 2009a)
18 - 20 March 2013
Material cascade Load cascade
δ0 = FR
ε1 = 0q1 Σi FSRi, 1 k = 1 Σj FSKj, 1
δ1 k = 1
q2 Σi FSRi, 2 k = 2 Σj FSKj, 2 ε2
δ2 k = 2
qRout FREG k = 3 ε3
δ3 k = 3
ε4
δk-1
qk Σi FSRi, k k Σj FSKj, k + FRE, r =1 εk
δk k
qk+1 Σi FSRi, k+1 k + 1 Σi FSKj, k+1 + FRE, r =2 εk+1
δk+1
δn-2
qn-1 Σi FSRi, n-1 k = n–1 Σi FSKj, n-1 + FRE, r=RG εn-1
k = n–1
qn δn-1 = FD εn
Automated targeting model (ATM)Automated targeting model (ATM)Automated targeting model (ATM)Automated targeting model (ATM)for material regenerationfor material regenerationfor material regenerationfor material regeneration
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 40
(Ng et al., 2009b)
Other variants…Other variants…Other variants…Other variants…
• Inter-plant/total site integration• Batch processes
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 42
Plant C
Process 1
Process 2
Regeneration
Treatment
Plant AProcess 1
Process 2
Process 3Treatment
Regeneration
Plant B
Process 1
Regeneration Process 3 Treatment
Pre-treatment
Process 2
InterInterInterInter----plant RCNsplant RCNsplant RCNsplant RCNs
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 43
SR6100
(100)
50
(50)
70
(150)
60
(250)
SK6
100 (50)
SK5
50 (20)
SK7
80 (100)
Network B
SK8
70 (200)
20 30
35 65
FFW65
(0) 30 35
35
15 (100)
SR5
100
(100)
20
(100)
40
(800)
SK2
100 (50)
SK1
20 (0)
SK3
40 (50)
FFW90
(0)
Network A
20
5
50
45 20
SK4
10 (400)
10
(800)
10
5.71
4.29
20
SR2
SR1
29.29
35.71
SR3
SR4
SR8
SR7
35 25
35
Direct integration schemeDirect integration schemeDirect integration schemeDirect integration scheme
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 44
Network A
8.57 11.43
2.38
33.33
74.29
71.43 28.57
SR2
SR3
SR4
SR1
10
(800)
40
(800)
100
(100)
20
(100)
SK2
100 (50)
SK1
20 (0)
SK3
40 (50)
20 (0)
20
SK4
10 (400)
5.71
4.29
Interception unit
FRW = 169.05
CRout = 30
SR6100
(100)
50
(50)
SR770
(150)
SR860
(250)
SK6
100 (50)
SK5
50 (20)
SK7
80 (100)
Network B
SK8
70 (200)
SR550
14.29 80
16.67 (0)
35
20.71
5.71
33.33 35.71
35
35
Wastewater treatment
FT = 12.25
RR = 0.95
4.290.13
12.38
FBP =
4.42
FW
F = 36.67 (0)
CUF
FWW =
16.67 (100)
Indirect integration with utility hubIndirect integration with utility hubIndirect integration with utility hubIndirect integration with utility hub
Batch process integrationBatch process integrationBatch process integrationBatch process integration
Waste discharge
Fresh resource
Fresh resource
Waste discharge
t1 t2 t3 t4 t5 t6
Process 1 Process 2
Time
(Sink) (Source)
(Sink)
(Source)
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 45
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 46
0 0.5 1.0 1.5
Time (h)
SK2 / SR2
SK1 / SR1
SK3 / SR3
ΣΣΣΣt FR, t =
102.5 (0)
40 (0)
ST
ΣΣΣΣt FW, t =
102.5
50 (0)
12.5 (0)
12.5
(200)
25 (200)
50 (200)
25 (200)
100 (400)
37.5
(200)
25 (200)
25 (200)
Direct reuse/recycle networkDirect reuse/recycle networkDirect reuse/recycle networkDirect reuse/recycle network
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 47
0 0.5 1.0 1.5
Time (h)
SK2 / SR2
SK1 / SR1
SK3 / SR3
FFW =
40 (0)
ST
FWW =
40 (50)
22.22
(200)
22.22
(200)
30.56
(400)30.56
(200)
9.44
(200)
2.78 (200)
RW
41.67
(400)
13.89
(20)
55.56
(20)
8.33
(200)
WWT
ST
27.78
(400)
6.67
(200)
2.77 (20) 8.33 (20) 22.22 (20)
Batch total networkBatch total networkBatch total networkBatch total network
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 48
The extended onion diagramThe extended onion diagramThe extended onion diagramThe extended onion diagram
(Foo & Ng, 2013)
Reactor
Primary Separation
System
Material Recovery
System
Heat Recovery
System
Energy Utility
System
Effluent Treatment
System
Recommended textsRecommended textsRecommended textsRecommended texts
� El-Halwagi, M. M. (2006). Process Integration, Elsevier, Amsterdam.
� Foo, D. C. Y. (2012). Process Integration for Resource Conservation, CRC Press.
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 49
PI for Production PlanningPI for Production PlanningPI for Production PlanningPI for Production Planning
• Supply chain analysis• Equipment planning
• Human resources
Production supply chain planningProduction supply chain planningProduction supply chain planningProduction supply chain planning
Time period, t
MonthPredicted
demand (units)Cumulative
demand (units)
1 January 1600 1600
2 February 3000 4600
3 March 3200 7800
4 April 5060 12860
5 May 1760 14620
6 June 1760 16380
(Singhvi et al., 2004)
18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 51
Supply chain pinchSupply chain pinchSupply chain pinchSupply chain pinch
2000 4000 6000 12000 14000 160008000 10000 180000
1
2
3
4
5
6
Tim
e (m
onth
)
Quantity (units)
1600
4600
7800
12860
14620
16380
Pinch
18790
20000Starting inventory: 1000
1000
Ending inventory: 2410
16880
500
unit/month _______Slope
1 Production == 2965
unit/month _______Production = 2010
(Singhvi & Shenoy, 2002; Singhvi et al., 2004)
18 - 20 March 2013 International PI Jubilee Conference, Sweden
Equipment planningEquipment planningEquipment planningEquipment planning
(Foo et al., 2007)
Product Machine-days tEND ∆t (days) tSTART
1 200 Day 20 20 Day 0
2 300 Day 20 10 Day 10
3 100 Day 40 30 Day 10
4 300 Day 50 30 Day 20
PI - 53
Equipment planning pinch Equipment planning pinch Equipment planning pinch Equipment planning pinch
100 200 300 600 700 800400 500 9000
10
20
30
40
50
Day
Reactor-days
Product 4
Product 3
Product 2Product 1
33.7
Pinch
____________Slope
1 reactor of No == 27 (~26.7)
Operation completed
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(Foo et al., 2007)
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Human resource planningHuman resource planningHuman resource planningHuman resource planning� A project consists of 4 tasks is to be completed by an
engineer in a consulting company within a span of 3 weeks. � The engineer cannot start working on the project until June
7th. � Task: to identify if the engineer will be able to deliver the
given tasks on time, and if not, to determine how the work bottleneck can be dealt with.
Task tEND ∆t (days)
1 9 June 4
2 14 June 4
3 18 June 6
4 25 June 3
Human resource pinchHuman resource pinchHuman resource pinchHuman resource pinch
Extra work days needed
Excess work days
Pinch(June 18th, Friday)
Source composite curve
Sink composite curve
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Human resource planningHuman resource planningHuman resource planningHuman resource planning
Pinch (June 18th Friday)
Time pocket
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Integration between engineersIntegration between engineersIntegration between engineersIntegration between engineers
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The similarities among all problemsThe similarities among all problemsThe similarities among all problemsThe similarities among all problems
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Quantity Quality Examples/ProblemsReferences
Heat TemperatureHeat exchange networkHeat integration
Linnhoff et al. (1984)Smith (1995, 2006)
Mass Concentration
Mass exchange network
Water minimisationRefinery hydrogen network
El-Halwagi and Manousiouthakis (1989)Wang and Smith (1994)Towler et al. (1996)
Mass Properties Property-based RCNs Kazantzi and El-Halwagi (2005)Steam Pressure Cogeneration Dhole and Linnhoff (1993)
Energy CO2Carbon-constrained energy planning
Tan and Foo (2007)
Mass Time Supply chain management Singhvi and Shenoy (2002)
Time Time
Process scheduling Human resource planning
Foo et al. (2007)Foo et al. (2010)
Energy Time Isolated power system Arun et al. (2007)
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Concluding remarksConcluding remarksConcluding remarksConcluding remarks
AcknowledgementsAcknowledgementsAcknowledgementsAcknowledgements� Prof Raymond Tan, De La Salle University-Manila, Philippines � Prof Mahmoud M. El-Halwagi, Texas A&M University, US� Prof Cheng-Liang Chen, National Taiwan University, Taiwan� Prof Feng Xiao, Xi’an Jiaotong University /China University of Petroleum-
Beijing, China� Prof Thokozani Majozi, University of Pretoria, South Africa � Prof Santanu Bandyopadhyay, India Institute of Technology, India� Prof Jiří Klemeš, University of Pannonia, Hungary� Prof Jacek M. Jeżowski, Rzeszow University of Technology, Poland � Prof Paul Stuart, École Polytechnique, Montreal, Canada� Dr Denny Ng, UNMC� Dr Irene M. L. Chew, Monash University Sunway Campus, Malaysia� Dr Chun Deng, China University of Petroleum-Beijing� Dr Alberto Alva-Argaez, CANMET, Canada� Dr Nick Hallale, Shell UK� Yin Ling Tan, Curtin University of Technology Sarawak Campus, Malaysia
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