61
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, PEng Professor of Process Design & Integration Director, Centre of Excellence for Green Technologies University of Nottingham Malaysia

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Page 1: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 2: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 3: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 4: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 5: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

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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)

Page 7: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

PI for resource conservation PI for resource conservation PI for resource conservation PI for resource conservation & waste minimisation & waste minimisation & waste minimisation & waste minimisation

Page 8: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 9: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 10: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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)

Page 11: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 12: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 13: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 14: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 15: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 16: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

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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)

Page 18: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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)

Page 19: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 20: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 21: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 22: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 23: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 24: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 25: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 26: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 27: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 28: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

ρψ1

=

( ) 44.1

iiRVPRVP =ψ

( )ii MM =ψ

( )i

iR

R1

)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

Page 29: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 30: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 31: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 32: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 33: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 34: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 35: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 36: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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)

Page 37: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

Distribution of papersDistribution of papersDistribution of papersDistribution of papers

(Foo, 2009)

18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 37

Page 38: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 39: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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)

Page 40: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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)

Page 41: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

Other variants…Other variants…Other variants…Other variants…

• Inter-plant/total site integration• Batch processes

Page 42: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 43: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

Page 44: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

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

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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

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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

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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

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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

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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

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PI for Production PlanningPI for Production PlanningPI for Production PlanningPI for Production Planning

• Supply chain analysis• Equipment planning

• Human resources

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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

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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)

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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

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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

18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 54

(Foo et al., 2007)

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18 - 20 March 2013 International PI Jubilee Conference, Sweden Lecture 2 - 55

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

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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

18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 56

Page 57: (Microsoft PowerPoint - PI for RCN & PP [Kompatibilitetsl\344ge])

Human resource planningHuman resource planningHuman resource planningHuman resource planning

Pinch (June 18th Friday)

Time pocket

18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 57

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Integration between engineersIntegration between engineersIntegration between engineersIntegration between engineers

18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 58

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The similarities among all problemsThe similarities among all problemsThe similarities among all problemsThe similarities among all problems

18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 59

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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18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 60

Concluding remarksConcluding remarksConcluding remarksConcluding remarks

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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

18 - 20 March 2013 International PI Jubilee Conference, Sweden PI - 61