ABSTRACT
'lbi. pdper high,:ghls \ome ol rhe key recen advdnces in researcr relared Lo Pioch ,q.nalr'sr'. o,nicu'orlv 'l'oie de\eloped rr he Deparrmer- of Chemicar Eng neencg' U n ; , e n r i i i e l o o l o g i V a l a ) s i r ' l h e ' o ' L S s o r t h e d e v e l o p n e n t o l s ) s l e o ' a r r c c o n c e o n a l , . a n " r . ' . u . d e s r m a n d ' e r o f i ' t e c h n i q L e ' i o ' e l f i c i e l r h e a r ' m < r < ' a r d { r l e r " e c o r e p : ' ; " ; ; ; ; ; ; ; ; ; * ; ; " " ' * i n l h e a - e a h a s a l s o c o n c e n r ' j r e d o r r n e u ' e o r math€matical Pro$amming
Keywords: Pinch Analvsis' MATRX, Hea!MATRIX, WATER-NIATRIX' Water Cascad€ Analysis,
Proceedings of the l8th SvmPosilm ofMalavsian Chdical E!8rnee's
NEW ADVANCES IN PROCESS
INTEGRATION
RESEARCH
Zainddin Abdul Manan
Facultr' of Chemical Engineering and Natunl Resources Engineerrng' Uiiversiti Teknologi Mataysia' 813I0 Skrdai, Johor'
Tel: +607-55355 12, Iax: +607-5581463' E-maili zain@fkkksa utm mY
1 INTRODUCTION
T h e c u . r e n ' d r ' r e r o * a r d s e D r o ' l n e o L a l s L s l a L n d b i l r r j a n d rh e n ' L n g c o ' ! s o f f u e l 3 n d $,j,er hrve ercoLrageo Il e proce* indt "Ey ro fnd neu wa)s ro reduce energi ino warer ;;;;!tio;. v..l-i'i"g enersv and water recovery and reuse can. minimise^
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2 THE NEW MATRIX TECHNIQUE
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" v . I e m r r c L e c h . ] ; q u e a i m e o a r r e d ! ' c _ r g
l h e b o r a n d c o ' d r r i l i q c o n ' u m o r o n L h . o . . L p r r ' h e , e t a n p o t e ' ( i ' l i n g h e r r e i c l " a n g e r n e M o d ( i n d c l e n r c a l
;;;.tui;;J"i";; rhe ieclurique has been utiliz€d for the retro{it of a palm oil ..i-." -',i'" o*l',i'. re.ult' rirs neq rechnique '1ich s c'lled N"l'{TRx r M A x i m i , r r s - b e T o r a l a r e a R e u ' e l n a n e X i ' l i n g n e h ' o r k ) i 5 fo c u s e d a n d r e o L r r e c m u c n iess diasnosis effon. IVIATRL\ combine' rhermodlramic insigf'' ald grap car approaco rc s rste"mancallr surde trse" lo explo'e a.' pos''De hear e\charge ralch oplron' Jno ; ; ' ; : ; ' i ; ; ; ; ' , . ' 0 . " * ' i n g o n e T h ' c e c h n i q J e c o n s s t s o r - ! h ' € + 5 r a g e s : M d l ' h l den,ilj.at o\ t4 Ln h S, "eening and Ve^ oI k I \ nl\ ton lu the March ldentrlr' arron srage' a ne,.ri eanhiial visualisation mol ca1led the Excrgv Block Diagram (EBD) is proposed to
Pioceedjrgs of the I 8th Symposium of Malayslan Chemical E gineeB
identify all possible heat exchanger. N€xt, a systematic screening techdque catled rhe Mdtch Mdtrte (M-Matix) is proposed ro sorr and filrer out th€ undesirable match oprions identified from the EBD. The fina1 srage of retrofir is network evolurion rhai invoives a syslematic loop and path optimisarion tecbnique to generate the fina1 rerrofit scheme. A case study on a iocal palm oil refinery was used io d€monstrate the advaniage of this approach for lhe retrofit ofexisting hea! exchanger neiwork. Economic analysis conducted showed projected ulility savings of more than tuV 80,000 (65 %) in hox utitib' and RM 25,000 (48%) in cold utili4/. An investment of RM 44,000 in heat r'ansfer area was required to realise these savings. The minimal sirudural modifications lead ro rhe small capitat investment and hence, a very aftractive pay back period of about 5 months.
3 MASS EXCHANCE Nf,TWORK
Synthesis of optimal MEN for continuous pfocesses based on pinch Anaiysis has been rather well estabiished. In contrast, very iittle work has been don€ on mass exchanqe n e N o k . v n r , e s r s
' M T \ S r f o r b , i r c h p r o c e s . 5 ) c r e n 1 . . t e c h n r q u e s d e v e t o p e d r o r b e MENS for batch systems involved the following vo key steps: 1_ Serting MEN design ta.rgets ahead of design thai inciude the utiliry and rhe nlmb€r of units targets; 2. MEN design to achieve the design targets. Urillry iargeting employs rhe verical and horizontal cascadmg approaches that have beer adapted ftom heat exchange netwo.k synihesis (HENS) for batch processes. Prior to MEN design, the iargering procedure establishes rhe minimum utility (solvent) requirement for maximum mass recovery G\,IMR), ma{imrun mass exchange (MNIXJ and maximum mass srorage (MMS). These targets are essential for network design and batch process rescheduUng. A sysiemaiic procedue for MEN design for barch processes, which include the new graphical toots called rhe tim€-qid d i a g a m r I G D , r , d o\er-l rime-gr d d i a g r a n t O t C D l f a r e b e e n r n r o d u c e d r o atio* designers to achieve the uiility rargets established for rhe MEN. The minimum number of mass erchange units target has also been developed to provide a lower bound for lhe number of units for a prelininary batch MEN. Finally a technique to evolve the balch MEN has been developed based on the conventional approach ftom &e conrinuous MEN
cleslg!-.I WATER MINIMISATION
The development of syslematic teclniques for water reduction, reuse and recycling within a process plant has seen extensive progess. The advenr of Water pinch Analysis (WpA) as a tool for the design of optimal water r€covery network has been one of the most significani advances in th€ area ofwater minimization over rhe lasr ten years (Ujang et al, 2002). A numerical method to establish the minimum water target for applicatjons beyond mass transfer based .lvater-using processes is however unavailable. The Water Cascade Anaiysis (WCA) described in the following section has been very have recenrty developed by our group to fi]t m rhis r€search gap_
4.1 THE WATER CASCADE ANALYSIS (WCA) TECHNIQUE
Proceedings olthe 18th SvDposium of Malavsia! Chmical Eng]!ee6
r e d u c , i o n d e r e l o p e d o ) ' f e P r o c e $ \ ) r e n s E . p o e e f i D e C ' r o t o . D e p a f t r e l r o f t b e n i c a l Engineering, Universiti Teknologi Malaysia (Manan et aI,2003)
4.? WATER MnIIMISATION ON A LOCAr PAPER MILL PLANT
The manufactur€ ofpulp and paper is a waler intensive industry' Due to th€ increase in the oii"" of pto"".. lvut".. ttte industy is under regulatory pressure to reduce ihe ft€sh waier "u."n". I. ti"t of this problem, a research to minimise the water consumpiion on an exis'tine paper mill was calried out. Process integrahon methodology such as water Pinch i * - o - r i c v w a ' a o p l i e d - o ' c r u r r i ' e r n e e n e ; r ; ' e r e . ' o f h e e \ i s l r g w a L e r n e n v o r L a n d
4 . " " 1
' i ! o p p " n " " i * " f o r G e s h q arer r e d L c h o r . ft e M d d ) ri a n \e q 'Drilr Tndu'me' o u o " . r , i t r p , r n , " ^ ' . . c r e d d - \ e c l s e s L d v i o r r f e r e ' e a r c b l h e ' 1 d ) i n \ o l v e s I u o # . ; ; ; " ; . . i e . f r e s \ q a e . a r g e ' n s b r d $ a r e r le r w o r r d e ' ; s n - o e ' r a o l i s h ' f e m n i m u r w a t e r _ a r g e l ' l l - e ll e a r \4 A r R l t r s o i r $ a r e w l ' r c b i m p l e - l e n l s _ l e nes sare'
"as"ua" -atysit t""tdq"e developed
by the PSE goup in UTM as used in conjunction *iin ,1" *."oftl""l t""tttiiques of aomposiie cun'es and water surplus diagam Targeting was folloired by the rlesign of a water dislribution network to acheve the minimum water iarqets. The d;sign technique based on water source and war€r demand approach was i . i " " . . " o . F r o m , , r e e . e a r c r L o n d u c . e d . a t o a l r e d u ' r ' o E o f l o o J ' o o f f r e ' h u a r e r . " ; , " r 0 ' . " " l o r - h e n x l l $ J . i d e 1 , i f i e d a n d s o n e m i r o r m o d r l c a t i o n ' o r r t e i d r e f
" . * " . f . " . n g " t r , i o . o r h e p . r p e r
n i l l w e r e D t o p o ' e o \ \ rb _be r m p r e n e n u l i o n o f r h i ' * u r . , n . - o t f ' l t r , . p u p . t " n i ' c " ! p o l e r r i a l l a c h e \ e a n a n n r ' i l i r e ' h h a ' e r c o " l ' a i i r g s ofRM 118400 which include th€ pumping costs, ihe chemical cosis and other raw water
4.3 SIMULTANEOUS ENERGY AND WATER REDUCTIONS
Water and energy are both used in siglificart quantities in process industdes -Even thoush the proc;ure for the optimal design of a water minimisation netivork and that of . n . . i - . . o ' . n r e $ o r k n . r { e b e e c v e D w e l l e s r d b l i r ' e o r h e a v a i l a b l e r e c b n i c u e " - o . " . # " .
' r . n e ' w o r r r o i e , : ' r n d w d ' e f J'Lem' nen ioled abo\e are "rill larcelv iid"pendent *d
"ignifi"nttly lacking in tems oftheir abilitv to capitalize on the s)'nerg'/ t'e#een one ano$ir. Based on ihese independent techniques, rcduction of energv does not suarantee the minimum of wat€| usag€ ln process indusaies and vic€ versa'
1 new systematic technique that minimizes water and €nergv consumption of a water-using netlvork simultaneouslv is undergoing development - in UTM Thermodl,namic hsights and graphical approach were used !o assist designeN m ,lesi,4ins a new watei-using neiwork in order to get minimum utiliry consumpiions under o o , ' i r r r r l o p . t , ' n g c o r d r i o n s A r o n g f e a t u t e " a p l o ( o f e m p e r a n i e v e r c u 5 ' t r e a m s
i " " i , " , '.** ,, u & t Lompo' Ie ( Lwe. . hd'r ' o \ e s a p F r c a l , o o . d e v e l o D e d ' n ,fri" t*"*"n to guid€ water and energy minimisation simultaneoustv The 'W&E ComDosite Curves; provided key information on the state of a wal€r_using nerwork and atto*"a r'ute"u.iog o"t*ork design to be canied ou! graphically and hence efectively
4.4 HEAT-MATRIX, WATER-MATRIX AND MA.XII4UM WATER RICOVERY FOR URBAN SYSTEMS
H e a F \ 4 A l R I X u d L e r \ 4 A T R l \ a r e s o t q a r e m o d t l e ( f o ' \ \
' e r "no er er$ co1'en a ion ;at is founded on th€ techniqr.e and principtes ofPl'c'h ''na1l'r;s' which is an esiablished
. o o l "or tre oe.ign a n d re r o f i l ,i r p l o . e r e n , o r o D t i n a fe a t r ' i ( a r d w ' r ' e r | e ( o \ e r y networks in industry lo achieve maximum energy as well as mass efficiency
To faciliiale the design and improvement ofnew as well as exisling plants, we have inteprated and jncorporated the faditional Pinch Analysis tecbniques and the laiest ae, iLoornen , in Lle area ol hea., ra . rnd wa,er teco\eq inro HPdr- lZ4 fR7( a conDu el ' o \ d r e d e v e ' o p e d i n L '"1. Hcat'lAtRJY har oeen ra loreo 'or rhe reuoFl , r m o l o \ e m e n r J o f n e a ' .! d s a l e r r e c o v e r y r e $ o r ! r o r e d t c e e r e r g ) 3 n d w a l e r rn c h e m ; c a l D r o c e s ' o d n < I } e s o f u a r e i n p e n e n r ' r' e e \ l a o l 5 f e d p n r c i p l e ' o f H e a r d n d W a e r " i n c h q n a i i " i ' t o a o e t p o n r . a 1 d rl e r e w r Z 4 T n ' l l t e c h n i ' J e f o r t b e r€ r o l I (improvemenr) ol existing processes to reduce the hot and cold uliliiy usage Th€
P.oceedings olthe 18ft Symposium ofMalayslan Chemical Engireers
,iulrR f technique is a new methodology thai is aimed at improving heat recovery by .4/,4ximising the Toial Reuse of the e,{isting heat recovery net\{'ork area fiU4TRA).
It is a Microsoft Windows,based progranme that was dev€loped io automate. and rapidly as well as efficienily assist the design and retrofd of a hear recovery network. It also enables the rapid determination of the minimum energy and water requirements for a process, and the improvement of heat recovery network structure for a prccess plant to achieve the minirnum hot and cold utility consumption. In addition, g€dr,rv47,4,/f can also automatically gererate the optimal urilily combinarion for a given process and aliow th€ automatic and semi-automalic design of heal exchanger network to achieve lhe energy targets. Due to irs capability to examine a wide vadery of heat exchanger match possibilities, and the inclusion ofthe capital and operaring costs during network evolution, the software offeN an attractive, pmctical and cost-effective altemative solurion for heat recovery nerwork retrcfi t,
Il/dter Pinch,4ralrrrr (WPA), in particular, considers ihe potential of ma-rimising water rcuse for various process operations io ninimise freshwat€r consumption and wastewatei generation. One ofthe key c.iteria to enable water recycling is that there nust be a driving forc€ for mass transfer. It follows that the maximum warer recovery (i.e. the wai€r recovery bottleneck , or the 'water rcca\rery prrc, ") occnrs at the smalles! practical driving force for rnass transfer.
Until today, the applicafioa of Pinch Analysis is perceived to exclusively belong to the process engmeenng domain. This project p.oposes a potenrial shift in the global traditional process engineering paradigm related to water and energy savings to allow Pinch Ahdlysis applicarian to be extended beyond the frontiers of process indusrry; into ihe domain of public and domestic buildings for the purpose of maximising water
Water-MATRIX feanles the said paradigm shift and four of our laies! key innovations in the area ofwater minimisation using Pinch Analysis.
. the desigrr and improvem€nt of water network srrudurc to achieve the baselln€ water consumptiol targets for urban v)ater rystems
. rapid dereinination ofth€ minimum walef requirements using rhe n€w water cascade analysis technique
. the establishment of savings and investmenr targets pdor io network reirofir omprovemefl)
. mpid determinarion of the midmurn utility targets for simuhaneous water and energy reductlon through ihe new heat surplus diagram
Water-MATRIX procedrre begins the €stablishment of rhe baseline minimum rvater consumption target prior to the design of a water network through rhe use of our new water cascade analysis technique. It also aisists the gen€mtion of energy rargets for the ma\rmum water recovery network through our new heai surplus diagi3m. Next, Warer, MATRIX automatically genemtes the maximum warer recovery network to achieve the baseline water target- For retrofit cases. water-I[ATRIX forecasts a cosfeffective network revamp tirough the esrablishment of economic targets ria our new feasible revamp region as well as payback period veni$ fteshwater savings curves.
Application ofWater-L4-{TRIX on a mosque yields potential maximurn reductions of 85.5% fresh water and 67.7% wasiewarer respecrively (afier rcgeneration). Applicaiion fbr reaofit of a papef mill predicts a potential savings of44.4% fresh water consumprion and 80.5% wastewater generatioq which corresponds to a toral saving of RM 4.9 miUior,/year.
5 CONCLUSION
W a . e - a n d e r e $ are rbe No ro:r colnj'1on u d l i r , e . a n d ,h e n"ain o p e r r . i n g c o 5 r s i r a chemical process plant. Steam, vhich is used for utiliry heating is the most common form of energy suppLy in a process that is produced by buming tuel. With the increase in water and firel prices, chemical process plants are under p.essure ro improve rhet profix margin or face possible closure ofpLants.
Proceedirys ofthe 18tb Svmposium ofMalavsia! Chemical En8lnee6
heat recovery, a technique named MATNX that is capable of considering a wide range of elsrins oesiao coqsuainrj has been -ntroouced for 'be rerolll ol]ear reco\ery net\ ork w o t l i
- a i * u l
r o d e v e l o p n e u v i s u a l i r a r i o n I o o l ' L o a s s s t r h e ' i ' n u l l a n e o L s r e d u c l i o r ofenerer aod waier in proce's olatrls lo th.s worl a'ocal paper mill l"as beer used as a ;;; t;;, nre aevilopneni of ')nemaric nerhod' for lhe svure'r' or baLch Fras' erchanse retwork s)\lens hrs al'o beer one our receoL main focu' areas Fina lv d new numeriial recruriqui fof esBblirhrng he .!in mum warer and wasLewarer 'argels s lhe most recent tecbnique we have ittroduced in Pinch Anaiysis Most of these recent J.'.r"Dln*,' f,,'. t.." 'uccesciull) 'ncoTorared in Heat WTRD aad Wat?frWrRlY
't'. p l.rl q"rrvs' 'oFware deveioped bv rhe Pfoce*
\vsrem' Frsheering Gtoup' D e p . : . o r e r r o f f h e m , c a l F a g r n e e r n g . U . 1 e r s i l e k n o ' o g i \ 4 a l a ! ' i a
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