!"#$%&'(#!

%" #%
*$%(+,, !"#+-$.#!%"
Slu Shawalllah ldrls, AMlChemL
laculLy of Chemlcal Lnglneerlng
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*$%(+,, !"#+-$.#!%"
WPA1 ?
WP? ?
PCW ?
WPLn?
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*$%(+,, !"#+-$.#!%"
Slmple concepL of lnLegrauon:
- WasLe heaL recovery

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3
*$%(+,, !"#+-$.#!%"
lmporLanL lmporLanL branch of process englneerlng.
lnluaLed ln Lhe laLe 1970's by 8odo Llnnho ( a hu sLudenL
under supervlslon of ur. !ohn llower (unlverslLy of Leeds)
lL refers Lo Lhe sysLem-orlenLed, Lhermodynamlcs-based,
lnLegraLed !""#$!%&'( Lo Lhe !*!+,(-(. (,*/&'(-( !*0 #'/#$1/
$2 "#$%'(( "+!*/(3
4!-* 5$!+( :
LmclenL use of maLerlals and energy
Mlnlmlzauon of emlsslons and wasLes generauons
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/.,!( (%"(+*# %0 *$%(+,,
&+,!-"
rocess deslgn sLarLs wlLh reacLor
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8eacLor
leed leed and roducL
8eacLor
SLA8A1C8
/.,!( (%"(+*# %0 *$%(+,,
&+,!-"
nexL - separauon sysLem
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8eacLor
leed
leed
and
roducL
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roducL
8LAC1C8
PLA1
LxCPAnCL8
nL1WC8k
SLA8A1C8
/.,!( (%"(+*# %0 *$%(+,,
&+,!-"
Cnce we know reacLor and separaLor deslgn,
we know maLerlal and energy balance
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8eacLor
leed
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and
roducL
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8LAC1C8
PeaL Lxchanger
neLwork
P
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u1lLl1lLS
PLA1
LxCPAnCL8
nL1WC8k
SLA8A1C8
/.,!( (%"(+*# %0 *$%(+,,
&+,!-"
Cnce process and PLn ln place ! u1lLl1lLS
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8LAC1C8
8eacL
or
leed
leed
and
rodu
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roducL
P
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PC1 u1lLl1lLS
CCLu u1lLl1lLS
/.,!( (%"(+*# %0 *$%(+,,
&+,!-"
u1lLl1lLS
PLA1
LxCPAnCL8
nL1WC8k
SLA8A1C8
8LAC1C8
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1PL 'CnlCn' ulAC8AM
/.,!( (%"(+*# %0 *$%(+,,
&+,!-"
8ase Case ueslgn
Lnergy exLenslve equlpmenL
PeaL Lxchanger
uullues requlred
PoL uullues - sLeam, hoL medla
Cold uullues- coollng waLer, refrlgeranL
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WPA1 ll ...
lncrease energy emclency
8educe emlsslons and wasLe
Save CaplLals
/.,!( (%"(+*# %0 *$%(+,,
&+,!-"
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lnCP 1LCPnCLCC?
SysLemauc approaches..
lnCP 1LCPnCLCC?
MlnL & MlL
Super Largeung
rocess Craph 1heory
*!"(1 #+(1"%2%-3
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Introduction
1
1.1 What is pinch analysis?
Figure 1.1(a) shows an outline flowsheet representing a traditional des
ign for the
front end of a specialty chemicals process. Six heat transfer units (i.e. heaters,
coolers and exchangers) are used and the energy requirements are 1,722kW for heating
and 654kW for cooling. Figure 1.1(b) shows an alternative design which was gener
ated by Linnhoff et al. (1979) using pinch analysis techniques (then newly deve
loped) for energy targeting and network integration. The alternative flowsheet us
es
only four heat transfer units and the utility heating load is reduced by about 40%
Reactor
Reactor
Steam
Steam
70
1
1652
654
3 2
Cooling
water
Feed
H
C
M
M
(a) Design as usual
1722

654
6 units
H
C
M
M
(b) Design with targets
1068
0
4 units
Product
Recycle
Feed Product
3
2
1
Recycle
Steam
1068
Figure 1.1 Outline flowsheets for the front end of a specialty chemicals process
Ch001-H8260.qxd 11/6/06 5:10 PM Page 1
*!"(1 #+(1"%2%-3
SysLemauc approach based on Lhermodynamlc prlnclples LhaL
guaranLee mlnlmum energy level ln deslgn of heaL exchanger
neLworks.
A meLhod LhaL provldes analysls for energy savlng ln
processes and LoLal slLes.
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PCW 1C uC l1?
ldenufy approprlaLe changes ln process condluons ! lMAC1
on LnL8C? SAvlnCS
*!"(1 #+(1"%2%-3
lnch Lechnology applles Lo:
new rocess ueslgn
8eLromng of exlsung process planL
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AnAL?SlS Anu 8CCLSS MCulllCA1lCnS lC8 8L11L8
ln1LC8A1lCn 1C ACPlLvL 1PL 8lML C8!LC1lvL Cl 8CCLSS
ln1LC8A1lCn
SLA8A1C8
*!"(1 #+(1"%2%-3
rocess Modlcauons carrled ouL aL Lhls sLage
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8eacLor
leed
leed
and
roducL
S
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r
roducL
8LAC1C8
lncrease Converslon
lncrease
ressure
8educe llow
*!"(1 #+(1"%2%-3
1he lnch ueslgn MeLhod ensures LhaL LargeLs are achleved
durlng Lhe *'/6$#7 0'(-5*3
1argeLs can also be seL for Lhe 89+-/, +$!0( !/ :!#-$8( +':'+(
;'353 (/'!< !*0 #'2#-5'#!9$* +':'+(=3
1he 89+-/, +':'+( supplled Lo Lhe process may be a parL of a
cenLrallzed slLe-wlde uullLy sysLem (e.g. slLe sLeam sysLem).
lnch 1echnology exLends Lo Lhe slLe level, whereln
approprlaLe loads on Lhe varlous sLeam malns can be
ldenued ln order Lo mlnlmlse Lhe slLe wlde energy
consumpuon. lnch 1echnology Lherefore provldes a
conslsLenL meLhodology for energy savlng, from Lhe baslc heaL

and maLerlal balance Lo Lhe LoLal slLe uullLy sysLem.

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