Heat integration of multipurpose batch plants through multiple heat storage vessels

Master of Science in Engineering by research: “A dissertation submitted to the Faculty of Engineering and Built Environment, University of the Witwatersrand, Johannesburg, in fulfillment of the requirements for the degree of Master of Science in Engineering.” Johannesburg, 05 February 2018In most industrial processes, energy is an integral part of the production process; therefore, energy consumption has become an intensified area in chemical engineering research. Extensive work has been done on energy optimisation in continuous operations; unlike in batch operations because it was believed that due to the small scale nature of batch plants, small amounts of energy is consumed. Certain industries such as the brewing and dairy industries have shown to be as energy intensive as continuous processes. It is, therefore, necessary for energy minimisation techniques to be developed specifically for batch processes in which the inherent features of batch operations such as time and scheduling are taken into account accordingly. This can be achieved through process integration techniques where energy consumption can be reduced while economic feasibility is still maintained. Most of the work done on energy minimisation either focuses on direct heat integration, where cold and hot units operating simultaneously are integrated, or indirect heat integration, where units are integrated with heat storage. The schedules used in these models are, in most cases, predetermined which leads to suboptimal results. This work is aimed at minimising energy consumption in multipurpose batch plants by using direct heat integration together with multiple heat storage vessels through mathematical programming. The proposed approach does not use a predetermined scheduling framework. The focus lies on the heat storage vessels and the optimal number of heat storage vessels together with their design parameters, namely size and the temperature at which the vessels are initially maintained, are determined. The formulation developed is in the form of a mixed integer non-linear program (MINLP) due to the presence of both continuous and integer variables, as well as non-linear constraints governing the problem. Two illustrative examples are applied to the formulation in which the optimal number of multiple heat storage vessels is not known beforehand. The results rendered from the model show a decrease in the external utilities, in the form of cooling water and steam, compared to the base case where no integration is considered and the case where only one heat storage vessel is used.MT 201

Optimisation of a condensate recovery system

In the past few years the energy demand in the world kept on increasing year by year. The part that will be focused is the designing of the condensate recovery system to optimise the system is how much condensate should be recovered and at what is the usage of equipment need in the designing of the equipment with the cost. The problems that will be addressed are minimising the cost of make-up water and energy. Suitable design based on the condensate condition of the condensate presence in the system is addressed also. In pharmaceutical industries, around 35 to 70 per cent of the condensate along with significant quantity of heat is being drained to the effluent treatment plant (ETP). Two objectives is considered in this research which is to develop an optimisation model of a condensate recovery system, with the objective of maximising the economic potential and to apply model on a case study to determine potential savings of condensate recovery system. The scope started with the data collection on the condition of the condensate based on the case study then proceed with the designing of each piping, pump and system type equipment. Then he parameters to design the system such as what time of systems, pumps and piping will be calculated and used in the construction of the superstructure. Then the formulation of the optimisation of the thermal energy system is formulated. Then the data will be input into the formulation and run it into GAMS modular software. Then the results are recorded and see how much energy is conserved and how much of the system is optimised. The modelling optimisation was successful and the maximum economic potential was recorded. The pipe, pump and system type were chosen the optimal in this case study. The conclusion in this research is the optimisation of the condensate recovery system economic potential is at 128915 $. This research can contribute to the reduction of energy demand in the thermal energy system

Achievements and perspectives of process integration in cis countries

Due to the rapid growth in the world population, there has been an increase in energy consumption globally. The problem of efficient energy use becomes more relevant and stimulates research and development of new energy and resource-saving technologies. This task is becoming more complicated when the other factors are accounted for, resulting in multiple-factor trade-offs, such as the water-energy-food nexus. This paper highlights the main points for the development of Process Integration in the Commonwealth of Independent States (CIS) countries. It shows the main achievements in the field to date and demonstrates the scientific schools that are working on these problems. A comprehensive review of modern approaches and methods, which are now being developed or have been recently developed, was done. It shows a research gap in Process Integration in CIS and other leading countries. It demonstrates the significant research potential as well as practical applications. The main challenges in process systems engineering and for the sustainable development of industrial energy systems are also discussed. Industry digital transformation, energy transition, circular economy, and stronger energy and water integration are pointed out as priorities in analysis, design, and retrofit of society in the future. A state-of-the-art review in the area of integration of continuous and batch processes, mass integration technologies, and process intensification is presented to show the variety of existing approaches. The necessity of Process Integration development in the CIS is shown to be a necessary condition for building a more sustainable society and a resource-efficient economy

Optimal design and operation of batch processes

Thesis (Ph. D.)--Massachusetts Institute of Technology, Dept. of Chemical Engineering, 1990.Includes bibliographical references (leaves 246-253).by Michael D. Barrera.Ph.D

Component and System Sensitivity Considerations for Design of a Lunar ISRU Oxygen Production Plant

Component and system sensitivities of some design parameters of ISRU system components are analyzed. The differences between terrestrial and lunar excavation are discussed, and a qualitative comparison of large and small excavators is started. The effect of excavator size on the size of the ISRU plant's regolith hoppers is presented. Optimum operating conditions of both hydrogen and carbothermal reduction reactors are explored using recently developed analytical models. Design parameters such as batch size, conversion fraction, and maximum particle size are considered for a hydrogen reduction reactor while batch size, conversion fraction, number of melt zones, and methane flow rate are considered for a carbothermal reduction reactor. For both reactor types the effect of reactor operation on system energy and regolith delivery requirements is presented

Development of systematic technique for energy and property integration in batch processes

The increasing consumption of energy, generation of waste as well as higher cost of fresh resources and waste treatment systems are the important driving forces for developing efficient, environmentally friendly and economic resource conservation techniques in the process industries. Process integration is being recognized as an useful systematic strategy for resource conservation and waste minimization. Up to date, less research works have been investigated on heat and property integration and these works are only focused on continuous processes.Since the application of batch processes is increasingly popular due to the development of technology-intensive industries such as pharmacy, fine chemistry and foods, it is necessary to consider both heat and property integration in batch processes simultaneously. In this thesis, a new mixed integer nonlinear programming (MINLP) mathematical model is introduced to synthesize a property-based heat integrated resource conservation networks (HIRCNs) for batch processes. A source-HEN-sink superstructure is constructed to embed all possible network configurations. Then, an MINLP model that consists of propertybased resource conservation network (RCN) and heat exchanger network (HEN) models is developed.In the proposed model, the property-based RCN model is formulated based on supertargeting approach while HEN model is formulated via automated targeting method (ATM). The optimization objective is to minimize total annualized cost (TAC) for a batch process system. This includes the operating cost of fresh resources, hot and cold utilities as well as the capital cost of storage tanks. To demonstrate the proposed approach, three case studies were solved. Based on the optimized results, the proposed simultaneous targeting approach for property-based HIRCNs is more effective in term of TAC for HIRCNs than the presented sequential targeting approach