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

Targeting Minimum Heat Transfer Area for Heat Recovery on Total Sites

This paper upgrades the Total Site integration methodology, when accounting for a trade-off between capital and heat recovery by selection of optimal temperature levels for intermediate utilities and therefore, decrease capital cost. Heat transfer area for recuperation in Total Site is a two-fold problem and it depends on the Sink Profile on one side and on the Source Profile on another. The resulting temperature of intermediate utility is a result of a trade-off since the heat transfer area on Source side is decreasing, when temperature of IM is decreasing, however increased on Sink side. In the opposite higher intermediate utility temperature leads to higher area on the Source side and lower on Sink side. The temperature of each intermediate utility may be varied between specified lower and upper bounds subject to serving the Sink and Source Profiles

The design of the total site exchanger network with intermediate heat carriers: Theoretical insights and practical application

The present work is focused on finding a cost-effective solution to the synthesis of Heat Exchanger Networks (HEN) for Total Site Integration (TSI). The possible solutions for minimum-investment retrofit of the Total Site HEN are also discussed. The feasibility of intermediate heat carriers number is also analysed for better plants interconnection considering the optimal amount of the recovered hea

Total Site Integration for Coke Oven Plant

The process of benzene distillation and process of coal tar distillation being typical for East European countries is analyzed in this paper. The pinch analysis method was selected to perform a reconstruction project. According to principles of pinch analysis, new network diagrams are designed and capacity of heatexchange equipment is calculated. The using of "Total Site Profiles" showed the feasibility of heat pump integration. Heat pump integration allowed to reduce the external hot utilities usage on 368 kW and cold utilities usage on 368 kW. This project let to decrease the external hot utilities usage on 23 % and cold utilities usage on 24,13 %, and also offered the way of step-by-step retrofit of the plant

Total Site Integration for Coke Oven Plant

The process of benzene distillation and process of coal tar distillation being typical for East European countries is analyzed in this paper. The pinch analysis method was selected to perform a reconstruction project. According to principles of pinch analysis, new network diagrams are designed and capacity of heatexchange equipment is calculated. The using of "Total Site Profiles" showed the feasibility of heat pump integration. Heat pump integration allowed to reduce the external hot utilities usage on 368 kW and cold utilities usage on 368 kW. This project let to decrease the external hot utilities usage on 23 % and cold utilities usage on 24,13 %, and also offered the way of step-by-step retrofit of the plant

Modified Criterion for Economic Efficiency Estimation of Heat Pumps

In this work the cost-effectiveness of coal mine waste water low potential heat utilization and integration in the enterprise local heating network by the bivalent parallel scheme is investigated. It is shown that the additive criterion of economic efficiency is not always sensitive to the target value because of the reason of non-linear coupling between the arguments of the target function. Several cases were considered from the viewpoint of cost-effectiveness criterion. Moreover, the arguments of the target function are also nonlinear, depending on technological parameters of the heat pump (HP) equipment. As a more effective criteria were proposed the modified canonical additive-multiplicative function and Kolmogorov-Gabor polynomial function to obtain the generalized multivariate estimation of alternatives in two stages procedure

The retrofit of the calcium chloride production by Pinch approach and process modifications

In this paper, the analysis of an existing calcium chloride evaporation unit was performed to cut primary energy use and harmful emissions. This paper proposes the use of several approaches for retrofit of existing calcium chloride production. The existing process’s energy efficiency was examined to identify drawbacks and bottlenecks and provide the pathways for proper process modificatio

Heat integration of ammonia refrigeration cycle into buildings heating systems in buildings

The possibility of utilizing the low potential heat of the ammonia refrigeration cycle has been shown. The design of an energy saving heat exchangers network to heat water and air in municipal buildings has been proposed. The possibility of increasing the pressure of ammonia with the purpose of improving the heat recovery in the system and reducing the load of the heating and cooling systems was considered. The minimum temperature difference in the heat exchangers network was selected. The economic efficiency of the retrofit project was estimated

Ammonia Refrigeration Cycle Integration in Buildings Heating System

This work investigates the possibility of ammonia low potential heat utilisation with use of Process Integration methodology. The two operation modes are considered. The first one is the use of ammonia gas super-heating and partly ammonia condensation. The low condensation temperature of ammonia is limiting the low potential heat usage. The second option is introduction of ammonia additional compression to increase the temperature of ammonia condensation. The low potential heat consumers are the hot water supply system, air pre-heating system and air heating for the fans

Process integration of sodium hypophosphite production

The case study of flexible integrated flowsheet development for sodium hypophosphite production is presented. It is based on phosphoric sludge utilization process. The weight concentration of phosphorous in raw materials is equal to 30e50%. The reaction and separation parts of the system were designed based on detailed analysis of production stages. After that the process equipment was selected. Process modelling is made for annual production of hypophosphite equal to 2500 t. It permitted to extract process streams for heat energy integration and to define their parameters. The operating pinch procedure was used to estimate the consumption of hot and cold utilities for non-integrated process. The influence of utilities cost on minimal temperature difference is investigated. Analysis of heat system topology modification depending on energy prices is conducted. Optimal structure of heat recovery system and minimal temperature difference are determined. It is shown that optimal integrated process consumes 45% of hot and 30% of cold utilities required by non-integrated process