This paper highlights some of the key recent advances in research related to Pinch Analysis, particularly those developed in the Department of Chemical Engineering, Universiti Teknologi Malaysia. The focus is on the development of systematic conceptual and heuristic design and retrofit techniques for efficient heat, mass and water recovery even though many recent work in the area has also concentrated on the use of mathematical programming

Abdul Manan, Zainuddin

English

Universiti Teknologi Malaysia Institutional Repository

pro.cdtde\.f tn?r)dt)orrl cdrfercn.e an chdrical ontl rjioprcas E^Eine?ti,327. z.l, Ausui2AU, Uniwtiti Malorsiastbdh. K.r;KnnhaiSystematic Design and Synthesis Of Heat, Mass and Water Recoy€ry Networks UsingPinch AnalysisZainuddin Abdul MananProcess Slstens Engineerinq Group, Depafinent ol Chmical Engineetine, Facubt.l Chenicat & N atu tdt ResourcrsEnSineenhg, Uaive tsni Teknologi MaLarsio, Sl3l0 Skddi, Johor, MAtAySIA.Tel: +647 55355t2.r'at: +607 5531163, Eanait: ..ain@ftkksa.urh.nyAbstractThis paper highlighlt some oJ the ke! rcca1t ddwnces ntrcseolch related ta Pinch Antll)'sis, panictlaru thosedevelc,ped ih the Depa nleit oJ ChenicaL ErcineeingUniNetsni Tekholoqi Malalsia. The focus is on ttEde|etoVment o! lJ-sten4tic conceptual und heuri:ric designon.l rctroft tecraiques far efrcient h.dt, nass antl taterlecovery even thaqh ntoN rcceat||ork in he arca has dLso""^at,,trttd on the u'p alht ,!h2r.-'t. ,.1 proetaaniaE.Keywords:Pinch Analysis, Mass Exchange Network. Waler Pinch,Simuhaneous Enersy and water, MATRIX. HeaFMATRIX.IntroductionThe cunenr drive towards environnental suslainability andthe rising cosB of fuel and water have encouaged theprccess rndusrry to nnd new ways ro reduce energy mdwaler consumption. Maximising energy and water recoveryand reuse can minilnise consunrprion and reduceenvironmental emissions. Corcurently, !b€ devetopmenr ofsystemaric rechniques fo.energy and warer reduclion withina process plant has seen extersive progress. The advenl ofPinch Analysis as a tool for the design ofoprimal heat massand water @overy n€rwork has been one of the mosls'gnificanr advances in $e area oI Focess synthesis over thelast ten years [1 ].In the arer of heat recovery, a rechnique named MATRXlhat is capable of considering a wide range of exjsring designconstainb has been inrroduced for the retrofit of h€atrecovery neMork. Work is underway ro develop newv'sualization rools 10 assisl th€ simultaneous reducuon orenergy and water in process plants. In this work, a rocarpaper mill has been used as a case srudy. The developmenlof syslematic methods for rhe synrhesis of balch massexcha.Se nelwo* systems has also been one our recenr mamfocus areas. Finally, a new numericat technique foreshblhhing the minimum water and wastewarer urge6 rsrhe mosr rccent rechnique w€ have inlrcduced in pinchAnalysis. Most of lhese recenr devetopmenh have beensuccesslitl\' incorporated in Hear-MATRIX, the pinchAnalysis softsare developed by rhe process SystemsEngineenng croup. DepafiDenr ot Chemical Enginee.inS.Universiti Teknolosi Malaysia.The New MATRIX Technique [2]A new syslemaric technique aimed at rcducing lhe hot andcold uliUty consumprion rhrough rhe revamp ofexisting heatexchanger network in a cherical process hd beensuccessfully developed. The lechnique has been utilized fo.tb€.etfofit ofa palm oilrefinery with d.amatic results. Thisnew technique. wh;ch k called MATRIX (MAximising rheTotal area Reuse In an exisring netwo.k) is fo.us€o. anorequires mucb less diagnosis effod. MATRIX combrnesthermodynamic insights and graphical approach rosystematically gdde us€rs to explore alt possible heatexchange malcb options and screen rhe most pronnungone.This technique consisrs of thrce-stages: Match l.lentif.atior,Match S.reening ard Network Erolutiot. tn rbe Matchldentification srage, a new g.aphical visuaiisarion tooj calledlhe Exersy Block Diagram (EBD) is proposed to identify altpossible heat exchanger. Next, a systematic screeningrechnique called lbe n1a/cl Ma'.v (M-Marrix) is proposed tosod and filter our the undsirable march options jdenlifiedfrom the EBD. The f,nal srage Df retrofir is networkevolution ftar involves a systemaric toop and pathoplimisalion technique to generate ihe final rerofil scheme.A case study on a local paln oil rcfinery was used bdemonstiate the advantage of rhh approach tb. the retrofil ofexisting heat exchanger nerwork. Econornic analysisconducted showed projecled uriliry savings of more than RM80,(y40 (65 %) in hot uriliry and RM 25,000 (48%) in cotdutility. An invesrmenr of RM 44,000 in heat rransfer areawar required !o realise thes€ svings. The minimal strucluralmodificalions lead 10 rhe small capital invesrnent and hence.a very attmctive pay back period of about 5 nonths.Mass Exchange Network [3]Synth€sis of oprimal MEN for continuous processes brsedon Pinch Aoalysis has be€n rather well esrablished. Inconirart, v€ry little work has been done on mass excbangenetwork syntbesis (MENS) for batch proc€ss systems.Techniques developed for lhe MENS fo. bach systemsISBN:983-264J-t5-5 443involved the ibllowitrg two key sieps: I Setting MEN designrargels abeld of design rhal include the utility and thenu;befofunits urgetsr 2. MEN design toachieve thedesignrrrger\  U. I  I /  Lxrger ing (mp r) '  r r re venica'  rnJ lor i /onral^. ,4,"g,p1.n ' .n" '  I i r  l td\e b*n rd.pred lmr healexchanqe ne!{ork synthesis (HENS) for batch processesPriort;MEN design.Ihe rarged.g procedurc esublishes theminimun utility Golven0 reqDircment fo. maximum nassrecovery (MMRI mdxinrum mass exchange (MMX) andmrximum mass stouge (MMS) These targets are essentalior nerwork .lesign and balch process rescheduling Asysrcmatic procedlre ibr MEN design for batch Processes.which include the Dew graphical tools called the ame gr;d.liasran (TCD) and olerallrime grid diasfam (OTGD) havebee-n introduced to allow designe6 to achieve the ulililytarse$ estrblished for tlre MEN Th€ 'ninimum number ofma--s exclange unhs target has also been deYeloped toprovide a low€r boLrnd for the number of unftc ror a;relimirarv batch MEN. Finallv a lechnique 10 evolve iheiatch MeN has been developed based on the conventionliapproacb f.om thecontinuous MEN designWater MinimisationThe development of systematic l@hniques tor waterredudion. reuse rnd recycling within a prmess plant hasseenexlensive progress. The advent ofWa|er Pinch Analysis(WPA) as a rcol for lhe design of optimal water recoveryneiwork has been one of the mosl significint advances in thearea of water mirimizalion over the last ten years [4]. Anumerical meftod to estabthh $e mininum water target toraoDLrcarion. bevond ma\' tran\ler based $.ler-usingprocesa' ;. no"ewr unalailable. The Water CascadeAnalj'L rwcAr described in the follo$ inB 'ecrion ha' beenvery have recently develoPed by our group to fill in thisTte Water Cascad€ Analysis (WCA) Technique tslA new metbod to estabUsh the minimum water andwastewater targets for continuous watecus'n8 processes.known as the Wa|erCascade Analysis (wCA). is one ofthelatesl lechtriques for warcr rargeting developed by our group.WCA is a numerical te.hnique rhlt can quicklv vieldaccumle water targets and pinch point locations ior a waernetwork. By etiminating th€ tedious iterative steps of thewater surptus diagram, WCA offers a kev clmplimeDtaryrole to the water rurplus diagmm in the design nnd retroftl ofwater recovery nelwork. Various options involving processchanges. includrng waler reSeneralion and equipmenlmodiiKarionscan be \ystemarically arses'ed using rhe wCA.Problerns involving multiple pirches can now be handledmore efficiently. accurately and lvith nuch less effon Allfte key fealures and lb€ systematic nature of ihe WCA makeit €ary foi$e technique to be automated and translated intoany computer language for sofiwde developmenr As ourexperience has shown, the WCA has simplified the task ofincorporating the water surplus diagram in a comPotersofiwa.e by elimiDating the tedious iterativ€ steps involvedPn-..r'ae:ollmcrnatidol.rat.e4 ?An I h 4i .t at t A rr 'c 'r4;'t.":182'  .J '  A.ru. '  !v ' .  Ur, . t ' r i  votoy,a \"baL A^ta Xnobo Lduing theconstruct;on of wabr su.Plus diagram The WCAtealure has been incorpomted in Heat'MATRIx. a nevlsoftware for energy and watet reduction developed by lheProcess Syslems Engineering Group, DePa'tment ofChemical Ensineering, Universiii Teknologi Malavsia [5]Wrter Mi misation oD a Local Prper Mill Plant t6lThe manofacture of pulp .nd paper is a watef inrensiveindusrry. Due to the increase in the price ofprocess wale( theindustry is under regulalory pressure lo rcduce the freshwarer usa8e. In v iew ul  lh i .  l rcbl-rn.  a re.errc l ,  lo mirr iTi 'ethe water consumption on an existing paPer mill was caniedout. Pmcess integmllon melhodology such as Water PinchTechnology was applied to sctutinise the effectiveness offteexisting waler network and identify lhe oppo.luniries rb.f.esh water reduclion. The Malaysian Newsprint Induslriespaper mill plant was selected as lhe case sludv lor theresearch. The study involves lwo main scopes ie freshwaler targetinS and watef nelwork desigr. To establish theminimum water targets, the Heal MAIRIX soflwrre whichimplemenls the Dew watef cascade analysis tecbnrquedeveloped by the PsE group in UTM was used inconjunction with the graphical lechniques of conpositecurves and water surPlus diagram Targeling was followedby the design ofi water distribudon network to.chieve theminimum wrler targets. The design lechnique based onwatersource and waterdemand approach was implementedFrom fte research conduct€d, a |otal reduction of 19.63% offresh wate. consumption for the mill was identified andsome m;nor modificalions on the water networkconfiguration for the paper mill were proposed. Wilh theimplementation of this waler nelwork, the paper mill canpotentifllly acbieve an annual fresh water cost saYings ofRMt 18400 which include the pumping costs, the chentcal costsand oth€r mw water treatment costs [6]Simultaneous Energy and Water Reductionst7lWaler and energy are bolh used in significatt quantities inprocess induslries. Even though the prccedure tbr theopiimal design of a water minimisation network and that ofenersy recovery Ft\tork have be€n v€ry well established,the available techniques to optimize the network of heal andwater sysrems mentioned abve a.e still largely independentand significantly lacking in terms of their ability to capitalizeon the synergy betw€en one another. Based on lheseindependent techniques, rcduction of energy does notguarmlee lhe minimun of water usag€ in process industriesA new systematic technique that minimizes water andene.gy consumption of a wateFusing tetworksimultaneously is undergoing development in LITMThermodynamic insights and graphical apprcach we.e usedto assist d€signers in deigning a new water-using network inorder lo get minimum utility consumptions under optimun444 ISBN:981-2643-15-5^nemr'ns conJiron. {mon3 Ine fed(ure\ '  J plo( of" 'p. ' ,L. .  ' . ,  " '  i re-m f lo\qJre renr "d 1 '  'w & Fio ip^ir .  c, , " . " .  "" '  I  '  o\e.  Emphicr l  rool  J(veloped in, i ; ,  , - "a,- l  ro euide $rrer and ener$ minimi ' r ion.rm' l r r ,neou' ty lhe w&h Compo!re Cur\ec ptuvioedke, ' l tom"r ion on rhe slale ol  n $bter 'urng nerunrr  anoal;*ed wuter-using nelwork des;gn 10 be camed outgfltphically and hence effectivelyHeaI-MATRIX [8]To r'acilirate the desiEn and inptolemenl of new as weu asexisring planls. we have integrated and incoryorated fter.aditionll Pinch Analysis rechniques and the larestdev€lopments in the a.ea of heat, mass and waief recoveryii|o HeaTMATRIX-aconputer soflwarc developed in UTM.Hea|-MATRIX has been tailofed for lbe rerrofi!(inprovemenl) ofheat a.d lvaterrecovery network to reduceenere\ and worer in c4emiJal  proce s Plana The \ol l*" te. ,a. ;eteloped br.eo on rhe .)  netgini . ,  omorndt ion olrhrcekey rechniques ro reduce lhe hol and cold ulilityconsumptios. The software implements the establishedprnc ples ol  Prnch Ana.) ' i '  lor  a neq pldnt and rhe newMA7fi lX rechnique for lhe relrof i r  I  Inprovemenr) ole\bt ingp'ncesses to reduce $e ho! and cold ulility usage TheM,4TR1X technique is a new melhodology thal is aimed alimproving heat rccovery bt MAximis;ng the lolal Reuse ofthe existing heat recoaery network area (M, fRry). Thethird technique being implemenl€d is the WCA techniqueflcar MAIRIX ;s the first computer soflware for heat andwaler network design lhal implemetts the MATRIX andWCA techniques. Ii is a Micrcsoft Windowsbasedprograrnme thai was develoPed to automate, and rapidly aswell as efficiently ssist the desigD and retrofit of a heatrccolery network. k ako enables the rap;d determinaion of!h€ minimum energy and water rcquirenents for a process.and the improvement ofheat rccovery network struclure fora process plant to achieve lhe minimum ho! and cold uliliiyconsumption. In alldirion, Heat-MATRlX can alsoautomatically 8€nemte lhe oplimal utility combination for agiven process and allow the aulomatic and semi-automati€design of heat exchanger nelwork to achieve the energytargets. Due to its capability to examine a wide variety ofheat €xchanger malch possibililies, atd the inclusion of thecapilal and operating costs during network evolution, thesoftware offers an attBctive. practical and cost-effectivealleroative solulion for hea. recovery network retiofil.ConclusionWaler and energy are the two nosl conmon utililies and themain operating cosls in a chenical process plant. Steam,which is used for utility heating is the most €ommon fo.m ofen€rgy supply in a process that is produced by buming tuel.With lbe increase in water and fuel prices, chemical processPtucedinit ol ht?netionaL C.teterct Or ChenieL aml Siopn.es Encineerirq27r 2f Ausui2,a3, Uniw'siti MaLofiosabah K.ta Kinbduplants are under p.essufe lo improve their profi1 natgin orlace possible closure ofplants.Some the key .ecent advances in research relaled to PinchAnalysis has been highlighted. The focus is on thedevelopment of systematic onceplual and heuristic designand retrofi! lechniques for efliclent heat. mass and watefrecovery. In the area of heal recovery, a technique namedMATRIX Ihal is capable of considerins :r wide range ofexisring design conslrains bas been inkoduced fo. theretrofit of heat recovery network. Wo.k is undeslay todevelop new v;slilizalion tools to assist lhe simullanmusreduction ofenergy and waleri. process planls. In thk work,a lcal paper mill has been used as a case sludy. Tbedevelopment ol syslematic nrethods for the synthesis ofbatcb mass exc hange network systems has also been one ourrecent main focusareas. Finally. a new nume.ical techniquefor establishing $e minimum wrter and wasrewarei rargetsis $e most recent technique we have inlroduced in PinchAnalysis. Most of these recenr deveLopnents have beensuccessfully incorporated in Hea|-MATRIX. th'e PlnchAnalysis softwde developed by the Process SysbmsEngin@nng Group, Deparrment of Chenical Engineenng,Universiti Tekrologi Malaysia.Referenceslll Z.A. Manan. Identifyins Energy Savils Opportunities ina Proc€ss Plant Through Preliminary Energy Audit,JunalTeknologi, inp'"rr to be published inJune.2003.I2l Lim Fang Yee, Z. A. Manan. "Developmenl of aSystematic Technique for Simultnneous Redudion ofEnergy and Waier in Chemical Process Plants",Pr@eedins of SOMChE, September, 2001.t3l C.Y., Foo, Z. A Manan. R. Yunus and R. A Aziz,Synthesis Of Mass ExchanSe Networks For BatchProcesses - Pa.t I: Utilily Targ€ting, h p.e$. ChemicalEngineenng Science, 2003.14) Z. Ujary, C. L. Wong and Z. A. Manan, " IndustrialWastewater Minimisadon Using wate. Pinch AnalyscA Case Study on an Old Texile Aa t" Water Scienceand Tech@logy, Y 01 46. No ll-12 pp 7'7 -81,2OO2t5l Z. A. Maoa., C. Y. Foo and Y. L. Tan, 'Targeting TheMininum Walef and wastewaFr Flowmtes Using TheNew Water Cascade Analysis Technique , papersubnitten b AtCl,E Jo&mal, Mac 2003.[6] Tan Sook Li, Application Of Water Pinch Analysis, Forwater Minimisation I  A PaperMili, B.Sc- Disserlation.Universiti Teknologi Malaysia, 2002.t7l S. Y. Tea, A New Systematic Te.hnique forSimultaneous Waler and Energy Reduction in PrccessPlants, MSc proposal, UDiversiti Teknologi MalaysiazNZ.[8] Z. AManan,Ooi,B. L.. Lim, F. Y. and Foo, C.Y. (2003)ISBN:983-2('43-15-5 445"HeaI'MATRIX ' A Computer Softwarc For TheReduction Of Energy And Water In Process Plants", 31"Inlemdrional E{hibilion of In.enrion. New Techniquesand Products of Geneva. Switz€rland.Pwedirys oJ InkMtional CnnJeerce On Chernicol and Bio?n..s EBireerins27 - 2l Aqui 2003 , Univesiti MaLaFio Sabah. Kotu Knnbatu446 ISBN:983-2643-15-5.

Systematic design and synthesis of heat, mass and water recovery networks using pinch analysis

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Systematic design and synthesis of heat, mass and water recovery networks using pinch analysis

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