Libros de Ing. Quim. Recursos para Ingenieria Quimica.

Pinch Analysis and Process Integration – Ian C. Kemp

Publicado: 2010-05-03 06:44:29

Pinch Analysis and Process Integration
Ian C. Kemp

                                                                   

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1 Introduction
1.1 What is pinch analysis?
1.2 History and industrial experience
1.3 Why does pinch analysis work?
1.4 The concept of process synthesis
1.5 The role of thermodynamics in process design
1.5.1 How can we apply thermodynamics practically?
1.5.2 Capital and energy costs
1.6 Learning and applying the techniques

2 Key concepts of pinch analysis
2.1 Heat recovery and heat exchange
2.1.1 Basic concepts of heat exchange
2.1.2 The temperature–enthalpy diagram
2.1.3 Composite curves
2.1.4 A targeting procedure: the "Problem Table"
2.1.5 The grand composite curve and shifted composite curves
2.2 The pinch and its significance
2.3 Heat exchanger network design
2.3.1 Network grid representation
2.3.2 A "commonsense" network design
2.3.3 Design for maximum energy recovery
2.3.4 A word about design strategy
2.4 Choosing Delta Tmin: supertargeting
2.4.1 Further implications of the choice of Delta Tmin
2.5 Methodology of pinch analysis
2.5.1 The range of pinch analysis techniques
2.5.2 How to do a pinch study

3 Data extraction and energy targeting
3.1 Data extraction
3.1.1 Heat and mass balance
3.1.2 Stream data extraction
3.1.3 Calculating heat loads and heat capacities
3.1.4 Choosing streams
3.1.5 Mixing
3.1.6 Heat losses
3.1.7 Summary guidelines
3.2 Case study: organics distillation plant
3.2.1 Process description
3.2.2 Heat and mass balance
3.2.3 Stream data extraction
3.2.4 Cost data
3.3 Energy targeting
3.3.1 Delta Tmin contributions for individual streams
3.3.2 Threshold problems
3.4 Multiple utilities
3.4.1 Types of utility
3.4.2 The Appropriate Placement principle
3.4.3 Constant-temperature utilities
3.4.4 Utility pinches
3.4.5 Variable-temperature utilities
3.4.6 Balanced composite and grand composite curves
3.4.7 Choice of multiple utility levels
3.5 More advanced energy targeting
3.5.1 Zonal targeting
3.5.2 Pressure drop targeting
3.6 Targeting heat exchange units, area and shells
3.6.1 Targeting for number of units
3.6.2 Targeting for the minimum number of units
3.6.3 Area targeting
3.6.4 Deviations from pure countercurrent flow
3.6.5 Number of shells targeting
3.6.6 Performance of existing systems
3.6.7 Topology traps
3.7 Supertargeting: cost targeting for optimal Delta Tmin
3.7.1 Trade-offs in choosing Delta Tmin
3.7.2 Illustration for two-stream example
3.7.3 Factors affecting the optimal Delta Tmin
3.7.4 Approximate estimation of ideal Delta Tmin
3.8 Targeting for organics distillation plant case study
3.8.1 Energy targeting
3.8.2 Area targeting
3.8.3 Cost targeting
3.8.4 Zonal targeting
3.8.5 Targeting with utility streams included
3.9 Appendix: Algorithms for Problem Table and composite curves
3.9.1 Problem Table and GCC
3.9.2 Composite curves

4 Heat exchanger network design
4.1 Introduction
4.2 Heat exchange equipment
4.2.1 Types of heat exchanger
4.2.2 Shell-and-tube exchangers
4.2.3 Plate exchangers
4.2.4 Recuperative exchangers
4.2.5 Heat recovery to and from solids
4.2.6 Multi-stream heat exchangers
4.3 Stream splitting and cyclic matching
4.3.1 Stream splitting
4.3.2 Cyclic matching
4.3.3 Design away from the pinch
4.4 Network relaxation
4.4.1 Using loops and paths
4.4.2 Network and exchanger temperature differences
4.4.3 Alternative network design and relaxation strategy
4.5 More complex designs
4.5.1 Threshold problems
4.5.2 Constraints
4.6 Multiple pinches and near-pinches
4.6.1 Definition
4.6.2 Network design with multiple pinches
4.7 Retrofit design
4.7.1 Alternative strategies for process revamp
4.7.2 Network optimisation
4.7.3 The network pinch
4.7.4 Example retrofit network design
4.7.5 Automated network design
4.8 Operability: multiple base case design
4.9 Network design for organics distillation case study
4.9.1 Units separate
4.9.2 Units integrated
4.9.3 Including utility streams
4.9.4 Multiple utilities
4.10 Conclusions

5 Utilities, heat and power systems
5.1 Concepts
5.1.1 Introduction
5.1.2 Types of heat and power systems
5.1.3 Basic principles of heat engines and heat pumps
5.1.4 Appropriate placement for heat engines and heat pumps
5.2 CHP systems
5.2.1 Practical heat engines
5.2.2 Selection of a CHP system
5.2.3 Refinements to site heat and power systems
5.2.4 Economic evaluation
5.2.5 Organic Rankine cycles
5.3 Heat pumps and refrigeration systems
5.3.1 Heat pump cycles
5.3.2 Refrigeration systems
5.3.3 Shaft work analysis
5.3.4 Cooling water systems
5.3.5 Summary
5.4 Total site analysis
5.4.1 Energy targeting for the overall site
5.4.2 Total site profiles
5.4.3 Practical heat recovery through the site steam system
5.4.4 Indirect heat transfer
5.4.5 Estimation of cogeneration targets
5.4.6 Emissions targeting
5.5 Worked example: organics distillation unit
5.6 Case studies and examples
5.6.1 Whisky distillery
5.6.2 CHP with geothermal district heating
5.6.3 Tropical power generation and desalination
5.6.4 Hospital site

6 Process change and evolution
6.1 Concepts
6.2 General principles
6.2.1 The basic objective
6.2.2 The plus–minus principle
6.2.3 Appropriate Placement applied to unit operations
6.3 Reactor systems
6.4 Distillation columns
6.4.1 Overview of basic analysis method
6.4.2 Refinements to the analysis
6.4.3 Multiple columns
6.4.4 Distillation column profiles
6.4.5 Distillation column sequencing
6.5 Other separation systems
6.5.1 Evaporator systems
6.5.2 Flash systems
6.5.3 Solids drying
6.5.4 Other separation methods
6.6 Application to the organics distillation process case study
6.6.1 Identifying potential process changes
6.6.2 Eliminating bottoms rundown: detailed analysis
6.6.3 Economic assessment
6.7 Summary and conclusions

7 Batch and time-dependent processes
7.1 Introduction
7.2 Concepts
7.3 Types of streams in batch processes
7.4 Time intervals
7.5 Calculating energy targets
7.5.1 Formation of stream data
7.5.2 Time average model
7.5.3 Time slice model
7.5.4 Heat storage possibilities
7.6 Heat exchanger network design
7.6.1 Networks based on continuous or averaged process
7.6.2 Networks based on individual time intervals
7.7 Rescheduling
7.7.1 Definition
7.7.2 Classification of rescheduling types
7.7.3 Methodology
7.8 Debottlenecking
7.9 Other time-dependent applications
7.9.1 Start-up and shutdown
7.9.2 Day/night variations
7.10 Conclusions

8 Applying the technology in practice
8.1 Introduction
8.2 How to do a pinch study
8.3 Heat and mass balance
8.4 Stream data extraction
8.4.1 Mixing and splitting junctions
8.4.2 Effective process temperatures
8.4.3 Process steam and water
8.4.4 Soft data
8.4.5 Units
8.4.6 Worked example
8.5 Targeting and network design
8.5.1 Targeting
8.5.2 Network design
8.6 Targeting software
8.6.1 Options available
8.6.2 Spreadsheet accompanying this book
8.7 Industrial experience
8.7.1 Oil refining
8.7.2 Bulk chemicals – continuous
8.7.3 Speciality and batch chemicals and pharmaceuticals
8.7.4 Pulp and paper
8.7.5 Food and beverage
8.7.6 Consumer products and textiles
8.7.7 Minerals and metals
8.7.8 Heat and power utilities
8.7.9 Buildings

9 Case studies
9.1 Introduction
9.2 Crude preheat train
9.2.1 Process description
9.2.2 Data extraction and energy targeting
9.2.3 Pinch identification and network design
9.2.4 Design evolution
9.2.5 Design evaluation
9.2.6 Conclusions
9.3 Aromatics plant
9.3.1 Introduction
9.3.2 Process description
9.3.3 Stream data extraction
9.3.4 Energy targeting
9.3.5 Design of an MER network
9.3.6 Network design based on existing layout
9.3.7 Practical process design considerations
9.3.8 Further considerations
9.3.9 Targeting and design with alternative stream data
9.3.10 Conclusions
9.4 Evaporator/dryer plant
9.4.1 Process description
9.4.2 Stream data extraction
9.4.3 Energy targeting
9.4.4 Heat pumping strategy
9.4.5 Process change analysis
9.4.6 Selection of final scheme layout
9.4.7 Conclusions
9.5 Organic chemicals manufacturing site
9.5.1 Process description and targeting
9.5.2 Practical implementation
9.5.3 Conclusions
9.6 Hospital site
9.6.1 Site description and stream data extraction
9.6.2 Targeting using time intervals
9.6.3 Rescheduling possibilities
9.6.4 Process change possibilities
9.6.5 Opportunities for combined heat and power
9.6.6 Conclusions
9.7 Conclusions

                                                                   

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