Industrial practices on process integration

PROCESS INTEGRATION

IMPLEMENTATION IN INDUSTRIAL CASES

ZULFAN ADI PUTRA, [email protected]

+60 5368 7562PROCESS SYSTEM ENGINEERING GROUP

CHEMICAL ENGINEERING DEPARTMENT

UNIVERSITI TEKNOLOGI PETRONAS

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What is Process Integration (PI)?

What can we do with it?

Industrial cases:• Minimizing Middle Pressure (MP) steam consumption

• Debottlenecking of crude oil preheat train

• 3 months payback period of a chemical plant

• Minimizing fresh &wastewater streams of a petrochemical plant

• And of a specialty chemical plant

• Uncertainty simulation for conceptual plant designs (e.g. biomass to chemicals)

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Outline

PI a holistic approach to process design, retrofitting, and operation which emphasizes the unity of the process (El-Halwagi1997).

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What is Process Integration (PI)?

Feed 1

Product

By product

Off gas

Feed 2

Reactor 1

Column 1

Reactor 2

Column 2

Column 3

To maximize Product, should we do something in Column 3? Or Reactor 2? Or Column 2? Or…?To minimize CAPEX, which unit should we focus on?To minimize OPEX, what should we look at? Energy? Water? Resources? Waste?

Many available techniques:• (The famous) Pinch analysis for heat, water, hydrogen, etc.

• Mathematical optimization via MS Excel, GAMS, Matlab, etc.

• Process modelling and optimization via Aspen HYSYS, Aspen Plus, gPROMS, etc.

• Experience, intuition, and engineering judgement.

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Optimization of current plant performances; low hanging fruits

Thermodynamic-based targeting benchmarking

Synthesis, design, & evaluation of practical alternatives/solutions

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What can we do with PI?

Industrial Case Studies(Indonesia, Malaysia, The Netherlands, South Korea)

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Minimizing MP steam (1)

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Minimizing MP steam (2)

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Minimizing MP steam (3)

HP steam header

MP steam header

LP steam header

HXs

HXs

HXs

LP condensate header

HXs LP steam boilerMP steam

boiler

HP steam supply

50 ton/hr

11.5 MW

20.6 MW

3.6 MW

4.8 MW

Cooling Tower

10.7 ton/hr

LP steam sold

49 MW

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Minimizing MP steam (4)

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Minimizing MP steam (4)

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Minimizing MP steam (5)

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Debottlenecking crude preheat train (1)

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Debottlenecking crude preheat train (2)

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Debottlenecking crude preheat train (3)

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Debottlenecking crude preheat train (4)

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Debottlenecking crude preheat train (5)

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3 months PBP of a chemical plant (1)

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3 months PBP of a chemical plant (2)

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3 months PBP of a chemical plant (3)

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3 months PBP of a chemical plant (4)

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3 months PBP of a chemical plant (5)

Estimated payback period (in-house) is about 3 months!

Amminudin, K. A., Sofian, M. N., Hawari, H., Putra, Z. A., Khamaruddin, P. N. F. M. and Buang, A., Consider water reuse options for your facility, HYDROCARBON PROCESSING, Dec 2008.

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Minimizing fresh & wastewater (1)

Basecases

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Minimizing fresh & wastewater (2)

Amminudin, K. A., Sofian, M. N., Hawari, H., Putra, Z. A., Khamaruddin, P. N. F. M. and Buang, A., Consider water reuse options for your facility, HYDROCARBON PROCESSING, Dec 2008.

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Minimizing fresh & wastewater (3)

Amminudin, K. A., Sofian, M. N., Hawari, H., Putra, Z. A., Khamaruddin, P. N. F. M. and Buang, A., Consider water reuse options for your facility, HYDROCARBON PROCESSING, Dec 2008.

Developed options via mathematical programming

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Minimizing fresh & wastewater (4)

Amminudin, K. A., Sofian, M. N., Hawari, H., Putra, Z. A., Khamaruddin, P. N. F. M. and Buang, A., Consider water reuse options for your facility, HYDROCARBON PROCESSING, Dec 2008.

Adi Putra, Z., Improve performance and reduce costs of wastewater treatment plants, HYDROCARBON PROCESSING, Dec 2015

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Minimizing fresh & wastewater (1)

Adi Putra, Z., Improve performance and reduce costs of wastewater treatment plants, HYDROCARBON PROCESSING, Dec 2015

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Minimizing fresh & wastewater (2)

Adi Putra, Z., Improve performance and reduce costs of wastewater treatment plants, HYDROCARBON PROCESSING, Dec 2015

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Minimizing fresh & wastewater (3)

Adi Putra, Z., Improve performance and reduce costs of wastewater treatment plants, HYDROCARBON PROCESSING, Dec 2015

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Minimizing fresh & wastewater (4)

Adi Putra, Z., Improve performance and reduce costs of wastewater treatment plants, HYDROCARBON PROCESSING, Dec 2015

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Minimizing fresh & wastewater (5)

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Uncertainty simulation for conceptual plant design (1)

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Uncertainty simulation for conceptual plant design (2)

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Uncertainty simulation for conceptual plant design (3)

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Uncertainty simulation for conceptual plant design (4)

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Uncertainty simulation for conceptual plant design (5)

Questions?

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