Recent Advances in Sustainable Process Design and Optimization

The following sections are included:

• PREFACE

• LIST OF CONTRIBUTORS

• CONTENTS

The following sections are included:

• Introduction

• Thermodynamic Foundations

• Economic Foundations

• Sustainability Assessment

• Epilog

• References

Life cycle assessment (LCA) is a compilation and evaluation of the inputs, outputs and the potential environmental impacts of a product through its life cycle.¹ LCA, also termed life cycle analysis, ecobalance, or cradle-to-grave analysis, is a type of input–output analysis focusing only on physical flows. Generally, LCA, comprising four phases, involves six stages in the life cycle of a product spanning from its conception signified by the extraction and processing of raw materials through manufacturing; transportation and distribution; use, reuse and maintenance; recycling; to its death signified by final disposal.²

The following sections are included:

• Introduction

• Transport Mechanistic and Irreversible Thermodynamics based Transport Models for NF and RO membranes

• Fundamental of Irreversible Thermodynamics in Membrane System

• Spiegler–Kedem Model for Single Solute System

• Spiegler–Kedem model for multiple solute systems

• Process Design for Membrane Systems

• Conclusion

• List of symbols

• References

The following sections are included:

• Introduction

• Polymerization Reaction and Polymer Properties

• Case Study of Inhibition

• Conclusions and Inference

• Acknowledgments

• Nomenclature

• References

The following sections are included:

• Introduction

• Design Tools for Resource Conservation

• Examples of RCN

• Further Improvement

• Conclusion

• References

The following sections are included:

• Introduction

• Use of Water Mains

• Optimal Design of Water Network with Internal Water Mains

• Optimal Design of Water Network Involving Wastewater Regeneration Recycle with Internal Water Mains

• Industrial Applications

• Case Study I: A PVC and Sodium Hydroxide Plant

• Case Study II: An Ammonia Plant

• Conclusion

• Nomenclature

• References

This chapter will present mathematical models for minimizing waste generation in process plants by optimal recycle/reuse of process effluents. As a consequence the mathematical models developed will also minimize fresh resource consumption. Typically resource planning problems render themselves to Mixed Integer Non-Linear Programs (MINLP) due to the cross-product of the unknown amount of resource (F_i,j) transferred from supply point (i) to demand point (j), with the binary decision variable (X_i,j) pertaining to decisions on whether or not to supply from a particular source "i" to a sink "j". In this chapter, some basic linearization schemes using logical "if–then–else" constraints will be adopted to convert the MINLP formulation into a Mixed Integer Linear Program (MILP). Furthermore, a "superstructure" of pre-conditioned resource-recovery options will be generated prior to employing mathematical models (MILP) for optimal resource planning. The novel ideas will be demonstrated within the context of the following industrial problems: (i) freshwater minimization from the textile and paper industries and (ii) optimal solvent utilization in the pharmaceutical industry.

This chapter presents a freshwater and wastewater minimisation technique that is based on continuous-time mathematical formulation.¹ The choice of this mathematical formulation is due to its ability to capture the time domain exactly with manageable computational complications. Wastewater minimisation is achieved through recycle and reuse within the boundaries of a process prior to end-of-pipe treatment. The mathematical model exhibits a mixed integer nonlinear programming (MINLP) structure that is inherently non-convex. In a situation where central intermediate storage does not exist, this nonlinearity is transformed into a linear formulation without any loss of accuracy in the model. Regarding time representation, two cases are considered. In the first case, the starting and ending times of all tasks are known beforehand and only feature in the model as parameters. In the second case, only task durations are fixed with start and finishing times treated as optimisation variables. In the latter case, use is made of an established scheduling method² in conjunction with wastewater minimisation…

Whilst the previous chapter dealt with single contaminants, this chapter presents the mathematical formulation for wastewater minimisation in batch processes where there are multiple contaminants present in the system. Section 1 of this chapter presents some background to the problem. The formal problem statement is given in Sec. 2. Section 3 is centred on the mathematical formulation, whilst Sec. 4 describes the solution procedure. The application of the methodology to a number of illustrative examples is given in Sec. 5 followed by conclusions in Sec. 6.

The following sections are included:

• Introduction

• Simulated Annealing

• Swarm Annealing I

• Swarm Annealing II

• Algorithm Implementation and Testing

• Test Problems

• Discussion of Results

• Conclusion

• References

The following sections are included:

• Introduction

• WWTN Problem Formulation and Description

• Literature Overview

• Hybrid Approach for WWTN

• Simultaneous Approach with the Use of Stochastic Optimization Method

• Symbols

• Superscripts

• Subscripts

• Abbreviations

• References

The following sections are included:

• Introduction

• Overview of Power Generation

• CO₂ Reduction Options

• CO₂ Capture and Sequestration

• Optimization and Planning Models for Power Plants

• Superstructure Representation

• Mathematical Model Development

• Case Study

• Summary

• Nomenclature

• Greek letters

• Abbreviations

• References

The following sections are included:

• Introduction

• Basics of P-graph

• Engineering Context: FCCC Systems and Biomass Resources

• Modelling Procedures

• Applying P-Graph: Heat and Power Generation Using FCCC

• Summary

• Sources of Further Information

• Nomenclature

• Abbreviations

• Symbols

• References

The following sections are included:

• Introduction

• Problem Statement

• Overall Approach

• Steam Header Balance

• Energy Integration Approach

• Extractable Work Method

• Case Study

• Conclusions

• References

The following sections are included:

• Introduction

• Design of Refrigeration Systems

• Driver Selection, Design and Optimisation

• Total Site-wide Utility Systems

• Summary

• References

The following sections are included:

• Introduction

• Characteristics of Streams in Batch Processes

• Operating Schemes of Batch Heat Integration

• Pinch Analysis Approach for Indirect Heat Integration

• Mathematic Programming Approach for Indirect Heat Integration Scheme

• Example 3: A Brewing Process

• Conclusion

• Nomenclature

• References

The following sections are included:

• Introduction

• Heat Integration

• Total Site Targeting

• Waste and Renewable Energy Sources

• Locally Integrated Energy Sector Case Study

• Conclusions

• Acknowledgements

• References

The following sections are included:

• Introduction

• Solar Thermal System Design

• Mathematical Model

• Generation of Design Space

• Conclusions

• Nomenclature

• References

The following sections are included:

• Introduction

• Why Conventional Dryers Have Low Energy Efficiency

• Classification

• Case Studies

• General Guidelines for Energy Savings

• Conclusion

• References

The following sections are included:

• Introduction

• Oil-Gas Separation Plants

• Heat Integration and Software Application in the GOSP

• Results and Discussion of Heat Integration Application in the GOSP

• Summary of Comparison

• Conclusions

• References

The following sections are included:

• Introduction

• Industry Response

• Conclusions

• References

The following sections are included:

• APPENDIX 1 THE PROCEDURE FOR DETERMINING THE DATUM LEVEL MATERIALS

• APPENDIX 2 ESTIMATION OF THE SPECIFIC CHEMICAL ENTHALPY, ENTROPY, AND EXERGY (AVAILABILITY)

• APPENDIX 3 DERIVATION OF THE MASS, ENERGY, ENTROPY-DISSIPATION AND AVAILABLE ENERGY BALANCES FOR AN UNSTEADY-STATE OPEN FLOW SYSTEM

• APPENDIX 4 ESTIMATION OF ENERGY (ENTHALPY) AND EXERGY (AVAILABILITY) CONTENTS IN STRUCTURALLY COMPLICATED MATERIALS

• APPENDIX 5 REACTION-NETWORK SYNTHESIS VIA THE GRAPH-THEORETIC METHOD BASED ON P-GRAPHS: VINYL-CHLORIDE SYNTHESIS

• APPENDIX 6 APPLICATION OF SUSTAINABILITY POTENTIAL: MANUFACTURE OF VINYL CHLORIDE (C₂H₃CL)

• APPENDIX 7 EMERGY AND EXERGY (AVAILABILITY)

• APPENDIX 8

• APPENDIX 9 MATHEMATICAL MODELS VIA LINGO 8.0

• APPENDIX 10 BRIEF MANUAL — HOW TO CODE WWTN PROBLEM IN OPTY-STO MODELING SYSTEM