CHEG 5165 –Process

Integration And Pinch Analysis

Department of Chemical Engineering

BiT-BDU
CHAPTER ONE
Introduction to process integration
Lecture No. 1
By Desalegn A.
July, 2021
 What is the purpose of this course?

This course is intended to covey the basic aspects of Process

Integration Methods and Tools, and places Process Integration
into a broad perspective. It will be identified as a pre-requisite for
all other modules related to the learning of Process Integration.

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Overview and content of the course

Course Title & Code : Process integration & Pinch Analysis

(Cheg 5165)

Module Title : Process systems Engineering

Student Workload in Hour (Per week): Lecture, Tutorials , Lab
Practice, Home Study

Pre-requisite (s): Plant Design and Economics

Course status : Compulsory

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Software Tools

For optimization and

simulation

For pinch analysis

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Outline

 Introduction to process integration

 Process synthesis and design
 Product and process design procedure
 Activities of process integration

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Introduction

 The process industries are among the most important

manufacturing facilities.
 They span a wide range of industries including chemical,
petroleum, gas, petrochemical, pharmaceutical, food,
microelectronics, metal, textile, and forestry products.
 The performance of these industries is strongly
dependent on their engineering and engineers.

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Why do human synthesize, design, built and operate
chemical processes?

• To make a product that has a specific desired function

• To convert waste materials into useful products

• To improve the performance of a natural material
• To convert material into energy

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 Definitions of process integration

"Process Integration is the common term used for the application of

methodologies developed for System-oriented and Integrated
approaches to industrial process plant design for both new and
retrofit applications.

Such methodologies can be mathematical, thermodynamic and

economic models, methods and techniques. Examples of these
methods include: Artificial Intelligence (AI), Hierarchical
Analysis, Pinch Analysis and Mathematical Programming.

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Cont…

Process integration is a holistic approach to process design,

retrofitting, and operation which emphasizes the unity of the
process (El-Halwagi 1997).

Process Integration refers to Optimal Design; examples of

aspects are: capital investment, energy efficiency, emissions,
operability, flexibility, controllability, safety and yields.
Process Integration also refers to some aspects of operation and
maintenance."

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What is unique in Process Integration (PI)?

♦ Pinch Analysis (PA) was developed in the 1970s/1980s based on the

discovery of a Heat Recovery Pinch, and PA was the Birth of PI.

♦ Improving Process Technologies through Operating and

Engineering Insight using Design base was replaced by Systematic
Design using Targets.
♦ The new Design Methods enabled Step Changes in Performance.
The real Value of Performance Targets ahead of Design:
♦ Removing the Uncertainty among Engineers whether a Process
Design could be further improved and by how much

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 Categories of Process Integration:
One method of classification is based on the two main commodities consumed
and processed in a typical facility:
Energy and mass integration
“Energy integration” is a systematic methodology that provides a
fundamental understanding of energy utilization within the process and
employs this understanding in identifying energy targets and optimizing
heat-recovery and energy-utility systems.”

“Mass integration” is a systematic methodology that provides a fundamental

understanding of the global flow of mass within the process and employs
this understanding in identifying performance targets and optimizing the
generation and routing of species throughout the process.

Other Recently Introduced

“Property integration’’ (El-Halwagi, chapter 8)

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Process synthesis and design
What Is Process Synthesis?
• ‘‘The discrete decision-making activities of conjecturing which of the
many available component parts one should use, and how they should be
interconnected to structure the optimal solution to a given design
problem’’
• Process synthesis is concerned with the activities in which the various
process elements are combined and the flow sheet of the system is
generated so as to meet certain objectives.
• Therefore, the aim of process synthesis (Johns 2001) is: ‘‘to optimize the
logical structure of a chemical process, specifically the sequence of steps
(reaction, distillation, extraction, etc.), the choice of chemical employed
(including extraction agents), and the source and destination of recycle 12
There are two important process synthesis models:

• Hierarchical approach

• Onion model

Hierarchical Approach (Douglas 1985)

• Hierarchical Approach is based on physical reasoning.

• The development of a flow sheet following the Hierarchical

Approach is essentially a top-down analysis organized as

clearly defined sequence of tasks grouped in levels.

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Douglas (1985)

‘After an extensive series of discussions with industrial

designers, there seems to be a consensus that the major errors in
existing designs were caused by fixing the flow sheet too early in
the development of a process.
In other words, someone realized that there was a better process
alternative when it was too late to make changes in the project
definition.

Thus, there is a need to have better tools available that can be

used to generate and screen process alternatives.

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Process synthesis and design

Operations? Desired
Available
Connectivity?
feedstock products
Conditions?

• What is process synthesis and design?

– Choosing a combination of operations, connections and
conditions to transform feedstock into products

• Streams are characterised by

– Flowrate, chemical composition, T, p, phase, physical
structure (if not a homogeneous fluid), …

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 Operations, connectivity and conditions
• Operations
– Reaction
– Separation of chemical mixtures
– Change of conditions (T, p or phase)
– Mixing or flow splitting of streams or batches
– Size enlargement or reduction for solids
– Task integration
• Connectivity
– Reaction and separation sections
– Vapour, liquid and solids processing sections
– Recycle and purge streams
• Operating conditions and equipment design specifications
– Temperature, pressure, flowrate, residence time, heat transfer area,
number of trays, feed tray location, …
(SSL2, p70,231)

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Process synthesis and design

Available
Operations? Desired
feedstocks Connectivity? products
Conditions?

Why is it difficult?
• A large number of operations
• Many ways to connect units
• An infinite choice operating conditions and equipment design
parameters
• We cannot try every possibility, or even come close to it

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Hierarchical Approach of Process Design
The classical hierarchical approach of conceptual design proposed by
Douglas is organized in eight levels
0. Input information.
1. Number of plants.
2. Input/output structure and connection of plants.
3. Recycle structure of simple plants.
4. Separation systems of simple plants:
 General architecture: identify specific separation subsystems.
 Vapor and gases recovery and separation system.
 Solid recovery: getting valuable solids from solutions.
 Liquid - separation system: separate products from liquid
mixtures.
 Solid - separation system: separate solid products.
 Combine the separation systems and study interactions

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5. Energy integration:
 Pinch - point analysis for optimal heat and power saving.
 Water minimization: design an efficient system for water recycling.
 Solvent minimization: design an efficient system for solvent recycling.

6. Design alternatives.
7. Hazop analysis:
 Identify the sources of hazards and risks.
 Perform hazard and operability study.

8. Control - system synthesis:

 Plant wide control.
 Control structure of units

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Source: Dimian, Alexandre C., Costin Sorin Bildea, and Anton A. Kiss.
Integrated design and simulation of chemical processes. Elsevier, 2014.

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The “Onion” Model (Smith and Linnhoff, 1995)

Basic idea source: The onion model is a graph-based diagram

template for describing an expanding or extending relationship
between process elements. The name is a metaphor (symbol) of the

layered shells that become visible when you cut open an onion.
Inside out interpretation of onion model

Process design start with the reactor

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2nd layer

Once we know the reactor design, we need to specify the

separation system

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 3rd layer

Once we know the reactor and separator design, we know the

material and energy balance Heat exchanger network.

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4th layer

Once we have the process and HEN design utilities

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Cont…
Utilities

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Cont.…
Water management

Water and effluent system treatment 26

Cont.…

Complete onion

Complex problem but with many facets

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Three broad approaches to process synthesis
1. Modify an existing structure
‘Take an existing process and tweak it’

2. Sequentially build up a new structure

‘Divide and conquer: build up the structure in a series of
logical steps’

3. Superstructure optimisation
‘Take a very flexible structure with in-built redundancy and
simplify it’

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1. Synthesis by modifying an existing structure

Take an existing process for the same or a similar product and explore
modifications
– It is not really synthesis (the act of combining elements into
a coherent whole) because we start from a complete structure
– Add, delete or modify units to suit the desired product,
available feed or other conditions (cost of energy, water, …)
Advantages
• Quick way to start
• Uses a proven process
Disadvantages
• Suppresses innovation
• Flowsheet may be good for its original design conditions, but may
not be best for the current conditions of interest

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1. Synthesis by modifying an existing structure

Consider a different Swap the order

reactor type of separation

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2. Synthesis by sequentially building up a new structure

Relies on considering the process as a hierarchy of operations,

then building up the structure in a series of steps according to
the hierarchy
– Several hierarchical descriptions for processes are available: Smith,
Douglas, …
– At each step, make decisions based on the information available at that
stage, that is, it is a sequence of ‘best local decisions’
– If we could look ahead, other decisions might be made
– Decisions are based on heuristics or algorithmic methods
– Equipment is added to the flowsheet only if it can be technically and
economically justified
– Consequently, the structure developed is irreducible, meaning that it
contains no redundancy (compare with approach 3.)

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Three hierarchical views of process synthesis:
(i) SSL (Seider, Seader & Lewin)

Feed Process Product

(xF, TF, pF) (xP,TP ,pp)

Synthesis is based on idea of ‘eliminating differences’ between (xF,TF,pF) & (xP,TP,pP)

Process synthesis steps of SSL: Corresponding operations:

1. Eliminate differences in molecular type Reaction
2. Distribute chemicals by matching Stream routing and mixing
sources and sinks
3. Eliminate differences in composition Separation
4. Eliminate differences in T, p and phase T, p and phase change
5. Integrate tasks Combine operations

Promising alternatives at each step are retained, forming a synthesis tree

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The synthesis tree concept

5. Task
3. Separations
1. integratio
Reaction n
4. T, p &
pathway phase
Abandoned 2. changes
infeasible Distribution
alternatives of chemicals

Competitive
alternatives

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Three hierarchical views of process synthesis:
(ii) Smith

‘Onion layer’ model of Smith:

Basic rule: inner

Reactor layers are completed
before outer layers
Separation &
recycle system

Heat recovery
system But, you may need to
backtrack and revise
Heating & cooling previous layers
utilities
Water & effluent
treatment

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Three hierarchical views of process synthesis:
(iii) Douglas

Feeds Process Products

(Inputs) (Outputs)

Process synthesis decision hierarchy of Douglas:

Level 1: Batch v continuous (Start here)
Level 2: Input-output structure of the flowsheet Economic evaluation is
Level 3: Recycle structure and reactor considerations used at end of each level
to find feasible range of
Level 4: Separation system specification design variables and to
Level 4a: Vapour recovery system decide whether to
continue with the design
Level 4b: Liquid recovery system
Level 5: Heat exchanger network (Finish here)

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2. Synthesis by sequentially building up a new structure
– Advantages
• The design team is in control at each stage of the
process, and can gain a feeling for the issues
• Concerns such as safety and plant layout can be included
in the decision making process as the design proceeds
– Disadvantages
• At each stage, the best option is sought, but it may not be
possible to decide which is best without evaluating
competing options – consequently many designs must be
completed and optimised
• There is no guarantee that the optimum design is chosen
because it is not possible to evaluate every option
• Complex interactions between different parts of the
flowsheet may not be recognised and exploited
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 3. Synthesis by superstructure optimisation
• A superstructure is a flowsheet that contains all feasible unit operations with

all feasible interconnections (for the design problem under consideration)

• The superstructure is a reducible flowsheet that intentionally contains

redundancy

• It is intended that the optimal structure is embedded somewhere within the

superstructure

• Optimisation is applied to the superstructure to reveal the best structure and

parameter values simultaneously

• Compared to approach 2, a sequence of discrete decision making steps is

replaced by a mixed structure and parameter optimisation problem

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A superstructure for the production of benzene from toluene and hydrogen

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Optimised flowsheet

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Setting up the optimisation problem
It may be formulated as a mixed integer nonlinear programming (MINLP)
problem, for example:

 T
z  min c y  f (x)
x,y
 Objective function

h ( x)  0
g ( x)  0
Constraints
Ax  a
By  Cx  d
x  X  {x | x  R n , x L  x  xU }
Variable
y  Y  {y | y  {0,1}m , Ey  e} definitions

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 y = binary variables: yi=1 if
Objective function: unit i is present, yi=0 if absent
minimise cost by
x = continuous variables,
varying x and y
 T
z  m in c y  f ( x )
x ,y
 e.g. reactor T and p,
recycle flowrate, tank
volume, heat transfer area
The process model:
material and energy
balances and design
equations
h ( x)  0 Process specifications,
e.g. purity ≥ 99%
g ( x)  0
Ax  a Constraints to enforce
conditions such as… if
By  Cx  d reactor i is not present,
then it has zero volume
and zero inlet flowrate
Continuous variables bounded
by upper and lower limits
x  X  {x | x  R n , x L  x  x U }
Binary variable restrictions, e.g.
select exactly one reactor y  Y  {y | y  {0,1}m , Ey  e}
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 3. Synthesis by superstructure optimisation
• Advantages
– Many different design options are considered simultaneously, compared to
sequentially with approach 2.
– Complex interactions and trade-offs in the plant are considered
automatically
– Consequently, the design process can be automated and, once set up, can
produce designs quickly and efficiently

• Disadvantages
– It can’t reach the best solution if the optimal structure is not embedded
somewhere in the superstructure
– Mixed discrete/continuous optimisations can be large and difficult problems
to solve
– Most serious problem – the design team is removed from the decision
making process; building up process understanding is lost; and it is difficult to
include factors such as safety and layout in the formulation of the
optimisation problem

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Product and process design procedure
Steps in chemical process design (or retrofitting)
– Create and assess the primitive problem

(which may include Product Design)

– Preliminary process creation
– Development of a base case
– Detailed process synthesis using algorithmic methods
– Process controllability assessment

– Detailed design, sizing, cost estimation, optimisation

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Product design
What chemical composition and physical structure
produces the desired set of product attributes?

– Melting point, solubility, viscosity, toxicity, strength, size,

flowability, dissolution rate, shelf life, …

– Tools used in product design

• A systematic procedure (SSL, p649)
• Property estimation methods
– Correlations: relating structure to properties, e.g. UNIFAC
– Micro-simulation: e.g. molecular dynamics
• Experiments
• Optimisation and experimental design methods

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Tools used to aid process synthesis
• Heuristics
• Algorithmic methods
• Process simulation

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1. Heuristics (rules of thumb)
Many are available in SSL, Ch6

e.g. “Use an excess of one chemical reactant in a reaction

operation to consume completely a valuable, toxic, or hazardous
chemical reactant. The MSDSs will indicate which chemicals are
toxic and hazardous.”
– Developed from years of experience

– Immensely helpful for quickly establishing a flowsheet

– Often lead to near optimal designs

– Should be checked and revised later in the design using

simulation, algorithmic methods and optimisation

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2. Algorithmic methods
• Algorithm: a set of unambiguous instructions (a procedure)
for solving a problem
• Used after a synthesis tree has been created, while developing
base case designs
• Examples where algorithmic methods are used:
– Reactor network synthesis
– Separation train synthesis
– Reactor – separator – recycle network synthesis
– Heat exchanger network synthesis
– Mass exchanger network synthesis
– Optimal design and scheduling of batch processes

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3. Process simulation
• Process simulators, such as HYSYS and Aspen Plus, have
many facilities:
– Property prediction
– Simulation
– Sensitivity analysis
– Optimisation
– Data fitting
– Plotting and report generation

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Steps of activities in Process integration
Process integration involves the following activities:
1. Task Identification:
2. Targeting:
3. Selection of Alternative(s) (Synthesis):
4. Analysis of Selected Alternative(s):

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 What is “Process intensification”
This definition can be usefully interpreted as being a process development
involving dramatically smaller equipment which leads to:
1. Improved control of reactor kinetics giving higher selectivity/reduced
waste products.
2. Higher energy efficiency.
3. Reduced capital costs.
4. Reduced inventory/improved intrinsic safety/fast response times.
‘Intensification’ is commonly associated with the increases in productivity of
any chemical engineering development that leads to a substantially smaller,
cleaner, safer and more energy efficient technology is process
intensification ’. D. Reay, C. Ramshaw, A. Harvey, 2013.
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Lecture summary
• Process synthesis and design is about transforming feedstock into products
in a safe, environmentally responsible and economical manner
• PS&D suffers from combinatorial complexity (w=2n(n-1)/2, plus an infinite
choice of operating conditions)
• We need tools to help overcome this problem, e.g. a well-developed
process synthesis and design procedure, heuristics, algorithmic methods, a
reliable process simulator, optimisation techniques, …
• Three approaches to synthesis are: modify something already available,
build up the flowsheet using some vision of a process hierarchy (‘reactors
are the heart of the process’, …), or create and optimise a superstructure
• Explanation on process integration and general activities involved in
process integration.
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References
• Douglas: JM Douglas (1985) “A hierarchical decision procedure for process
synthesis”, AIChE Journal 31(3):353-362

• K&G88: GR Kocis and IE Grossmann (1988) “Global optimization of nonconvex

mixed-integer nonlinear programming (MINLP) problems in process synthesis”,
Industrial and Engineering Chemistry Research 27(8):1407-1421

• K&G89: GR Kocis and IE Grossmann (1989) “A modelling and decomposition

strategy for the MINLP optimization of process flowsheets”, Computers &
Chemical Engineering 13(7):797-819

• Smith: R Smith (2005) Chemical Process Design and Integration, John Wiley &
Sons, Chichester, England

• SSL2: WD Seider, JD Seader and DR Lewin (2004) Product & Process Design
Principles, 2ed, John Wiley & Sons, New York

• Dimian, Alexandre C., Costin Sorin Bildea, and Anton A. Kiss. Integrated design
and simulation of chemical processes. Elsevier, 2014.

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