DISEO SOSTENIBLE DE PROCESOS A TRAVS DE

INTEGRACIN MSICA

Prof. Eduardo SNCHEZ TUIRN

Prof. Karina OJEDA DELGADO

Maestra en Ingeniera Qumica

Universidad de Cartagena
Marzo de 2017
1
 DIRECT RECYCLE STRATEGIES

Objective: to develop a graphical procedure that determines

the target and implementation for minimum usage of the fresh
resource, maximum material reuse, and minimum discharge to
waste as a result of direct recycle.

Direct Recycle: rerouting of streams without the addition

of new units. It involves segregation, mixing, and allocation.

2
 DIRECT RECYCLE REPRESENTATION

Sources Segregated Sinks

Sources Constraints on feed flowrate
and composition

?
Source: A stream which contains the targeted species
3
Sink: An existing process unit/equipment that can accept a source
 PROBLEM STATEMENT

Consider a process with a number of process sources (e.g.,

process streams, wastes) that can be considered for possible recycle
and replacement of the fresh material and/or reduction of waste
discharge.

Each source, i, has a given flow rate, Wi, and a given

composition of a targeted species, yi. Available for service is a fresh
(external) resource that can be purchased to supplement the use of
process sources in sinks.

The sinks are process units such as reactors, separators, etc. Each
sink, j, requires a feed whose flow rate, Gj , and an inlet composition
of a targeted species, zj, must satisfy certain bounds on their values.
4
 DESIGN CHALLENGES

Should a stream (source) be segregated and split? To how many

fractions? What should be the flowrate of each split?

Should streams or splits of streams be mixed? To what extent?

What should be the optimum feed entering each sink? What

should be its composition?

What is the minimum amount of fresh resource to be used?

What is the minimum discharge of unused process sources?

5
 SOURCE-SINK MAPPING DIAGRAM

Flowrate sink
source

a
S

b
c

6
Composition
How to identify bounds on Sinks?
1. From physical limitations
(e.g., flooding flowrate, weeping flowrate, channeling flowrate, saturation
composition)
2. From manufacturer's design data
3. From technical constraints
(e.g., to avoid scaling, corrosion, explosion, buildup, etc.)
4. From historical data
5. Tolerate a certain deviation from nominal case
(e.g., allow +/- certain %ages from nominal flowrate and compositions)

Flowrate Upper bound

Entering
the Sink Lower bound

Composition Upper bound

Entering
the Sink Lower bound
7
Time
6. By constraint propagation How to identify bounds on sinks? (continued)

Unknown Constraints Known Constraints

z min
j z z in
j
max
j z min
j 1 z in
j 1 z max
j 1

in
z j
Unit j
in
Unit j+1
z j 1

From process model: z in

j 1 2z in
j

0.03 z 0.04
in 0.06 z inj1 0.08
j

8
 LEVER-ARM RULES
Flowrate
Resulting
Mixture
Wa+Wb Source
b
Source Wb
a
Wa
ya ys yb
Composition
Wa yb ys
y s (W a Wb ) y a W a y bWb
Wb y s ya
9
 LEVER-ARM RULES
Flowrate
Resulting
Mixture
Wa+Wb Source
b
Source Wb
a
Wa
ya ys yb Composition
Arm for b Arm for a
Total arm
Wa Arm for a Wa Arm for a

Wb Arm for b Wa Wb Total arm
10
 LEVER-ARM RULES FOR FRESH USAGE
Flowrate
Source
a

Feed to
Sink j

Fresh Fresh arm

Total arm
yF z Feed to sink ya
Fresh flowrate used in sink Fresh arm Composition

Total flowrate fed to sink Total arm
Fresh flowrate used in sink ya zFeed to sink
11
Total flowrate fed to sink ya y F
 SINK COMPOSITION RULE
Flowrate
Source
a

Sink j

Fresh ? ? ?

min avg max

z j z j z j
ya
What should be feed composition to sink to minimize fresh usage?

12
 SINK COMPOSITION RULE
Flowrate
Source
a

Sink j

Fresh
Minimum
fresh arm

max
z j
ya
What should be feed composition to sink to minimize fresh usage?
Sink Composition Rule: When a fresh resource is mixed with process
source(s), the composition of the mixture entering the sink should be set to a
value that minimizes the fresh arm. For instance, when the pure fresh, the
13
composition of the mixture should be set to the maximum admissible value.
 SOURCE PRIORITIZATION RULE
Source
Flowrate Source b
a

Sink j

Fresh

yF z max ya yb
j Composition
Which source (a or b) should be used to minimize fresh usage?
Source Prioritization Rule: To minimize the usage of the fresh resource, recycle of
the process sources should be prioritized in order of their fresh arms starting with the
source having the shortest fresh arm. 14
 Targeting Rules
Recycle Strategies
Fresh_Loadk,1
1 4 Terminal_Loadk,1
Fresh_Loadk,2
2
Terminal_Loadk,2
Fresh_Loadk,3 3 5 Terminal_Loadk,3
Terminal_Loadk,4

Process Before Recycle

Recycle Alternatives to Reduce Terminal Load
Fresh_Loadk,1
1 4 Terminal_Loadk,1 Rk,1+ Rk,2
Fresh_Loadk,2 Rk,2
2
Terminal_Loadk,2 Rk,2
Rk,1
Fresh_Loadk,3 3 Terminal_Loadk,3
Terminal_Loadk,4 + Rk,1
5

Poor Recycle Net terminal load unchanged 15

Fresh_Loadk,1 Rk,2
1 4 Terminal_Loadk,1 Rk,1
R k,2
Fresh_Loadk,2 Rk,1 R k,1
Terminal_Loadk,2 Rk,2
2

Fresh_Loadk,3 3 5 Terminal_Loadk,3
Terminal_Loadk,4

Effective Recycle From Terminal

Fresh_Loadk,1 Rk,2
1 4 Terminal_Loadk,1 Rk,1
R k,2
Fresh_Loadk,2 Rk,1 R k,1
Terminal_Loadk,2 Rk,2
2

Fresh_Loadk,3 3 5 Terminal_Loadk,3
Terminal_Loadk,4

Effective Recycle From Terminal and Intermediate

16
Example 1: Minimization of Reactant Usage

Fresh
Reactant Top
Product
Wfresh = 100 kg/s
yfresh = 0.0% Other Wtop= 60 kg/s
(impurities) units ytop = 10%
Reactor Separator (impurities)
Maximum inlet
concentration = 5%
of impurities

Bottom
Product
Wbottom= 216 kg/s
What is optimum recycle strategy? ybottom = 75%
(impurities)

17
 Problem Representation
R
W Top
Fresh
Reactant Top
Product
Wfresh = 100 kg/s
yfresh = 0.0% Other Wtop= 60 kg/s
(impurities) units ytop = 10%
Reactor Separator (impurities)
Maximum inlet
concentration = 5%
of impurities

Bottom
Product
R Wbottom= 216 kg/s
WBottom ybottom = 75%
(impurities)
18
 Source-Sink Mapping

Recycling top product

Flowrate
Fresh 0.10 0.05 Bottom
216

100 0.10 0.00
Fresh = 50 kg/s
Fresh
Reactor
100

Top
60

0.00 0.05 0.10 0.75

Mass Fraction of Impurities

19
 Comparison with Inferior Alternative (Longer Arm)

Examine recycle from bottom product

Fresh + FRbottom = 100

Fresh * 0.0 + FRbottom * 0.75 = 100*0.05

FRbottom = 6.7 kg/s
Fresh = 100.0 - 6.7 = 92.3 kg/s 6.7% reduction in fresh

Better to recycle from the shorter arm (can recycle more and save more)

20
 Example 2: Minimization of Nitrogen Usage in Magnetic Tape Facility

Gaseous
Decomposed
Emission
Organics WTotal= 8.5 kg/s
0.011 kg/s Coating 0.93% Solvent
Waste
Dispersants W1= 3.0 kg/s Drying
Magnetic and Waste
Pigments W = 5.5 kg/s
2
Lubricants 1.90% Solvent 0.40% Solvent
Solvent
Resin Slurry
Binders Premixing Dispersion Coating Drying
Premixing
Dry Tape
Additives Base Product
Resins Film
Fresh Fresh
Nitrogen Nitrogen

21
Coating
3.0 flowrate of gaseous feed (kg/s) 3.2
0.0 wt % of solvent 0.2

Dryer
5.5 flowrate of gaseous feed (kg/s) 6.0
0.0 wt % of solvent 0.1

22
 Source-Sink Mapping
Dryer
5.5 flowrate of gaseous feed (kg/s) 6.0
6.0 0.0 wt % of solvent 0.1
Flowrate, kg/s
5.5 Drying
5.0 Waste
Dryer

4.0

3.2 Coating
3.0 flowrate of gaseous feed (kg/s) 3.2 Coating
3.0
0.0 wt % of solvent 0.2 Waste
Coating
2.0

1.0
0 0.20 0.40 0.60 0.80 1.00 1.20 1.40 1.60 1.80 2.00
0.10% 1.90%
Composition, wt.% solvent

23
 Determine WDryingWast e Coating

Coating
Coating Feed
3.0 kg/s
0.2% solvent
WDryingWast e Coating ?
Drying
Fresh
Waste
Nitrogen ?
5.5 kg/s
Fresh nitrogen in coating 0.004 0.002 0.4% solvent

3.0 0.004 0.00
Fresh nitrogen used in coating = 1.5 kg/s
WDryingWast e Coating = 1.5 kg/s 24
 Drying Unit
Drying waste is shortest arm

Fresh nitrogen used in drying 0.004 0.001

5 .5 0.004 0.00

Fresh nitrogen used in drying unit = 4.125 kg/s

WDryingWast e Drying = 5.500 - 4.125 = 1.375 kg/s

Minimum fresh nitrogen consumption in coating and drying

after direct recycle = 1.500 + 4.125 = 5.625 kg/s

34% Savings
25
Example 3: Minimization of AA Usage in VAM Process

Gas CO2

Ethylene Purification
Oxygen
H2O

Absorber II
5,100 AA 200
1,200 AA
+ Ethylene,
O2 and CO2

Absorber I
Ethylene
Oxygen 1,200 AA
Reactor 200 H2O
(7,000 kg/hr (86% AA)
10,000 AA Acetic Acid
200 H2O Reacted)

Acid Tower Primary 10,000 VAM

(Evaporator) 10,000 VAM 100 AA
6,900 AA Tower
200 H2O
2,300 H2O
10,000 AA
6,800 AA
200 H2O
2,300 H2O
(75% AA) To Neutralization
and Biotreatment 26
 Source-Sink Mapping Diagram for AA Example
Flowrate, 12,000
kg/hr 11,200
S1
10,200
Acid Tower Bottoms of
10,000 Primary Tower
R2
9,100

8,000

S2
6,000
Abs. I
5,100

4,000

2,000 Bottoms of
Absorber II
1,400 R1
0
0.0 5.0 10.0 15.0 20.0 25.0 30.0
14.0

Water content, wt.% 27

 For S1, R1 has shortest AA arm
Flowrate, 12,000
kg/hr 11,200
S1
10,200
Acid Tower Bottoms of
10,000 Primary Tower
R2
9,100

8,000
Fresh AA used in S1 0.14 0.10

6,000
S2 10,200 0.14 0.00
Abs. I Fresh AA in S1 = 2,914 kg/hr
5,100 WR1 S1 10,200 2,914 = 7,286 kg/s
4,000 Use all of R1 (1,400 kg/s)

2,000 Bottoms of
Absorber II
1,400 R1
0
0.0 5.0 10.0 15.0 20.0 25.0 30.0
14.0

Water content, wt.% 28

 Acid Tower Continued
Flowrate, 12,000
kg/hr 11,200
S1
10,200
Acid Tower Bottoms of
10,000 Primary Tower
R2
9,100

8,000
1,400*0.14 + *0.25 + Fresh AA in S1* 0.0 =
S2
6,000 10,200*0.10
Abs. I
5,100 WR2 S1 = 3,296 kg/hr
4,000 Fresh AA in S1 = 10,200 1,400 3,296 =
5,504 kg/hr
2,000 Bottoms of
Absorber II
1,400 R1
0
0.0 5.0 10.0 15.0 20.0 25.0 30.0
14.0

Water content, wt.% 29

 Absorber I Calculations
Flowrate, 12,000
kg/hr 11,200
S1
10,200
Acid Tower Bottoms of
10,000 Primary Tower
R2
9,100

8,000
Fresh AA used in S2 0.25 0.05
S2
6,000 5,100 0.25 0.00
Abs. I Fresh AA in S2 = 4,080 kg/hr
5,100

4,000 WR2 S 2 5,100 1,020 =

1,020 kg/hr
2,000 Bottoms of
Absorber II
1,400 R1
0
0.0 5.0 10.0 15.0 20.0 25.0 30.0
14.0

Water content, wt.% 30

SOLUTION TO AA MINIMIZATION PROBLEM
R1
1,400 kg/hr S1
Acid Tower

5,504 kg/hr
3,296 kg/hr
R2
9,100 kg/hr 1,020 kg/hr S2
Abs. I
4,080 kg/hr
Fresh AA
9,584 kg/hr
Waste
4,784 kg/hr

31
ALTERNATE SOLUTION TO AA MINIMIZATION PROBLEM
Start with S2 and use R1 for shortest arm.
R1
1,400 kg/hr S1
4,080 kg/hr
Acid Tower

6,120 kg/hr
R2
9,100 kg/hr 236 kg/hr S2
Abs. I
3,464 kg/hr
Fresh AA
9,584 kg/hr
Waste
4,784 kg/hr

32
ALTERNATE SOLUTION TO AA MINIMIZATION PROBLEM
Split R1 between two sinks.
R1
1,400 kg/hr 700 kg/hr S1
Acid Tower
700 kg/hr
5,812 kg/hr
3,688 kg/hr
R2
9,100 kg/hr 628 kg/hr S2
Abs. I
3,772 kg/hr
Fresh AA
9,584 kg/hr
Waste
4,784 kg/hr

Same target, infinite implementations.

33
Need a targeting procedure before detailed implementation
MATERIAL RECYCLE PINCH DIAGRAM

34
 Sink Composite Diagram

Load Rank in ascending

order of composition
Sink
Composite
Sink , max Curve
M 3

0z z in
j
max
j
Sink , max M Sink , max
G z max
M 2
j j j

Sink , max
M 1
Flowrate
G1 G2 G3 35
 Source Composite Diagram
Load

M Source M i
Source
Wi y i
3

Source
Composite
Curve
Source
M 2

Rank in ascending
Source
M 1
order of composition

W1 W2 W336
Flowrate
 Sink Composite Must Lie Above Source Composite

Load
Sink
Composite
Curve

Source
Composite
Curve
37
Flowrate
 Integrating Source and Sink Composites

Load
Sink
Composite
Curve
Material
Recycle
Pinch
Point

Source
Composite
Curve
38
Flowrate
 Material Recycle Pinch Diagram

Load Rigorous targets ahead

of detailed design Sink
Composite
Curve
Material
Recycle
Pinch
Point

Source
Composite
Curve

Minimum Maximum Minimum

Fresh Recycle Waste 39
(pure fresh) Flowrate
 Passing Flow through the Pinch
Load (not enough integration)
Sink
Composite
Curve

Source
Composite
Curve

Fresh Recycle Waste

Minimum Minimum Flowrate
40
 Infeasible Recycle
(too much integration)

Load
Sink Source
Composite Composite
Curve Curve
Infeasible
Region

41
Flowrate
 Material Recycle Pinch Diagram for Impure Fresh
Load
Sink
Composite
Curve Source
Composite
Material
Curve
Recycle
Pinch
Point

Fresh
Locus

Minimum Maximum Minimum

Fresh Recycle Waste 42
Flowrate
 Sink
Composite
MaterialCurve
Recycle
Useful Design Rules Pinch
For Material Recycle Point
Pinch Diagram
Source
Composite
Curve
Minimum Maximum Minimum
Fresh Recycle Waste
No flowrate should be passed through the pinch
(i.e. the two composites must touch)
No waste should be discharged from sources
below the pinch
No fresh should be used in any sink above the
pinch 43
 Effect of Interception
Load
Sink
Composite
Curve

Material
Recycle
Pinch
Inter- Point
ceptor

Source
Composite
Curve

44
Minimum Flowrate Minimum
Fresh Waste
Example Revisited: Minimization of AA Usage in VAM Process

Gas CO2

Ethylene Purification
Oxygen
H2O

Absorber II
5,100 AA 200
1,200 AA
+ Ethylene,
O2 and CO2

Absorber I
Ethylene
Oxygen 1,200 AA
Reactor 200 H2O
(7,000 kg/hr (86% AA)
10,000 AA Acetic Acid
200 H2O Reacted)

Acid Tower Primary 10,000 VAM

(Evaporator) 10,000 VAM 100 AA
6,900 AA Tower
200 H2O
2,300 H2O
10,000 AA
6,800 AA
200 H2O
2,300 H2O
(75% AA) To Neutralization
and Biotreatment 45
 2500
Sink Flowrate Maximum Maximum
2250 kg/hr Inlet Inlet
Mass Load, kg/hr
Load Fraction
kg/hr2000 Absorber I 5,100 0.05 255

1750
Acid 10,200 0.10 1,020
Tower
1500
1275
1250

1000
Acid Sink
750 Tower Composite
Curve
500

255
250 Absrober

0
0 2 4 5.1 6 8 10 12 14 15.3 16 18 20 46
Flowrate, 1000 kg/hr
 2500
2471

2250
Load
Source
kg/hr2000 Acid Composite
Tower Curve
1750
Bottoms
1500
Source Flowrate Inlet Inlet
kg/hr Mass Load,
1250 Fraction kg/hr

1000 Bottoms of 1,400 0.14 196

Absorber II

750
Bottoms 9,100 0.25 2,275
500 of Primary
Tower
250
196
Absrober II
Bottoms
0 47
0 1.4 2 4 6 8 1010.5 12 14 16 18 20
 2500

2250
Load
kg/hr2000

1750
Material Reuse
Pinch Point Source
1500 Composite
Curve
1275
1250

Sink Waste = 4.8

1000
Composite
Curve
750

500
Material Recycle Pinch Diagram
250 For AA In the VAM Facility
Fresh = 9.6
0 48
0 2 4 6 8 10 12 14 15.3 16 18 20
 Example 4: Food Processing Facility
Scrubbing
Water

Scrubber
Wash
Water Offgas

Condensate I
Feedstock Washer
Processing
Condensate II
Facility

Main Product

Solid Byproducts
Waste

49
Two sources (Condensate I and II), Two Sinks (Washer and Scrubber)
 Sink Data for the Food Processing Example
Sink Flowrate Maximum Inlet Maximum Inlet
kg/hr Mass Fraction Load, kg/hr

Washer 8,000 0.03 240

Scrubber 10,000 0.05 500

Source Data for the Food Processing Example

Source Flowrate Inlet Inlet
kg/hr Mass Fraction Load, kg/hr

Condensate I 10,000 0.02 200

Condensate II 9,000 0.09 810

50
 Scrubbing
Water
10,000 kg/hr
Scrubber
Wash
Water Offgas
8,000 kg/hr Condensate I

Feedstock Washer
Processing Condensate II
9,000 kg/hr
Facility

Main Product

Solid Byproducts
Waste

Critique project proposed by engineer:

Recycle Condensate I to Scrubber
51
Reduce fresh water to 8,000 kg/hr (down from 18,000 kg/hr)
 1,125
Load
kg/hr1,000
1,010 Before assessing
the proposed project,
875 Pinch Source lets benchmark
Composite using the material recyc
750 Curve pinch diagram
740

Scrubber
625 Waste
Sink
500 Composite Condensate II
Curve Material Recycle Pinch Diagram
375 For Food Processing Facility
without Proposed Project
250
240
200
125 Washer Target for fresh AA == 2,000 kg/hr
Condensate I (25% of proposed project)
0
0 2 4 8 12 16 20 24 28 32 36 4052
18 21
Fresh Flowrate, 1000 kg/hr
 1,125
Load Waste
Lets represent
kg/hr1,000
1,010
proposed project
875
Proposed
Recycle
Pinch
Location =
6,000
750 kg/hr
740

Scrubber
625

500 Condensate II

Proposed project:
375
6,000 kg/hr more
250
than fresh target
240
200 = Flowrate passed
125 Washer through the pinch
Condensate I Do not pass flow
0 through the pinch
0 4 8 12 16
18
20 24 2728 32 36 4053
Fresh Flowrate, 1000 kg/hr
 1,125
Load If proposed project has been implemented,
Can we still use pinch analysis to reduce
kg/hr1,000
Fresh usage?

875 Improvement after implementation of

proposed project
750
740
Fresh usage: 5,300 kg/hr (265% of target)
625

500
Condensate II

375 Big picture yields insights unseen by

detailed engineering (unit/stream based)
250
240
Short-term projects must be part of an
125 Washer overall integrated strategy

0
0 4 5.3 8 12 14.3 16 20 24 28 32 36 4054
Fresh Waste
Flowrate, 1000 kg/hr
 CONCLUSIONS
Source and sink optimization rules
Stream rerouting and direct recycle opportunities
using source-sink mapping
Overall targeting for direct recycle using
material recycle pinch diagram
Big-picture insights unseen by detailed eng.
Short-term projects must fit in integrated
strategies

55