Pollution Prevention through Process

The environmental impact of industrial waste is one of the most serious challenges facing the chemical process industries. From a focus on end-of-pipe treatment in the 1970s, chemical manufacturers have increasinglyimplemented pollution prevention policies in which pollutants are mitigated at the source or separated and recovered and then reused or sold. this book is the first to present systematic techniques for cost-effective pollution prevention, altering what has been an art that depends on experience and subjective opinion into a science rooted in fundamental engineering principles and process integration. Step-by-step procedures are presented that are widely applicable to the chemical, petrochemical, petroleum, pharmaceutical, food, and metals industries. various levels of sophistication ranging from graphical methods to algebraic procedures and mathematical optimization, numerous applications and case studies, and integrated software for optimizing waste recovery systems make Pollution Prevention through Process Integration: Systematic Design Tools a must read for a wide spectrum of practicing engineers, environmental scientists, plant managers, advanced undergraduate and graduate students, and researchers in the areas of pollution prevention andprocess integration.

Preface

xiii

CHAPTER ONE Introduction

1

(15)

1.1 The Environmental Problem and Pollution Prevention

1

(2)

1.2 What is Process Integration?

3

(3)

1.2.1 Process Synthesis

3

(2)

1.2.2 Process Analysis

5

(1)

1.2.3 Process Optimization

5

(1)

1.3 Can Flowsheets Provide Global Insights?

6

(4)

1.4 Branches of Process Integration: Mass Integration and Energy Integration

10

(2)

1.5 Structure of the Book

12

(4)

CHAPTER TWO Modeling of Mass-Exchange Units for Environmental Applications

16

(28)

2.1 What Is a Mass Exchanger?

16

(1)

2.2 Equilibrium

17

(2)

2.3 Interphase Mass Transfer

19

(1)

2.4 Types and Sizes of Mass Exchangers

20

(6)

2.5 Minimizing Cost of Mass-Exchange Systems

26

(18)

CHAPTER THREE Synthesis of Mass-Exchange Networks A Graphical Approach

44

(40)

3.1 A Network versus a Unit

44

(1)

3.2 Problem Scope, Significance, and Complexity

44

(1)

3.3 Mass-Exchange Network Synthesis Task

45

(2)

3.4 The Targeting Approach

47

(1)

3.5 The Corresponding Composition Scales

47

(2)

3.6 The Pinch Diagram

49

(19)

3.7 Constructing Pinch Diagrams without Process MSAs

68

(4)

3.8 Trading Off Fixed versus Operating Costs

72

(12)

CHAPTER FOUR Graphical Techniques for Mass Integration with Mass-Exchange Interception

84

(21)

4.1 The Source-Sink Mapping Diagram

84

(2)

4.2 Application of Mass Integration to Enhance Yield, Debottleneck the Process and Reduce Wastewater in an Acrylonitrile "an" Plant

86

(19)

CHAPTER FIVE Synthesis of Mass-Exchange Networks--An Algebraic Approach

105

(21)

5.1 The Composition-Interval Diagram "CID"

105

(1)

5.2 Table of Exchangeable Loads "TEL"

106

(1)

5.3 Mass-Exchange Cascade Diagram

107

(2)

5.4 Example on Dephenolization of Aqueous Wastes

109

(2)

5.5 Synthesis of MENs with Minimum Number of Exchangers

111

(1)

5.6 Feasibility Criteria at the Pinch

112

(3)

5.6.1 Stream Population

113

(1)

5.6.2 Operating Line Versus Equilibrium Line

113

(2)

5.7 Network Synthesis

115

(4)

5.8 Trading Off Fixed versus Operating Costs Using Mass-Load Paths

119

(7)

CHAPTER SIX Synthesis of Mass-Exchange Networks: A Mathematical Programming Approach

126

(28)

6.1 Generalization of the Composition Interval Diagram

126

(1)

6.2 Problem Formulation

127

(1)

6.3 The Dephenolization Example Revisited

128

(5)

6.4 Optimization of Outlet Compositions

133

(4)

6.5 Stream Matching and Network Synthesis

137

(2)

6.6 Network Synthesis for Dephenolization Example

139

(15)

CHAPTER SEVEN Mathematical Optimization Techniques for Mass Integration

154

(37)

7.1 Problem Statement and Challenges

154

(1)

7.2 Synthesis of MSA-Induced WINs

155

(6)

7.2.1 The Path Diagram

156

(2)

7.2.2 Integration of the Path and the Pinch Diagrams

158

(2)

7.2.3 Screening of Candidate MSAs Using a Hybrid of Path and Pinch Diagrams

160

(1)

7.3 Case Study: Interception of Chloroethanol in an Ethyl Chloride Process

161

(14)

7.4 Developing Strategies for Segregation, Mixing and Direct Recycle

175

(1)

7.5 Case Study Revisited: Segregation, Mixing and Recycle for the Chloroethanol Case Study

176

(6)

7.6 Integration of Interception with Segregation, Mixing, and Recycle

182

(9)

CHAPTER EIGHT Synthesis of Reactive Mass-Exchange Networks

191

(26)

8.1 Objectives of REAMEN Synthesis

191

(2)

8.2 Corresponding Composition Scales for Reactive Mass Exchange

193

(6)

8.3 Synthesis Approach

199

(18)

CHAPTER NINE Combining Heat Integration with Mass Integration

217

(31)

9.1 Synthesis of HENs

217

(15)

9.1.1 Minimum Utility Targets Using the Pinch Diagram

218

(3)

9.1.2 Case Study: Pharmaceutical Facility

221

(4)

9.1.3 Minimum Utility Targets Using the Algebraic Cascade Diagram

225

(1)

9.1.4 Case Study Revisited Using the Cascade Diagram

226

(1)

9.1.5 Minimum Utility Targets Using Mathematical Programming (Optimization)

227

(4)

9.1.6 Case Study Revisited Using Linear Programming

231

(1)

9.2 Synthesis of Combined Heat- and Reactive Mass-Exchange Networks "CHARMEN"

232

(3)

9.3 Case Study: CHARMEN Synthesis for Ammonia Removal from a Gaseous Emission

235

(5)

9.4 Case Study: Incorporation of CHARMEN Synthesis into Mass Integration for an Ammonium Nitrate Plant

240

(8)

CHAPTER TEN Synthesis of Heat-Induced Separation Network for Condensation of Volatile Organic Compounds

248

(14)

10.1 Problem Statement

248

(1)

10.2 System Configuration

249

(1)

10.3 Integration of Mass and Heat Objectives

250

(1)

10.4 Design Approach

251

(2)

10.4.1 Minimization of External Cooling Utility

251

(1)

10.4.2 Selection of Cooling Utilities

252

(1)

10.4.3 Trading Off Fixed Cost versus Operating Cost

253

(1)

10.5 Special Case: Dilute Waste Streams

253

(1)

10.6 Case Study: Removal of Methyl Ethyl Ketone "MEK"

254

(5)

10.7 Effect of Pressure

259

(3)

CHAPTER ELEVEN Design of Membrane-Separation Systems

262

(27)

11.1 Classification of Membrane Separations

262

(2)

11.2 Reverse Osmosis Systems

264

(9)

11.2.1 Operating Principles

264

(1)

11.2.2 Modeling of HFRO Units

265

(8)

11.3 Designing Systems of Multiple Reverse Osmosis Modules

273

(16)

11.3.1 Synthesis of RON's: Problem Statement

273

(1)

11.3.2 A Shortcut Method for the Synthesis of RON's

274

(15)

CHAPTER TWELVE Environmentally Benign Chemistry and Species

289

(8)

12.1 Synthesis of Environmentally Acceptable Reactions

289

(2)

12.2 Synthesis of Environmentally Benign Species

291

(6)

Appendix I: Useful Relationships for Compositions

297

(3)

Appendix II: Conversion Factors

300

(3)

Appendix III: Overview of Process Economics

303

(6)

Appendix IV: Instructions for Software Package

309

(6)

Index

315

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