A two-stage approach for the synthesis of inter-plant water networks involving continuous and batch units

This paper presents a mathematical optimization model for inter-plant water network (IPWN) synthesis, where process units operate in mixed continuous and batch modes. The current developed model consists of a two-stage approach, and is dedicated to the special case where there are more continuous than batch units. In the first stage, all batch units are treated as continuous units by using auxiliary water storage tanks, and a continuously operated IPWN is synthesized to minimize the fresh water consumption. Subject to the determined IPWN flow rates, the water storage policy for the batch units is determined in the second stage to minimize the total storage capacity. Alternatively, the formulations of both stages can be combined and solved simultaneously to minimize the IPWN cost. Two modified literature examples are used to illustrate the proposed approach.     

A game theory based method for inter-plant heat integration considering cost allocation

Inter-plant heat integration is an effective way for energy recovery in process industry. Although inter-plant heat integration can significantly reduce energy consumption, it is not widely applied in the multiple stakeholders' situation due to profit or cost distribution problems. Therefore, this work considers both the technique aspects of heat integration and its business aspects between stakeholders simultaneously. The new proposed methodology consists of three steps. Firstly the optimal matching of heat integration between plants is obtained through mathematical programming. Then the cost distribution is decided through game theory. Finally the cost distribution obtained previous is corrected by an ideal expert model. A case study is used to illustrate the effectiveness of the method in the end of the work.     

A global optimal formulation for the water integration in eco-industrial parks considering multiple pollutants

A mathematical programming formulation for the water integration in eco-industrial parks considering streams with several pollutants is presented. The formulation is based on a superstructure that allows the wastewater reuse in the same plant, the water exchange with different plants, and a shared set of interceptors that must be selected to determine the network configuration that satisfies process equipments and environmental constraints. The model formulation considers wastewater with several pollutants, and optimizes the network according to the minimum total annual cost, which includes the costs of fresh water, piping and regeneration. A new discretization approach is also proposed to handle the large set of bilinear terms that appear in the model in order to yield a near global optimal solution. The results obtained in several examples show considerable savings with respect to the solutions of the individual plant integration policy commonly employed for these types of problems.     

过程工业水分配网络的研究进展

回顾了水分配网络的发展历程,介绍了水分配网络的用水网络和废水处理网络2个子系统的研究进展,阐述了图解方法、数学优化法等用水网络综合方法的发展状况,并对水分配网络设计中多杂质和热集成等方面的问题进行了展望。     

Synthesis of non-isothermal heat integrated water networks in chemical processes

This paper presents a new approach for the simultaneous synthesis and optimization of heat integrated water networks. A new superstructure for heat exchanger network (HEN) synthesis is proposed. The procedure is based on mixed integer non-linear mathematical programming (MINLP). Four relevant examples are presented to illustrate various aspects of the proposed approach.     

Optimization-based method for calculating water networks with user specified characteristics

This paper addresses problem of designing water usage network that consists of fixed flow rate water using processes. A design method is founded on the solution of mixed-integer linear programming (MILP) model of network superstructure. The application of optimization to solve basic formulation of network synthesis has been reported in some works. However, this approach applies certain extensions of the standard formulation that allow accounting for several industrial scenarios. In particular, it is possible to apply various performance indices and imposing conditions on continuous variables as well as on network topology. Multiple contaminant case is easily accounted for. At least but not at last, the method is able to generate several solutions of identical values of major performance indices but of different structure and other features. All these possibilities are available within single optimization framework. Several examples are given to illustrate advantages of the approach.     

考虑非等温混合的能量集成用水网络综合

提出了考虑非等温混合的新的水网络模型,并结合线性规划（LP）转运模型同时优化水网络的水耗及公用工程目标。新的水网络模型引入非等温混合以改善用水网络的能耗特性及减少模型中参与集成换热网络的流股数,从而降低设计换热网络的复杂程度。在确定水网络的水耗及公用工程目标后,采用夹点法设计详细的换热网络结构。两个算例结果表明,新的水网络模型不仅能确定用水网络的最优水耗及公用工程目标,而且还能得到一个更加简单的换热网络。这对节省设备投资及减少操作费用具有重要意义。     

Automated targeting for inter-plant water integration

Apart from in-plant water recovery, inter-plant water integration (IPWI) offers another promising mean for the reduction of fresh water and wastewater flowrates for process plants. This paper extends the automated targeting technique that was developed for single water network into IPWI. This optimisation-based technique is based on the concept of pinch analysis, which enables the setting of various network targets prior to detailed design. The automated targeting technique is formulated as a linear programming model for which global optimum is guaranteed. The proposed technique is demonstrated using several industrial and literature examples.     

世界化工园区发展现状

对石化和化学品需求的不断增长,推动了世界各地化工园区的兴起、建设和发展。介绍了欧洲、美国和亚洲10个化工园区的发展现状。     

Synthesis of water networks considering the sustainability of the surrounding watershed

This paper presents a new mathematical programming model for the optimal synthesis of recycle and reuse networks considering simultaneously the integration of the water network system and the surrounding watershed to satisfy process and environmental constraints. The model considers the optimal location of the new industrial facility to integrate its wastewater discharge to the environment with the surrounding watershed through a disjunctive formulation. The pollutants discharged for the new plant are tracked simultaneously with the other discharges to the watershed (i.e., residential, sanitary, industrial and extractions), and the natural phenomena that affect the composition of the watershed (i.e., evaporation, filtration, etc.), in addition to the chemical reactions that are carried out in the rivers. The objective function consists in minimizing the total annual cost that is constituted by the installation of the new plant cost (including the transportation for raw materials, products and services, as well as the land cost), the wastewater treatment costs (including the piping cost) and the fresh sources cost. Two example problems were used to show the applicability of the proposed methodology.     

Synthesis of robust water reuse networks for single-component retrofit problems using symmetric fuzzy linear programming

Water integration techniques can be used to minimize the utility water consumption and effluent generation of process plants through the implementation of reuse or recycle networks. There are a number of graphical and mathematical programming techniques available for the synthesis of such water reuse networks. However, effective use of these methods requires the availability of reliable process data, which in reality might be difficult to acquire. This paper describes a procedure for the synthesis of robust water reuse networks from imprecise data using symmetric fuzzy linear programming (SFLP). Two model variants, one based on mass exchange units and the other on source/sink allocation, are presented. Each variant is illustrated with a numerical example.     

Optimal design of reverse-osmosis networks for wastewater treatment

An optimization study of reverse-osmosis networks (RON) for wastewater treatment has been carried out by describing the system as a nonconvex mixed-integer nonlinear problem (MINLP). A mixed-integer linear problem (MILP) is derived from the original nonlinear problem by the convex relaxation of the nonconvex terms in the MINLP to provide bounds for the global optimum. The MILP model is solved iteratively to supply different initial guesses for the nonconvex MINLP model. It is found that such a procedure is effective in finding local optimum solutions in reasonable time and overcoming possible convergence difficulties associated with MINLP local search methods. Examples of water desalination and wastewater treatment from the pulp and paper industry are considered as case studies to illustrate the proposed solution strategy.     

基于全过程污染控制策略的钢铁工业园区水网络全局优化

作为典型的高耗水工业,节水减排是我国钢铁工业可持续发展亟须解决的关键问题之一。本研究基于全过程污染控制策略,提出了面向钢铁工业园区水网络特点的多尺度优化建模方法,充分考虑了钢铁园区涉水单元-工序水网络-园区水网络等不同尺度水系统的用排水特点及相互作用,有助于进一步发掘园区节水减排新空间。在此基础上建立了园区水网络全局优化模型,利用数学规划方法来探索综合用水成本最低的园区水网络优化方案。一年产能为500万吨钢材的钢铁工业园区水网络优化案例研究表明,采用全过程污染控制策略的钢铁园区水网络全局优化方案,综合用水成本、新水用量及新水成本占比等用水指标与其他采用局部水污染控制技术的方案相比有较大幅度的降低,与园区现用水指标相比,各指标均降低20%以上。案例研究表明所提出的园区水网络优化模型可行有效,优化结果对于钢铁园区水污染控制技术的集成和水网络全局优化方案的精准确定具有重要的参考价值。     

Optimal synthesis of multi-plant heat exchanger networks considering both direct and indirect methods

Heat exchanger networks (HENs) in separated plants can be simultaneously synthesized through process streams directly or intermediate fluids indirectly. However, the direct and indirect methods are studied separately in most existing researches. As the result, conventional designs are probably suboptimal, because optimal solutions may call for hybrid approach wherein direct and indirect integration methods are used synchronously. To circumvent this drawback aforementioned, we propose in this research a novel methodology to synthesize multi-plant HENs considering both direct and indirect approaches. The methodology employs a novel superstructure covering most potential topologies for both interplant and intra-plant heat integration. We also take into account multiple kinds of intermediate fluids for indirect integration and this has not been fully addressed in previous research. A mixed-integer nonlinear programming (MINLP) is formulated to optimize multi-plant HENs involving indirect and direct methods. One example from existing literature and one industrial problem are solved to demonstrate the methodology's capability.     

经济增长和环境协调发展的石化工业园区建设

在工业园区建设中 ,经济增长和环境的协调发展是可持续发展的原则在工业实践中的具体体现。用以炼油厂为核心的丹麦凯隆堡工业园区建设为典型实例 ,说明其所体现的转变生产方式 ,节约资源、保护环境的生态系统运行机制应该引起注意和值得学习。     

Simultaneous integration of water and energy in heat‐integrated water allocation networks

This article proposes a new methodology for simultaneous integration of water and energy in heat‐integrated water allocation networks (WAHEN). A novel disjunctive model is first developed to determine an optimal water allocation network (WAN) where water and energy are integrated in one step. Based on the optimal WAN, a detailed heat exchanger network (HEN) to satisfy the utility target is then synthesized. Although the final network structure is obtained through two steps, the targets of freshwater and utility are optimized simultaneously. The proposed method has specific advantages. First of all, it can capture a tradeoff among freshwater usage, utility consumption, and direct heat transfer by nonisothermal mixing. Second, it can greatly reduce the complexity of subsequent HEN design. Finally, it is effective for simultaneous water and energy integration in large‐scale WAHEN systems. The advantages and applicability of this new method are illustrated by three examples from literature. © 2015 American Institute of Chemical Engineers AIChE J, 61: 2202–2214, 2015     

最小化新鲜水量与废水处理量的图形方法

水分配网络由回用、再生和废水处理3个相互作用的子系统构成。设计水分配网络需考虑质量负荷固定和流量固定两类用水操作模型。目前,兼顾两类用水操作的图形方法对水分配网络的研究局限于一个或两个子系统的设计,而缺少一种能同时处理3个子系统的方法。本文用新的方法合成了反映用水网络水源盈亏情况的总组合曲线,并由此得到最小废水量和新鲜水量。为考虑废水再生情况,提出通过用再生水线和废水线合成废水排放线的方法求解再生情况下的最小新鲜水量。同时,根据总组合曲线得到了废水组合曲线,求得最小废水处理量。实例表明,本文所提方法可在具体网络设计前,在同一浓度-质量负荷图中确定单杂质水分配网络的各目标参数,且简便易行。     

考虑非等温混合的能量集成多杂质水网络优化设计

提出了一种分步综合多杂质体系水网络和换热网络的新方法。对于水网络,考虑进入操作单元的新鲜水与回用水之间的非等温混合,确保流股间的直接热回收;对于换热网络,可以只考虑水网络中的新鲜水和回用水流股之间的换热匹配。采用无进化次数的改进粒子群算法对本文建立的多杂质体系水网络非线性模型和换热网络混合整数非线性模型进行求解。实例表明,与不考虑非等温混合时比较,考虑非等温混合时的最优网络结构更简单,且年度总费用要节省2.4%。因此,本文提出的方法在实际生产中有较好的可行性和有效性。     

LP-based solution strategies for the optimal design of industrial water networks with multiple contaminants

This paper presents a new approach for the optimal design of water-using networks. Starting with a superstructure that accounts for all possible connections between water sources and water-using operations, different substructures are generated that consider all possible sequences of operations. Then, each operation is tackled one at a time, from the first to the last element in the sequence. This procedure has the advantage of replacing a nonlinear program (NLP) by a succession of linear programs (LP) that are solved for all operation sequences. Although part of the feasible region is lost in the process, the results have shown that the optimal solution is often obtained. The new procedure is at the same time a good approach of generating structurally different solutions that can be used as starting points for the full NLP. By doing this, local solutions can be avoided and the probability of finding the global optimal solution to the problem is increased. When compared to the standard initialization procedure that features a single starting point, the new approach is more efficient but substantially more demanding computationally. A trade-off can be reached by using the standard technique with multiple starting points originated from the possible operation sequences.     

New industrial titania photocatalysts for the solar detoxification of water containing various pollutants

A new series of titania industrial photocatalysts have been elaborated by Millennium Inorganic Chemicals and were denoted Millennium-PC/10, PC/25 and PC/50 with respective specific surface areas equal to 11, 23 and 43 m² g⁻¹. Their photocatalytic activities have been determined and compared in the solar pilot CPC-photoreactor at the Plataforma Solar de Almeria (PSA) (Spain) in the photocatalytic degradation of four different representative pollutants (4-chlorophenol, nitrobenzene, 2-chlorobenzoic acid and hydrobutanedioic (malic) acid), whose degradation pathways had previously been elucidated in laboratory experiments with artificial light, using titania Degussa P-25 as a reference photocatalyst. The study concerned the influence of (i) the nature of organic pollutants, (ii) the surface area and (iii) the concentration of suspended TiO₂. The affinity of the pollutants for TiO₂ and the presence of heteroatoms in the reactant molecules intervened on the activities of Millennium-PCs when compared to Degussa P-25. The higher the affinity of the organic pollutants for titania, the higher the efficiency of Millennium-PC/10 photocatalyst calibrated on the initial rate of pollutant disappearance. The degradation pathways were found similar for both photocatalysts and the primary steps of the degradation for the different types of molecules were discussed.

4-Chlorophenol (4-CP), a model pollutant for waste waters, was then chosen for the study of the influence of the surface areas and of the concentration of Millennium-PC photocatalysts. The initial apparent rate constants of 4-CP degradation in presence of all Millennium-PC catalysts were all higher than that obtained with Degussa P-25. When choosing the total organic carbon (TOC) disappearance rate as an overall kinetic parameter, Millennium-PC/10 and PC/25 appeared as less active than Degussa P-25, with longer solar exposures (by about 10%) necessary to obtain a total mineralisation. However, Millennium-PC/50 resulted as the best catalyst in all cases. The optimal slurry concentration (g l⁻¹) has been determined for each Millennium TiO₂ sample.

While the optimum of Degussa P-25 had previously been found equal to 0.2 g l⁻¹, higher amounts of Millennium-PC samples were required. A twice higher concentration (0.4 g l⁻¹) increased the activities by factors equal to 1.2 and 1.5 for Millennium-PC/50 and PC/10, respectively. The rate constants of disappearance of intermediates and of TOC were quantitatively affected by factors in agreement with a multiple consecutive reactions model. In any case, titania Millennium-PC/50 appeared as the best catalyst among all those tested, including Degussa P-25.