1. PROCESS INTEGRATION
IMPLEMENTATION IN INDUSTRIAL CASES
ZULFAN ADI PUTRA, PDENG
zulfan.adiputra@utp.edu.my
+60 5368 7562
PROCESS SYSTEM ENGINEERING GROUP
CHEMICAL ENGINEERING DEPARTMENT
UNIVERSITI TEKNOLOGI PETRONAS
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2.  What is Process Integration (PI)?
 What can we do with it?
 Industrial cases:
• Minimizing Middle Pressure (MP) steam consumption
• Debottlenecking of crude oil preheat train
• 3 months payback period of a chemical plant
• Minimizing fresh &wastewater streams of a petrochemical plant
• And of a specialty chemical plant
• Uncertainty simulation for conceptual plant designs (e.g.
biomass to chemicals)
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Outline

3.  PI  a holistic approach to process design, retrofitting, and
operation which emphasizes the unity of the process (El-Halwagi
1997).
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What is Process Integration (PI)?
Feed 1
Product
By product
Off gas
Feed 2
Reactor 1
Column 1
Reactor 2
Column 2
Column 3
To maximize Product, should we do something in Column 3? Or Reactor 2? Or Column 2? Or…?
To minimize CAPEX, which unit should we focus on?
To minimize OPEX, what should we look at? Energy? Water? Resources? Waste?

4. Many available techniques:
• (The famous) Pinch analysis for heat, water, hydrogen, etc.
• Mathematical optimization via MS Excel, GAMS, Matlab, etc.
• Process modelling and optimization via Aspen HYSYS, Aspen
Plus, gPROMS, etc.
• Experience, intuition, and engineering judgement.
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5.  Optimization of current plant performances; low hanging fruits
 Thermodynamic-based targeting  benchmarking
 Synthesis, design, & evaluation of practical alternatives/solutions
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What can we do with PI?

6. Industrial Case Studies
(Indonesia, Malaysia, The Netherlands, South Korea)
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7. 7
Minimizing MP steam (1)

8. 8
Minimizing MP steam (2)

9. 9
Minimizing MP steam (3)
HP steam header
MP steam header
LP steam header
HXs
HXs
HXs
LP condensate header
HXs LP steam boiler
MP steam
boiler
HP steam supply
50 ton/hr
11.5 MW
20.6 MW
3.6 MW
4.8 MW
Cooling Tower
10.7 ton/hr
LP steam sold
49 MW

10. 10
Minimizing MP steam (4)

11. 11
Minimizing MP steam (4)

12. 12
Minimizing MP steam (5)

13. 13
Debottlenecking crude preheat train (1)

14. 14
Debottlenecking crude preheat train (2)

15. 15
Debottlenecking crude preheat train (3)

16. 16
Debottlenecking crude preheat train (4)

17. 17
Debottlenecking crude preheat train (5)

18. 18
3 months PBP of a chemical plant (1)

19. 19
3 months PBP of a chemical plant (2)

20. 20
3 months PBP of a chemical plant (3)

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3 months PBP of a chemical plant (4)

22. 22
3 months PBP of a chemical plant (5)
Estimated payback period (in-house) is about 3 months!

23. Amminudin, K. A., Sofian, M. N., Hawari, H., Putra, Z. A., Khamaruddin, P. N. F. M.
and Buang, A., Consider water reuse options for your facility, HYDROCARBON
PROCESSING, Dec 2008.
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Minimizing fresh & wastewater (1)

24. Basecases
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Minimizing fresh & wastewater (2)
Amminudin, K. A., Sofian, M. N., Hawari, H., Putra, Z. A., Khamaruddin, P. N. F. M. and Buang, A., Consider water
reuse options for your facility, HYDROCARBON PROCESSING, Dec 2008.

25. 25
Minimizing fresh & wastewater (3)
Amminudin, K. A., Sofian, M. N., Hawari, H., Putra, Z. A., Khamaruddin, P. N. F. M. and Buang, A., Consider water
reuse options for your facility, HYDROCARBON PROCESSING, Dec 2008.
Developed options via mathematical programming

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Minimizing fresh & wastewater (4)
Amminudin, K. A., Sofian, M. N., Hawari, H., Putra, Z. A., Khamaruddin, P. N. F. M. and Buang, A., Consider water
reuse options for your facility, HYDROCARBON PROCESSING, Dec 2008.

27. Adi Putra, Z., Improve performance and reduce costs of wastewater treatment
plants, HYDROCARBON PROCESSING, Dec 2015
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Minimizing fresh & wastewater (1)

28. Adi Putra, Z., Improve performance and reduce costs of wastewater treatment plants, HYDROCARBON
PROCESSING, Dec 2015
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Minimizing fresh & wastewater (2)

29. Adi Putra, Z., Improve performance and reduce costs of wastewater treatment plants, HYDROCARBON
PROCESSING, Dec 2015
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Minimizing fresh & wastewater (3)

30. Adi Putra, Z., Improve performance and reduce costs of wastewater treatment plants, HYDROCARBON
PROCESSING, Dec 2015
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Minimizing fresh & wastewater (4)

31. Adi Putra, Z., Improve performance and reduce costs of wastewater treatment plants, HYDROCARBON
PROCESSING, Dec 2015
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Minimizing fresh & wastewater (5)

32. 32
Uncertainty simulation for conceptual
plant design (1)

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Uncertainty simulation for conceptual
plant design (2)

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Uncertainty simulation for conceptual
plant design (3)

35. 35
Uncertainty simulation for conceptual
plant design (4)

36. 36
Uncertainty simulation for conceptual
plant design (5)

37. Questions?
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