Chapter 10: A Unifying Approach to Process Integration

10.1 Introduction
Traditionally, the developers of process integration have been reluctant to acknowledge
the relationships among its many branches (Smith, 1995; El-Halwagi, 1997). This chapter
presents a unifying approach to process integration through pinch technology and mathematical
optimization and points out areas where further developments are needed.
In previous chapters and in Industrial Water Reuse and Wastewater Minimization (Mann
and Liu, 1999), we introduced the concepts of thermal-pinch technology, mass integration
through pinch technology, water-pinch technology and mathematical optimization in a
standalone manner. Here, we present many of the same tools for analyzing, synthesizing and
retrofitting heat-exchanger, mass-exchange and water-using networks in a common framework
to emphasize the relationships among the branches of process integration. This approach allows
us to better understand process integration and to fully develop the field through a combined
knowledge of the technology.
Figure 10.1 illustrates the tools of process integration. We see two interrelated
approaches to process integration pinch technology and mathematical optimization. This
chapter first presents key relationships within the separate branches of process integration.
Section 10.2 discusses pinch technology and Section 10.3 investigates mathematical optimization
and introduces an advanced approach to optimization know as reformulation/linearization
techniques (RLTs). Section 10.4.1 examines some interactions of pinch technology and

mathematical optimization and guides the engineer in selecting appropriate solution techniques
for each problem type. Finally, Section 10.4.2 summarizes the capabilities of some available and
emerging commercial software tools for process integration.

Figure 10.1. The tools of process integration.

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10.2 A unifying Approach to Process Integration through Pinch Technology
10.2.1 Introduction
Figure 10.1 illustrated the pinch-technology branch of process integration. In the figure,
thermal-pinch technology and mass integration appear as the two main branches of pinch
technology. Both apply the pinch concept to analyze systems containing hot and cold streams
(thermal-pinch technology), or contaminant-rich and lean streams (mass integration). However,
we include water-pinch technology as a subset of mass integration. Here, we only consider the
interactions of rich streams (i.e., water-using operations) and lean utilities (i.e., water streams).
This section examines the relationships among the branches of pinch technology by identifying
similar concepts and tools of thermal-pinch technology, mass integration and water-pinch
technology.
Table 10.1 lists some tools available to the engineer through pinch technology. In the
table, the first column lists a tool for heat-integration problems. Then, the second and third
columns show the corresponding tools for mass integration and water-pinch technology,
respectively. For example, we see that designing water-using networks through water-pinch
technology is not equivalent to designing heat-exchanger networks or mass-exchange networks.
Instead, the analogy exists between designing water-using networks and designing cooling-utility
networks for heat integration and external MSA networks for mass integration.
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Table 10.1. Some tools of process integration through pinch technology.
Thermal-Pinch Technology
Temperature-Enthalpy
Doiagram
Temperature-Interval Diagram
(TID)
Temperature-Composite
Curve
Grand Composite Curve
Preliminary Heat-Exchanger
Network Design
Heating-Utility System Design
Cooling-Utility System design
Heat-Exchanger Network
Evolution
Mass Integration Water-Pinch Technology
Limiting-Water Profile Limiting-Water Profile
Concentration-Interval Concnetration-Interval
Diagram (CID) Diagram (CID)
Concentration-Composite Concentration-Composite
Curve Curve
Grand Composite Curve Grand Composite Curve
Preliminary Mass-Exchange
None
Network Design
None None
External MSA System Preliminary Water-Using
Design Network Design
Mass-Exchange Network Water-Using Network
Evolution Simplification

10.2.2 Composite Curves

Figure 10.2a shows the hot and cold composite curves for a heat-integration problem. In
the figure, the intersection of the curves denotes the systems pinch-point temperature. Above
that temperature, we do not use cooling utilities and below that temperature, we do not use
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heating utilities. The horizontal distance between the hot and cold composite curves at the top
and bottom of the figure define the minimum heating- and cooling-utility duties, respectively.
However, Figure 10.2b illustrates the process-stream composite curve and process MSA
composite curve for a mass-integration problem. In the same manner, the intersection of the
curves is termed the system pinch. For mass integration, we do not apply external MSAs above
the pinch concentration. In contrast to heat integration with a possible heating-utility duty
(Figure 10.2a), a contaminant-rich utility duty does not exist in mass-integration problems and
the system exhibits an additional pinch at the highest (i.e., the richest) concentration interval. The
horizontal distance at the bottom of Figure 10.2b gives the duty of external MSAs.
Figure 10.2c is a concentration-composite curve for water-pinch technology. This plot is
essentially a mass-integration problem (Figure 10.2b) without process MSAs (and the process
MSA composite curve) with water as an external MSA. For wastewater-minimization problems,
we are able to target (place utilities) on the concentration-composite curve because without a
process MSA composite curve, the concentration-composite curve becomes equivalent to the
grand composite curve. Section 10.2.3 discusses the construction of grand composite curves for
water-pinch technology.

Table 10.2 compares the features of composite curves for pinch technology. In the table,
the first column lists a feature of the composite curve for thermal-pinch technology. The second
and third columns identify the analogous property of composite curves for mass integration and
water-pinch technology, respectively. For example, the hot composite curve (heat integration)
corresponds to the process-stream composite curve (mass integration) and the
concentrationcomposite curve (water-pinch technology).
Table 10.2. Composite curves for pinch technology.
Thermal-Pinch Technology Mass Integration Water-Pinch Technology
Process-Stream Composite Concentration-Composite
Hot Composite Curve
Curve Curve
Process-MSA Composite
Cold Composite Curve None
Curve
Heating-Utility Duty None None
Cooling-Utility Duty External MSA Duty Freshwater Flowrate
Pinch Temperature Pinch Concentration None
Heating-Utility Pinch
None None
Temperature
Cooling-Utility Pinch External MSA Pinch Freshwater-Pinch
Temperature Concentration Concentration

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10.2.3 Grand Composite Curves
Essentially, the grand composite curve is a plot of the surplus heat (or mass of
contaminant) cascaded down through the temperature (concentration ) intervals. We use grand
composite curves to identify minimum duties and to optimize the placement of utilities.
It is important to realize that the grand composite curve and the concentration-composite
curve for water-pinch technology are the same curve due to the lack of lean streams (equivalent
to process MSAs in mass-integration problems). For example, placing cooling water as a cooling
utility on the grand composite curve during heat integration is similar to placing external MSAs
and targeting freshwater consumption for mass-integration and wastewater-minimization
problems, respectively. Figure 10.3 illustrates the construction of a grand composite curve from a
concentrationcomposite curve for water-pinch technology. In the figure, we begin with the
concentration-composite curve shown in Figure 10.3a and mirror it horizontally to give the grand
composite curve of Figure 10.3b. Finally, we draw a water-supply line from our water-supply
concentration (zero ppm for freshwater). Rotating the line clockwise until we contact the grand
composite curve.
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Table 10.3 lists some key features of grand composite curves for thermalpinch
technology and compares them to the analogous features of grand composite curves for mass
integration through pinch technology and water-pinch technology. For example, we see that
grand composite curves for both mass integration and water-pinch technology exhibit only
leanutility pinch points, while we see both heating- and cooling-utility pinch points in grand
composite curves for thermal-pinch technology.
Table 10.3. Grand composite curves for pinch technology.
Thermal-Pinch technology Mass Integration Water-Pinch Technology
Heating-Utility Duty None None
Cooling-Utility Duty External MSA Duty Freshwater Duty
Pinch Temperature Pinch Concentration None
Process-to-Process heat Process-Stream-to None
Transfer Process-MSA Mass
 Transfer
Pocket of Self Sufficient Heat Pocket of Self Sufficient
None
Transfer Mass Transfer
Heating-utility Placement None None
Cooling-Utility Placement External MSA Placement Freshwater Targeting
Heating-Utility Pinch
None None
Temperature
Cooling-Utility Pinch External MSA Pinch Freshwater Pinch
Temperature Concentration Concentration

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Figure 10.4 illustrates some similarities between grand composite curves for heat
integration (Figure 10.4a), mass integration (Figure 10.4b) and wastewater minimization
(Figure 10.4c). In the figures, the pinch points of each system (pinch temperature or pinch
concentration) are located where the grand composite curves intersect the y-axis. At these points,
the residual heat or mass loads vanish. In other words, no heat or mass is transferred across this
interval boundary (the pinch). Above that point, we place heating utilities for heat-integration
problems and below these points, we place cooling utilities, external MSAs and water streams
for heat-integration, mass-integration and wastewater-minimization problems, respectively. Note
that the grand composite curves for mass-integration problems exhibit two system pinches. The
first, at a lower concentration, corresponds to the traditional system pinch. The second, at the
higher concentration, is commonly seen as we reduce the flowrate of process MSAs to eliminate
the excess capacity of process MSAs to remove contaminant from the process streams.
Furthermore, grand composite curves for water-pinch technology show only a single system
pinch. This point is always located at the highest concentration-interval boundary because these
problems lack process MSAs (i.e., lean process streams) (equivalent to a heat-integration
problem without cold streams).

10.2.4 Network Synthesis

This section discusses network synthesis for problems including system-pinch points
(i.e., thermal-pinch and mass-integration problems). We do not include the design of water-using
networks, as those techniques are similar to the design of heating- and cooling-utility systems,
not to designing heat-exchanger networks or mass-exchange networks.
Table 10.4 lists the techniques for network synthesis common to thermal-pinch
technology and mass integration. As an example, the identification and breaking of loops in both
heat-exchanger and mass-exchange networks leads to simplified networks with fewer units that
may be penalized by increased utility duties. However, shifting heat loads along network paths
can eliminate small heaters and coolers, but does not have an application for mass integration. In
all cases, we relax constraints on minimum approach temperatures and concentrations.
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Table 10.4. Network design through pinch technology.
Thermal-Pinch Technology Mass Integration
Preliminary Heat-Exchanger Network Preliminary Mass-Exchange Network
Heat-Load Loop Mass-Load Loop
Heat-Load Path None
Stream Splitting Stream Splitting
Heating-Utility System Design None
Cooling-Utility System Design External-MSA System Design

Figure 10.5 illustrate some similarities between preliminary heat-exchanger and massexchange
networks. Horizontal lines in Figure 10.5a denote hot (left to right) and cold (right to
left) streams while in Figure 10.5b, they represent contaminant-rich process streams (left to
right) and process MSAs (right to left). Vertical lines correspond to heat-exchanger or
massexchange units with the heat or mass loads listed within the circles.
In preliminary heat-exchanger networks, we include hot and cold streams (along with
certain hot and cold utility streams like flue gas from a fired furnace) and design from the system
pinch out. Later, we add utilities like steam heaters and water coolers for heat-exchanger
networks. In preliminary mass-exchange networks, we include process streams and all MSAs
and design from the system pinch out.
We use network evolution to simplify preliminary networks along network paths and
loops by relaxing the restrictions of pinch boundaries and minimum approach temperatures or
concentrations .Figure 10.6a shows that by shifting heat loads along network paths, identified
between hot and cold utilities in heat-exchanger networks, we eliminate small, inefficient
exchangers. However, Figure 10.6b illustrates that, in mass exchange networks, we do not have
rich utilities and thus can not identify paths between rich and lean utilities. We shift both heat
and mass loads around loops in the preliminary heat-exchanger and mass-exchange networks,
respectively, until the smallest process-to-process unit is eliminated.
The limiting factor for mass-exchange networks is often the availability of each massexchange
unit. When designing heat-exchanger networks, we are rarely concerned with match
compatibility. However, when specifying each mass-exchange unit, we must consider the
availability or development costs of such a unit. In other words, although concentrationdriving
forces may exist between a rich and lean stream, it may be cost-prohibitive to develop suitable
process equipment and to identify the appropriate mass-separating agents (e.g., solvents). Note
that for both heat-exchanger and mass-exchange networks, we consider other factors like
physical location and piping costs when specifying each match.
Cooler
No Hot Utility - Heat-Load Paths Not Seen
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10.2.5 Process Changes and the Plus/Minus Principle
Pinch technology provides insights for effective process changes to reduce heating- and
cooling-utility duties, and external MSA and freshwater consumption through the plus/minus
principle. Figure 10.7 illustrates the principle on composite curves applied to (a) thermal-pinch
technology, (b) mass integration through pinch technology and (c) water-pinch technology. In all
cases, the objective is to modify operations, in the region surrounding the system or utility
pinches, shifting the composite curves and allowing increased process integration.
In Figure 10.7a, we shift hot streams to higher temperatures and shift cold streams to
colder temperatures (i.e., Keep Hot Streams Hot and Cold Streams Cold) in the region
surrounding the system's pinch. Additionally, we decrease the temperature of cold streams
surrounding hot-utility pinches to shift heat loads to less expensive hot utilities and increase the
temperature of hot streams in regions near cold-utility pinches to shift cooling duties to less
expensive cold utilities.
Figure 10.7b describes the plus/minus principle applied to mass integration. Here, we
shift rich process streams near the system pinch to operate at lower concentrations and decrease
the demand for process and external MSAs. Furthermore, by altering the source of process
MSAs to allow them to operate at lower concentrations, we decrease the demand for external
MSAs. We summarize this principle as Keep Rich Streams Rich and Lean Streams Lean.

10.3 A Unifying Approach to Process Integration through Mathematical Optimization

10.3.1 Introduction to Mathematical Optimization
Chapter 9 of Industrial Water Reuse and Wastewater Minimization (Mann and Liu, 1999)
gives an introduction to linear programming (LP) and nonlinear programming (NLP) and
describes in detail how wastewater-minimization problems are successfully solved through
mathematical-optimization techniques. Simple linear programming (LP) models predict the
minimum freshwater duty for these problems in essentially the same manner as the graphical
(concentration-composite curve) and tabular (concentration-interval diagram) techniques of
water-pinch technology. Nonlinear programs determine water-using network structures that meet
minimum freshwater targets established through either water-pinch technology or LPs.
Wastewater-minimization problems are readily solvable through NLPs, as the level of
nonconvexity in these problems is lower that that in heat- and mass-integration problems (Mann
and Liu, 1999). However, the systematic analysis and synthesis of heat-exchanger and
massexchange networks can only be accomplished through decomposition of superstructure-
type,
nonlinear programming (NLP) models to reduce the number of possible structures and
nonconvexities that hinder the solution of these problems.
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10.3.2 Introduction to Reformulation/Linearization Techniques
Figure 10.8 illustrates a nonconvex feasible region. Here, the circular border represents
the constraints on or the feasible region of a simple two-dimensional system, while the contour
lines show the value of the objective function within the feasible region. As opposed to the
convex regions encounters in many problems in Chapter 9 of Industrial Water Reuse and
Wastewater Minimization (Mann and Liu, 1999), we are not guaranteed optimality through
traditional solution techniques for convex NLPs. Here, we see several near optimal solutions
that, in reality, could correspond to significantly different network structures.
A number of specialized solution algorithms are available for optimizing these types on
nonconvex problems (Sherali and Adams, 1999). These algorithms are tailored to efficiently
solve specific problems. Commercial software is being developed for implementing
reformulation/linearization techniques (RLTs) to find optimal solutions to nonconvex
wastewater-minimization problems.
techniques (Floudas, 1995). For example, targeting procedures for the minimum
heating- and cooling-utility duties, described in Chapter 2, are analogous to optimizing a LP
model for the transportation of a commodity (heat) from sources (hot streams) through
warehouses (temperature intervals) to destinations (cold streams) known as the transshipment
model. We describe the model and its applications to water-pinch technology in detail in
Industrial Water Reuse and Wastewater Minimization (Mann and Liu, 1999). NLP models
representing superstructures of every possible heat-exchanger network are solved to give optimal
heat-exchanger networks (Papoulias and Grossmann, 1983). These problems suffer from
nonconvexities that often result in suboptimal solutions and are more difficult to implement that
the traditional pinch analysis and synthesis described in Chapters 2 and 3. However, in some
cases, NLPs can overcome limitations inherent to the pinch approach (e.g., forbidden matches).
10.3.4 Mass-Integration Problems
The decomposition of mass-integration problems into LPs to predict the minimum
flowrate of process and external MSAs and NLPs to find optimal mass-exchange networks are
not well studied. We expect that mathematical optimization will be particularly adept at solving
mass-integration problems as it is capable of handling complex, nonlinear models often
associated with mass-exchange equipment (e.g., strippers, extractors, reactors, etc.). It is pinch
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technology that will first analyze simple problems and suggest mass-exchange networks as
starting solutions to NLPs for optimizing more complex systems.
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10.4 Guidelines for Implementing Process Integration
10.4.1 Selecting Solution Techniques
Heat-integration problems are well studied and supported by numerous literature sources
and commercial software tools. However, mass integration and wastewater minimization are
developing fields featuring a wide range of solution techniques. The following sections present
guidelines for each type of process-integration problem.
10.4.1.1 Heat-Integration Problems
Thermal-pinch technology is the industry-wide standard for implementing process
integration for energy conservation. Since its conception in the 1980s, it has been proven as a
cost-effective tool for heat integration. Figure 10.9 illustrates the step-by-step procedure for
implementing pinch technology for heat integration. Note that the procedure is often iterative.
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Chapter 3
Figure 10.9. Solving heat-integration problems through thermal-pinch technology.
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10.4.1.2 Mass-Integration Problems
Few literature sources are available for the successful industrial application of process
integration to mass-integration problems.
10.4.1.3 Wastewater-Minimization Problems
Figure 10.10 illustrates guidelines for selecting solution techniques for wastewaterminimization
problems. Here, the solution technique is determined by the complexity of the
models applied to water-using operations. For example, if we model each unit as a
countercurrent contact between a contaminant-rich stream and a water stream, we choose
waterpinch analysis and synthesis for targeting freshwater consumption and designing a water-
using
network, respectively. However, when we include complicating factors such as multiple
contaminants and alternative models for water-using operations, mathematical optimization is
preferred. Further increases in complexity often result in nonconvex problems (see Chapter 9 of
Industrial Water Reuse and Wastewater Minimization). Two commercial software tools are
available or in development that optimize nonconvex problems (see Section 10.4.2).
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Process Integration for
Wastewater Minimization
 Single-Contaminant
Single-Contaminant Multiple-Contaminant and Multiple-
Targeting Targeting and Synthesis Contaminant
Synthesis
Nonlinear Programming
Water-Pinch Analysis Water-Pinch Synthesis
(Reformulation/Linearizatio
or or
n
Linear Programming Nonlinear Programming
Often Required)
Simple Models for Complex Models for
Water-Using Operations Water-Using Operations

10.4.2 Advanced Commercial Software Tools of Process Integration

Several software tools have been developed commercially to solve heat-integration ,
mass-integration and wastewater-minimization problems through process integration. The first
column in Table 10.5 lists some of these software packages. In the table, the second column lists
industrial applications of the software tools.
Table 10.5. Commercial software and industrial applications.
Software Tool Developer Industrial Application
Aspen Pinch Aspen Technologies, Inc. Heat and Power Integration
HEXTRAN Simulation Sciences, Inc. Heat and Power Integration
PinchExpress Linnhoff March, Inc. Heat and Power Integration
Aspen Split Aspen Technologies, Inc.
Complex Azeotropic, Extractive
and Reactive Distillation
Processes
MASS-EXCHANGE
NETWORK
Auburn University General mass integration
Aspen Water Aspen Technologies, Inc.
Water Reuse and Wastewater
Minimization
WaterTarget Linnhoff March, Inc.
Water Reuse and Wastewater
Minimization
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10.5 Summary
Pinch technology is applicable to both heat- and mass-integration problems. In
addition, wastewater minimization is a simplification of mass integration.
The composite curve is a pinch-technology tool for determining the minimum utility
duties for process-integration problems.
The grand composite curve is a pinch-technology tool for placing heating and cooling
utilities (heat integration), external MSAs (mass integration) and water streams
(wastewater minimization). We can represent unit operations for energy (heat
engines, heat pumps, refrigeration systems, etc.) and mass transfer (reactors,
extractors, water regeneration processes, etc.) on the grand composite curve.
The designs of heat-exchanger and mass-exchange networks are similar. However,
the design of water-using networks corresponds to the design of utility networks.
Linear programming approaches to the targeting of utility duties have been applied to
heat-integration, mass-integration and wastewater-minimization problems.
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Linear programs have been developed to predict heat-exchanger units and massexchange units
that meet the minimum utility targets determined through pinch
technology or through a LP.
The decomposition of superstructures of heat-exchanger and mass-exchange
networks into a LP and a simplified NLP allows the solution via mathematical
optimization.
Water-using networks can be generated for wastewater-minimization problems
through mathematical optimization (NLP) without the decomposition approach that is
required for heat- and mass-integration problems.
Heat integration, mass integration and wastewater minimization through pinch
technology and mathematical optimization are interrelated concepts that can be
further developed through a combined knowledge of all the branches of process
integration.
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References
El-Halwagi, M. M., Pollution Prevention through Process Integration: Systematic Design Tools,
Academic Press, San Diego, CA (1997).
Floudas, Christodoulos A., Nonlinear and Mixed-Integer Optimization, Oxford University Press,
New York (1995).
Mann, J. G. and Y. A. Liu, Industrial Water Reuse and Wastewater Minimization, McGraw-Hill,
New York (1999).
Sherali, Hanif D. and Warren P. Adams, A reformulation-Linearization Technique for Solving
Discrete and Continuos Nonconvex Problems, Kluwer Academic Publishers, Dordrecht
(1999).
Smith, R., Chemical Process Design, McGraw-Hill, New York (1995).