Services

Features and objectives:

• Identifying energy and water saving opportunities
• Process Integration & Pinch analysis
• CHP and thermal utility optimisation
• Energy and water efficient processes
• Heat recovery, water & effluent minimisation systems
• Efficient use of steam and hot water
• Heat and material balances/simulations
• Identifying process safety and operability hazards
• Process energy and water efficiency integrated into conceptual design

Typical assignments:

• Preliminary studies and audits
• Detailed studies and reviews
• Feasibility studies
• Strategic studies
• Conceptual design
• Process conceptual design and operability review
• Design review and supervision of detailed design
• Project management

Indicative activities:

• Develop process flow diagrams/schematics suitable to support the review
• Identify and quantify process & utility heating and cooling duties — amount and temperature
• Develop heat and material balances/simulation models if appropriate
• Pinch analysis if appropriate - data extraction, composite curves, heat exchanger network analysis, thermal utility targets, scope for heat recovery, CHP and process modifications
• Identify theoretical and practical scope for additional heat recovery
• Identify practical projects for heat (& water) recovery, CHP and improved thermal utilities
• Preliminary conceptual design
• Systematic process design reviews

Suggested outputs/deliverables:

• Schematic flow diagrams if not previously available in suitable form
• Heat and material balances and other models if relevant
• Quantified scope for energy savings
• Key features/process design concepts which materially influence the opportunities for savings
• Conceptual design/feasibility study of retrofit projects - water and energy savings
• Optimum heat recovery and water use/reuse configurations — new plant/major expansions
• Optimum thermal utility configurations
• Conceptual design of optimum CHP
• Recommended ongoing strategy to reduce carbon emissions by improved energy integration

Downstream activities:

• PI investigations often identify some low cost projects which can be implemented with minimal further investigation
• Other opportunities typically require further assessment
• Additional data gathering analysis and optimisation after completion of initial PI review
• Detailed technical and economic feasibility studies
• Strategic ‘road map’ of energy and water optimisation projects depending on outcome of external events and/or future marketing and production decisions
• Maximum value from PI is achieved by updating the analysis to account for ongoing changes on the site
• PI review before future process developments are implemented minimises the probability of missing future opportunities to improve efficiency

Harry Cripps MA MSc DMS CEng FIChemE MEI hrc at hrcconsultants dot co dot uk