Energy Level Composite Curves—a new graphical methodology for the integration of energy intensive processes

Pinch Analysis, Exergy Analysis and Optimization have all been used independently or in combination for the energy integration of process plants. In order to address the issue of energy integration, taking into account composition and pressure effects, the concept of energy level as proposed by [X. Feng, X.X. Zhu, Combining pinch and exergy analysis for process modifications, Appl. Therm. Eng. 17 (1997) 249] has been modified and expanded in this work. We have developed a strategy for energy integration that uses process simulation tools to define the interaction between the various subsystems in the plant and a graphical technique to help the engineer interpret the results of the simulation with physical insights that point towards exploring possible integration schemes to increase energy efficiency. The proposed graphical representation of energy levels of processes is very similar to the Composite Curves of Pinch Analysis—the interpretation of the Energy Level Composite Curves reduces to the Pinch Analysis case when dealing with heat transfer. Other similarities and differences are detailed in this work. Energy integration of a methanol plant is taken as a case study to test the efficacy of this methodology. Potential integration schemes are identified that would have been difficult to visualize without the help of the new graphical representation.