Using process integration technology for CLEANER production

Process integration technology design tools have been developed over the past two decades that target reductions in the operating and capital costs of chemical processes. The primary focus of these tools has been the identification of energy conservation and waste reduction process designs. These tools have been used successfully to obtain solutions for a large number of design problems. For example, the past two decades have seen the development and application of process integration design tools for heat exchange networks (HENs), mass exchange networks (MENs), heat-induced and energy-induced separation networks (HISENs and EISENs), waste interception and allocation networks (WINs) and heat-induced and energy-induced waste minimization networks (HIWAMINs and EIWAMINs). In addition, a group of systems analysis tools have been developed to simplify and manage the design process. Finally, a systematic design strategy for CLEANER production, that couples these systems analysis tools with the process integration design tools, has recently been developed. This paper provides an overview of the CLEANER (Combining Lower Emissions And Networked Energy Recovery) production design strategy, a brief summary of several systems analysis tools, and a summary of several process integration technology design tools. Solutia has applied the CLEANER production strategy at sites within Florida, Texas and Alabama and more than 150 process designs that allow large waste reduction and energy conservation opportunities have been identified. Highlights of results achieved, along with the economic and environmental benefits, are provided.