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The suitability of different types of industries for inter-site heat integration

Panel: 4. Undertaking high impact actions: The role of technology and systems optimisation

This is a peer-reviewed paper.

Authors:
Thomas Hills, Grantham Institute for Climate Change, Imperial College London, United Kingdom
Ajay Gambhir, Grantham Institute for Climate Change, Imperial College London, United Kingdom
Paul Fennell, Chemical Engineering Department, Imperial College London, United Kingdom

Abstract

Several studies have shown that some highly energy-intensive processes such as refineries and power stations are suitable for heat integration with each other (inter-site heat integration). This paper shows the results of attempting to integrate the waste heat sources and potential sinks across several industries which have received less inter-site heat integration attention, namely a steel mill, cement plant, recycled paper plant and fertiliser plant. By building three theoretical heat exchange networks, one to maximise heat recovery at isolated plants, another to maximise heat recovery with integrated plants and one to maximise electricity generation, the characteristics of different process streams which are conducive or obstructive to successful, profitable integration can be identified. This can then be extrapolated to entire processes, and thus a ‘first-pass’ identification of the most promising processes for integration can be attempted. An exergy analysis has been performed to identify the exchanges which are least exergy efficient. In general, processes involving large quantities of liquids and condensing and evaporating gases, such as refineries, offer significant potential. Processes with incondensable, low-pressure gases and solid streams, such as cement plants, are generally more difficult or costly to integrate. The costs and payback periods of the networks are estimated, and these findings are then put into a policy perspective, with ideas about how to focus investment and subsidy on better value-for-money schemes.

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