Chemical Engineering Journal 172 (2011) 799810

Contents lists available at ScienceDirect

Chemical Engineering Journal

journal homepage: www.elsevier.com/locate/cej

Design of discontinuous water-using systems with a graphical method

Jin-Kuk Kim
Department of Chemical Engineering, Hanyang University, 17, Haengdang-dong, Seongdong-gu, Seoul 133-791, Republic of Korea

a r t i c l e

i n f o

a b s t r a c t
A systematic approach using the graphical representation of water use and its system-wide manipulation is proposed for minimising freshwater and wastewater generation for discontinuous water systems. Design interactions of time-dependant water reuse and implications of storage tank in the network design have been fully addressed, and a new targeting and design method has been proposed to provide guidelines for achieving minimum freshwater requirements and to design the conguration of water re-use networks. Design complexity associated with simultaneous consideration of concentration and time constraints has been effectively dealt with in the proposed design method, which clearly provides benets by reducing water consumptions and maintaining sustainable water usage. 2011 Elsevier B.V. All rights reserved.

Article history: Received 3 March 2011 Received in revised form 21 June 2011 Accepted 22 June 2011 Keywords: Water pinch analysis Water reuse Water minimisation Discontinuous water use

1. Introduction Water is one of the key resources in manufacturing as it is widely used as heat transfer media, for example, cooling water and steam, and mass transfer agents, for example, water for washing, stripping steam. The efcient use of freshwater with less generation of wastewater to the environment has been regarded one of the priorities in process industries, in order to minimise costs associated with water use and its discharge, as well as to ensure much reduced environmental burden to the society. Minimising water consumption and, consequently, wastewater generation from process industries can be made through various measures, including process changes, water reuse and water recycling. The way to use water is dependent on how the process is designed and operated, and therefore water requirement for the process can be reduced by adopting appropriate change of processing mechanism or design. This might be regarded as a straightforward option to be considered for water reductions, as process changes for a particular process can be made in isolation to other parts of the plant. However, process changes can be problematic due to practical and engineering constraints, and may require heavy capital expenditure to accommodate the change. On the other hand, water reuse and recycling has been widely considered and implemented in process industries as a practical method for water conservation. As long as the reused or reproduced water does not degrade the quality of product and process performance, reusing water with/without regeneration can be seen as a cost-effective and practical approach. However, it is not an

Tel.: +82 2 2220 2331. E-mail address: jinkukkim@hanyang.ac.kr 1385-8947/$ see front matter 2011 Elsevier B.V. All rights reserved. doi:10.1016/j.cej.2011.06.066

easy task to identify the most appropriate manner of water reuse and recycling, especially, in industrial practice, where a large number of water-using operations are involved with complex design interactions among them. In order to investigate water-using systems in a holistic way, a system-wide analysis has been proposed by Wang and Smith [1] who introduced the graphical denition of water usage in process operations and provided a design procedure to manipulate graphically the proles of water usage for obtaining minimum water requirements. This design framework also includes a design method of water-using networks which achieve the target. One of the signicant benets from using their method is to screen all the available system-wide opportunities for water re-use, as well as to provide conceptual understanding and insights of water network design problem. Water regeneration and recycling had been also investigated by Wang and Smith [1], which allows further reductions of freshwater consumption at the expense of water regeneration cost. This graphical design method had been further extended to cover the wide range of design problems in water systems, including treatment systems using distributed treatment concepts, design with water-using operations and treatment systems together, water reuse for multi-component systems and network design with process or engineering constraints [27]. There are limitations associated with graphical design methods. For example, it is not straightforward to design large-size industrial water systems in which multi-component analysis is necessary and complex design interactions between various water-using and water-treating units are to be systematically investigated. These practical and computational issues have been addressed by adopting mathematical programming and optimisation techniques, with which practical constraints can be readily added, as well as rigorous economic trade-off can be effectively carried out [812].

800

J.-K. Kim / Chemical Engineering Journal 172 (2011) 799810

Nomenclature C M P T Ts Tf concentration [ppm] contaminant mass load [kg] water-using operation storage tank starting time of water-using operation [h] end time of water-using operation [h]

Concentration

(B) P2 P1

X
(C)

(A) P4

P3

X
(D) t1

P5 t2 Time

tO

Fig. 1. Time-dependent water reuse.

Attention has been paid to consider the time-dependant nature of water usage in process industries, and this non-continuous water use is common in chemical batch and semi-batch processes. Fig. 1 illustrates design implication associated with time-dependant water reuse, and water reuse is controlled by the sequence of process operation. For example, water discharged in P5 cannot be reused in P4 in Fig. 1, unless wastewater is collected and recycled for the next batch of operation. Water efuent from P1 can be reused for water-using operation in the next time interval, as long as quality of efuent from P1 can be acceptable for the waterusing operations. In Fig. 1, water reuse from P1 to P3 is not feasible unless freshwater is mixed with wastewater from P1. Wang and Smith [13] extended a water pinch concept to reect time-dependant water reuse. Their targeting method is based on owrate vs. time diagram, with which it is difcult to consider concentration constraints simultaneously. Consequently, it is impractical to apply their method to a design problem with a large number of water-using operations in which there are a large number of opportunities for water reuse. Also, their design method has

not fully addressed the storage capacity required in the design, as illustrated in Fig. 2. A storage tank with dotted line in Fig. 2 was not identied in their work. Methodological improvement on Wang and Smiths [13] graphical design method had been made by Majozi et al. [14] for minimising water and wastewater in completely batch operations. Although further understanding on the water use in the batch processes had been made, their works are based on certain assumptions which limit the full potentials of water reusability during the targeting and design. One of the key benets of using water pinch analysis based on the concept of limiting water proles is to exploit possibility in changing water concentration and hence owrate in the water network design from the viewpoint of overall system integration, which provides opportunities for further water reuse and recycling. However, one of the key assumptions made in their study is that water requirement of water-using operations is xed. On the other hand, Majozi et al. [14] restricted the water reuse opportunities during the course of the operation, which means that reusing water can be only considered in the beginning or the end of the operation, not during the operation. This can simplify the targeting and design procedure, however, signicant potential for reducing freshwater consumptions through water reuse during the same time interval cannot be realised in the resulting water network design. Foo et al. [15] proposed the design method for maximising water recovery using WCA (Water Cascade Analysis) with which water purity and water demand is manipulated in a time-dependant interval table. Further development has been made by applying a time-dependent concentration interval analysis (CIA) which can solve the discontinuous water-using systems involving both mass and non-mass transfer based operations [16]. Later, Chen and Lee [17] developed a graphical technique for the design of discontinuous water-using networks, considering inlet and outlet streams separately as water demands and water sources and, accordingly, identifying matches between demands and sources. Another way of improving Wang and Smiths graphical method has been made by several researchers who developed automated design methods, typically, by setting a superstructure of discontinuous water network s, and applying deterministic or stochastic optimisation techniques [1820]. Kim and Smith [19] proposed an MINLP optimisation framework in which rigorous economic trade-off between freshwater cost, piping cost and storage tank cost are carried out with systematic identication of water re-use in the batch operation. Majozi [20] presented an MILP optimisation model for water minimisation in multipurpose batch plants, and the design problem is formulated such that the outlet water concentration from each operation is xed at its maximum, which allows the linear formulation for the optimisation problem, although relaxing outlet concentration during the optimisation is more desired for fully appreciating all the possible water re-use opportunities available

Fig. 2. Example 1 Wang and Smiths [13] design.

J.-K. Kim / Chemical Engineering Journal 172 (2011) 799810

801

in the design. Recent review papers by Gouws et al. [21] has provided the detailed overview and summary of contribution made by process integration and system engineering communities in the area of water system studies in batch and semi-batch processes. Although the automated design method has contributed by providing a decision-support tool for water and wastewater minimisation in discontinuous processes, it is still required to fully gain the fundamental understanding of time-dependency on water reuse and its design implications for water network, which will help engineers to implement water reuse in various industrial practices. Therefore, the development of a graphical design methodology has been aimed at providing systematic targeting and design tools for the use and reuse of water when concentration and timing information has to be simultaneously considered in a single design framework. Drawbacks identied from previous studies of Wang and Smith [13] and Majozi et al. [14] have been addressed as a new design method proposed in this paper which considers those issues systematically. This includes that the requirement of storage capacity and its interactions in the water network design is fully considered; water owrate for each operation is not xed, but varied when targeting and designing of water-using operations are made; water reuse is considered for the operation as long as the concentration constraints are met. The paper is organised to explain a new targeting method rst, which is then followed by a novel design procedure for the water network. Three case studies are illustrated to demonstrate the effectiveness and robustness of the developed design method, and the limitation of the developed method has been also discussed. 2. New design method: targeting The proposed design methodology has two steps: targeting and network design. The targeting is to represent time-dependant water-using operations and their water use in a unied and integrated format, to collectively investigate overall characteristics of time-dependant water use and re-use, and to obtain minimum water requirement for the water systems. The new design method presented in this paper adopts the limiting water ow prole concept used in Kim and Smiths optimisation study [19] for discontinuous water systems, as shown in Fig. 3. For continuous water processes, the limiting water conditions are dened with the rate of mass load to be transferred to the water stream, and maximum allowable water concentration for inlet and outlet, while the limiting water ow prole, for time-dependant water systems, is based on overall mass load to be transferred to the water stream, which inherently includes timing information by multiplying time duration with the rate of mass load. It should be

Fig. 3. Limiting water ow prole [19].

noted that any proles below and at the limiting water ow prole will be considered, which ensures that water owrate to be achieved in the design is not xed, but varied, subject to targeting and design procedure. Another point to be made is that the limiting water ow prole is separately dened for each time interval for all the water-using operations, which allows the identication of reuse potentials within the same time interval as well as across different time intervals. In this study, the minimum water requirement or maximum water re-use has been targeted in two parts, which provides the boundary of target. A single gure for the target would be ideal, however, identifying a unique target for minimum water requirement using graphical representation and its manipulation is not realistic, because both concentration and timing information should be simultaneously taken into account. Using mathematical programming and optimisation techniques is clearly an attractive alternative option for targeting purposes. But, this automated way had been previously attempted [19] and it is aimed in this study at creating conceptual understanding of design problems and providing fundamental knowledge for how time-dependant water reuse should be considered in the design. First, the minimum water requirement without considering time constraints is identied, which is termed as lower bound targeting (LBT). LBT provides a theoretical minimum water requirement, and the water owrate obtained from LBT may not always be achieved through the network design, due to timeconstraints. However, this LBT procedure provides valuable insight

C [ppm] 400

(a)

C [ppm] 400

(b)
Composite curve

P1 P3 200 P2 100 100 200

Pinch

Minimum flow Lower bound target: 102.5 t

2.5

30

M [kg]

20.5

40.5

M [kg]

Fig. 4. Example 1 lower bound targeting.

802 Table 1 Example 1 limiting water data [13]. Process Limiting concentration (ppm) Cin P1 P2 P3 100 0 100 Cout 400 200 200 100 80 50 Limiting owrate (t/h)

J.-K. Kim / Chemical Engineering Journal 172 (2011) 799810

Time (h)

Ts 0.5 0 0.5

Tf 1.5 0.5 1.0

of discontinuous water systems as how good the nal design is can be checked against the lower bound target. The second part of the targeting approach is to consider time constraints into the investigation of water re-use potential, but the maximum reuse of water is only considered within the same time interval, and the reuse possibility from previous time interval to next through storage tank is not permitted. This procedure provides another target which can be further reduced by implementing water re-use between different time intervals. The identied upper bound target results from conservative application of water re-use as the multi-period nature of water re-use has not been fully considered. This upper bound targeting (UBT) method allows users to avoid possible poor design with more freshwater owrate required than target from UBT. The LBT and UBT will be explained with the example 1, as given in Table 1, which includes limiting water data and time information for three water-using operations. It is assumed that freshwater is available at the concentration of 0 ppm. The limiting water data conditions are expressed in terms of limiting water ow prole, based on limiting concentration and limiting ow. In LBT, the rst step of the procedure is to draw individual limiting water ow proles in the graph as shown in Fig. 4(a), and the single prole of composite curve is created by combining three individual proles for each concentration interval as shown in Fig. 4(b). The manipulation for creating a single composite curve from individual proles follows the same method developed by Wang and Smith [1]. However, the method in this paper is based on limiting water ow proles with which time duration of water-using operation has been embedded, and, consequently, used for targeting of discontinuous water-using processes. The minimum ow target from LBT is calculated to be 102.5 t, which can be obtained from a simple mass balance for the pinch point.

There are two steps for UBT, as illustrated in Figs. 5 and 6. The rst step of UBT is to divide time intervals based on the limiting data, and to put individual water-using elements specic to the particular time interval in the separate concentration and mass load diagram. In Fig. 5, three time intervals (four boundaries based on timing information) are rst made, and individual operations are represented in the each time interval, for example, the limiting water ow prole of P2 is drawn in the rst interval [00.5 h], and proles of P3 and P1 are given in the second interval [0.51 h]. The water use of P1 is split to two parts, according to timing information, which are put in the second and third time interval, respectively. The second step of UBT is to analyse water re-use opportunities in each time interval and to nd minimum freshwater owrate required for each interval separately. To screen maximum water re-use potentials, it is required to create the limiting water ow proles and to obtain minimum freshwater ow separately by following the same approach used in LBT. The minimum freshwater needed for each time interval are 40 t for the rst interval, 43.75 t for the second interval and 37.5 t for the third interval, which gives 121.25 t of freshwater ow as a upper bound target. Upper bound target from UBT and lower bound target from LBT provides the range of possible minimum ow which can be achieved through network design explained in the following section. Water reuse is only considered within a single batch or production campaign, which means that water re-use from previous batch to next batch is not allowed. 3. New design method: network design The design of the network of water-using operations is made by following a few design rules as below: Design rule 1: the network design is carried out in sequence from the rst time interval to the following interval, which allows full utilisation of available water sources from the previous interval to the next interval. Design rule 2: reusing as much water from available water sources from previous time interval as possible is preferred as long as the intake of freshwater can be reduced. Also, reusing wastewater source(s) with the lowest concentration, other than freshwater, is to be fully utilised rst. These will minimise the overall intake of freshwater for the whole network. However, this strategy results in the introduction of storage tanks for enabling water reuse in

Concentration

Concentration 400 ppm P3 25 t P2 P1 50 t

Concentration 400 ppm P1 50 t

200 ppm 40 t

200 ppm 100 ppm 100 ppm

8 kg Mass load (M)

2.5 kg

17.5 kg Mass load (M)

15 kg Mass load (M)

0h

0.5 h

1h
Fig. 5. Example 1 upper bound targeting (I).

1 .5 h

J.-K. Kim / Chemical Engineering Journal 172 (2011) 799810

803

Concentration

Concentration 400 ppm

Composite curve (P1 + P3)

Concentration 400 ppm P1

P2 200 ppm 40 t 200 ppm 100 ppm

75 t 50 t 37.5 t 100 ppm 43.75 t

8 kg Mass load (M)

17.5 kg

15 kg

Design region

Mass load (M)

Design region

Mass load (M)

0h

0.5 h

1h

1.5 h

Upper bound target: 121.25 t (= 40 t + 43.75 t + 37.5 t)

Fig. 6. Example 1 upper bound targeting (II).

different time intervals. As demonstrated by Kim and Smith [19], the cost of storage tank is relatively cheap, and it is benecial to save further water requirements. Design rule 3: once the selection of water source(s) to be used in the particular time interval, the maximum re-use between operations is sought and the corresponding water network is designed by following water main method developed by Kuo and Smith [5]. The details of water main method are not explained in this paper, but can be found elsewhere, including Smith [22], as it had been well established and widely applied. Design rule 4: when more than one re-use possibilities exist, the matching between water sources and sinks should be made such that, rst, the design to minimise freshwater consumption for the particular time interval is selected. If there is no difference in freshwater requirements, then, the number of connections between sources and sinks should be minimised. This strategy helps to reduce piping cost and design complexities, although piping cost is heavily dependent on hydraulic design of piping systems and physical distances between water sources and sinks. The design procedure for water network design is explained with example 1. Based on the design rule 1, the design of rst time interval is carried out rst, which then followed by second and third time interval. Fig. 7 shows the rst time interval in which only one water-using operation is employed. The freshwater ow required for the rst interval is 40 t, and correspondingly, wastewater generated in the end of time interval is 40 t with the concentration of 200 ppm. For the second time interval, there are two water sources, namely, 40 t of wastewater generated from the previous time interval at 200 ppm (shown as intermediate water (I) in Fig. 8) and freshwater at 0 ppm. By following design rule 2, wastewater from intermediate water (I) is re-used, but the addition of freshwater is required, because maximum inlet concentration allowed in this time interval is 100 ppm. By mixing two sources of water equally, 100 ppm of water is generated and supplied to this time interval, and the required freshwater is 37.5 t. From intermediate water (I), 37.5 t of wastewater rare used, while 2.5 t of unused water will be remained to be used for the next available time interval. The network conguration of this time interval is shown in Fig. 8 such that no re-use of water between operations are envisaged, due to the same inlet maximum concentration allowed, by following design

rule 3. Water consumed in P1 and P3 can be used for the next time interval as water sources at 200 ppm and 400 ppm, respectively. For the time interval between 1 h and 1.5 h, there are four water sources available which include one from the rst time interval, two from the second time interval and freshwater (Fig. 9). The 200 ppm water source is selected, rather than 400 ppm the water source, by following design rule 2, which will minimise the use of freshwater. As the maximum inlet concentration acceptable for P1 is 100 ppm, equal amounts of water from freshwater source and 200 ppm of water sources are combined to supply 50 t to P1. There are two possibilities for taking 25 t of 200 ppm water: one option is to use intermediate water (II-b) only; the other option is to use both sources of intermediate water (I-a) and (II-b). By following design rule 4, the design for this time interval include only one water re-use from intermediate water (II-b) as shown in Fig. 9. Final water network design is obtained by simply assembling the design of each time intervals and representing it in a single network, as shown in Fig. 10. Overall freshwater requirement is 102.5, which achieves the lower bound target through the design,

Fig. 7. Example 1 design: time interval [00.5 h].

804

J.-K. Kim / Chemical Engineering Journal 172 (2011) 799810

Fig. 8. Example 1 design: time interval [0.51 h].

Fig. 9. Example 1 design: time interval [11.5 h].

Fig. 10. Example 1 nal design.

J.-K. Kim / Chemical Engineering Journal 172 (2011) 799810 Table 2 Example 1 results comparison. Method No water reuse New conceptual design Mathematical optimization [19] Water consumption (t) 127.5 102.5 102.5 Storage tank (t) 0 62.5 37.5

805

while 62.5 t of storage capacity is necessary to support water re-use between time intervals. The result is compared with other methods as shown in Table 2. When a conventional method based on once-through water usage is applied, 127.5 t of freshwater is consumed without intermediate storage required. With the new design method, water consumption is reduced by 19.6% at the expense of storage capacity. Compared to the results obtained from an automated design method [19], as well as to the design obtained with the aid of WCA (Water Cascade Analysis) [15], the requirement of storage tanks that results from the developed design method is bigger than optimal although the required freshwater owrate is the same. 4. Application of new design method The new design methodology presented in this paper is applied to a second example. Details of example 2 are given in Table 3, which had been used in the study of Kim and Smith [16], and it is assumed that the freshwater source is available at 0 ppm. The procedure of LBT, gives 185 t of minimum freshwater requirement, while Fig. 11 shows the UBT, resulting in 211.25 t of upper bound target. The rst step of the design is to achieve the target between the two boundaries obtained from UBT and LBT, so the design of the rst time interval [01 h] is carried out. 20 t of freshwater is consumed in P1 and its efuent is available for re-use in the next time interval. In the next time interval, the reuse of water from the intermediate water (I) does not contribute reducing the amount of freshwater required. This is because water source for the reuse is available at 100 ppm, and the maximum inlet concentration to the liming water ow composite curve is also 100 ppm (Fig. 12). For example, if 20 t at 100 ppm is fully reused in this time interval, freshwater required is 100 t and 120 t of the water is supplied to this time interval at 16.7 ppm. When no water from the intermediate water (I) is reused, 100 t of freshwater is still required. Therefore, by following design rule 4, it is decided not to re-use water from the intermediate water (I). The rest of the design is based on design rule 3, which identies water re-use between P2 and P4 within this time interval. Two additional water sources at 100 ppm and 800 ppm, become available from the result of water main method. For the third time interval [33.5 h] there are many potential options for water reuse, due to three available water sources that result from the design of previous two time intervals, as shown in
Table 3 Example 2 limiting water data [19]. Process Limiting concentration (ppm) Cin P1 P2 P4 P2 P3 P3 0 50 400 50 50 50 Cout 100 100 800 100 800 800 20 100 10 100 40 40 20 200 20 50 20 60 Limiting owrate (t/h)

Fig. 13. One of the possibilities is to mix equal amounts of 35 t from water sources at 100 ppm and freshwater, which is then supplied at 50 ppm. From design rule 4, it is not benecial to mix freshwater with the contaminated water in this case, as the same 35 t of freshwater is needed even if only freshwater is supplied. Another possibility is to utilise water from the intermediate (II-b) source, which requires more than 35 t of freshwater. Therefore, freshwater is taken as a single water source for time interval [33.5 h]. The wastewater from P2 is reused for P3 after mixing with freshwater, by following design rule 3. It should be noted that consideration made in the second and third time intervals also contributes to avoid unnecessary introduction of storage tanks. The nal time interval between 3.5 h and 5 h introduces the mixing between freshwater and intermediate (II-a) (Fig. 14). The four sub-networks of water systems are now combined, as illustrated in Fig. 15. The overall freshwater required for the nal design is 185 t with 30 t of storage capacity, which satises the lower bound target. Table 4 illustrates the benets of using the developed design method, which compares with optimal results published by Kim and Smith [19]. Against a design with no water reuse, considerable cost saving with the reduction of freshwater demand is achieved. The design identied from the developed graphical method coincides with the design obtained from mathematical optimisation when costs of freshwater and storage tanks are considered in the objective function. When compared the result from the proposed method in this paper to the network design in which piping cost is simultaneously considered with freshwater and storage tank costs, it gives conceptual insights that piping cost plays an important part in the water network design and the developed method is limited to deal with more rigorous economic trade-off. However, Table 4 clearly illustrates the proposed design method is able to provide signicant savings for discontinuous water systems by systematically implementing water re-use under time constraints, although optimal or near-optimal solutions may not be achieved.

5. Discussion on new design method Two examples illustrated in the previous sections demonstrated the applicability and usefulness of the new design method. However, there are a few issues to be addressed in terms of the methodological limitation associated with the targeting concept and design procedure presented in this paper. As commented in the previous sections, the developed targeting provides the feasible range of possible target freshwater owrate, and it has been attempted to achieve as close to the lower bound target as possible during the design. In examples 1 and 2, the network design is based on the lower bound target owrate. This may not be the case for other design problems, which will be explained with example 3. Table 5 shows the water data of four water-using operations, of which water concentration and ow condition is

Limiting ow (t)

Time (h)

Ts 0.0 1.0 3.0 3.5

Tf 1.0 3.0 3.5 5.0

P2 and P2 are the same operation; P3 and P3 are the same operation.

806

J.-K. Kim / Chemical Engineering Journal 172 (2011) 799810

C [ppm]

C [ppm] 800 Composite curve (P2 + P4) P1 20 t 100 t 400 100 50 2 M [kg] Design region 10 200 t 18 M [kg]

C [ppm] 800 Composite curve (P2 + P3) 400 100 50 3.5 17.5 M [kg] 35 t 70 t

C [ppm] 800 P3 60 t

100

56.25 t 50 45 M [kg]

0h

1h

3h

3.5 h

5h

Upper bound target: 211.25 t (= 20 t + 100 t + 35 t + 56.25 t)

Fig. 11. Example 2 upper bound targeting.

Table 4 Example 2 results comparison. Method No water reuse New graphical design method Mathematical optimization [19]a

Optimal design 1 Water Storage tank Piping cost (t) Overall cost (k year1 ) Consumption (t) Cost (k year1 ) Capacity (t) Cost (k year1 ) 230 368.0 150.1 518.1 (100%) 185 296.0 30 7.3 170.8 474.1 (91.5%) 185 296.0 30 7.3 170.8 474.1 (91.5%)

Optimal design 2 190.6 305.0 45 13.6 123.6 442.2 (85.3%)

a Design 1: objective function considers freshwater and storage tank costs only. Design 2: objective function considers freshwater, piping and storage tank costs.

Fig. 12. Example 2 design: time interval [13 h].

J.-K. Kim / Chemical Engineering Journal 172 (2011) 799810

807

Fig. 13. Example 2 design: time interval [33.5 h].

the same to example 2, but different operating time intervals are applied for each operation. The lower bound target obtained is 250 t, while 276.25 t of upper bound target is identied in Fig. 16. After design rules are applied, the nal water network requires 276.25 t of freshwater, as given in Fig. 17, which is the upper bound target. This is mainly because the water reuse is only identied within the same time interval, but reuse from the previous time interval to the next time interval is not selected during water network design, which is the same situation for UBT. This implies that any target owrate between two boundaries can be possible, depending on the problem specication. The proposed design method considered only water re-use in a single batch production schedule. The water may be reused repeatedly between different batches, although it may increase build-ups of undesired contaminants in the water circuit. The proposed design method is now extended for considering repeated

batch processes in which the manufacturing of products follows the same sequence of batch operations and, hence, water reuse in the plant can be scheduled in a periodic manner from the previous batch production to the next batch production. A design procedure to minimise freshwater consumption for the repeated batch process is proposed as below:
Table 5 Example 3 limiting water data. Process Limiting concentration (ppm) Cin P1 P2 P3 P4 0 50 50 400 Cout 100 100 800 800 20 100 40 10 Limiting owrate (t/h) Time (h)

Ts 2.5 1.5 0.0 2.5

Tf 5 4.5 2.5 4.5

Fig. 14. Example 2 design: time interval [3.55 h].

808

J.-K. Kim / Chemical Engineering Journal 172 (2011) 799810

Fig. 15. Example 2 nal design.

Step 1: the design of water network is rst carried out, assuming that no water can be reused between different batches as it has been done in the three previous examples. Step 2: all the possible water sources which are to be discharged from the current batch production, but can be reused in the next batch production, are identied. Step 3: the water network design for the next batch production is repeated, but water sources identied from step 2 are included in the network design. Design rules explained in Section 3 are applied to screen all the possible water sources and sinks, and select additional match which can further reduce freshwater consumption for the next batch production. Step 4: steps 2 and 3 are repeated until no improvements have been achieved. The design method extended for designing repeated batch processes is now explained with example 3. The result of step 1 is Fig. 17, which is the design for a single batch production and water reuse is not considered beyond the single batch cycle. From step

2, water sources available for the next batch are identied, which include discharged water of P3 in the rst time interval, that of P2 and P3 in the second time interval, that of P1, P2 and P4 in the third time interval and that of P1 in the fourth interval. When additional water sources are included in the design step 3, wastewater discharged from P3 and P4 is not chosen for the water reuse from the previous batch to the next batch, as 800 ppm of wastewater does not contribute for reducing the freshwater consumption. Water discharged from P1 or P2 can be reused from the previous batch to the next batch by mixing it with freshwater. Water reuse from P1 in the third time interval [2.54.5 h] of the previous batch to P3 in the rst time interval [01.5 h] of the next batch is selected, as this match reduces design complexities, compared to other potential matches. If P2 in the third time interval is selected for the water reuse for P3 in the next batch, water stream from P3 is split to three streams, leading to a complex splitting junction. After one iteration of steps 2 and 3, no improvement was observed and the water network is nalised as illustrated in Fig. 18. The nal water network obtained for the repeated batch production consumes 250 t of freshwater, which

C [ppm] 800 P3 60 t

C [ppm] 800 Composite curve (P2 + P3) 70 t 400 100 50 45 M [kg] 10 Design region 140 t 18 M [kg]

C [ppm] 800 Composite curve (P1 + P2 + P4)

C [ppm]

400 100 50 2 14 140 t 22 M [kg] 100

P1 10 t

56.25 t 50

1 M [kg]

0h

1.5 h

2.5 h

4.5 h

5h

Uper bound target: 276.25 t (= 56.25 t + 70 t + 140 t + 10 t)

Fig. 16. Example 3 upper bound targeting.

J.-K. Kim / Chemical Engineering Journal 172 (2011) 799810

809

Fig. 17. Example 3 nal design.

corresponds to a lower bound target. This illustrates that the design obtained in Fig. 18 achieves theoretical minimum water requirement for the discontinuous water systems by allowing repeated water reuse between different batch productions. The methodology presented in this paper is based on the graphical representation of water usage of water-using operation and its manipulation for identifying the target and designing the network conguration, and therefore, all the common drawbacks documented for pinch analysis in the process engineering communities are also observed. This includes difculties related to when the methodology is applied for complex water network problems,

for example, a large number of water-using operations and multicontaminant systems, as well as when it is required to address rigorous economic trade-offs. However, it should be noted that the proposed method clearly enables to reduce water consumptions considerably in the discontinuous water systems by giving systematic design guidelines for engineers, as well as provides methodological advantages by gaining fundamental understanding of time-dependant water use and reuse. Also, the method explained here helps users to consolidate their condence in applying process integration technologies to discontinuous systems in practice.

Fig. 18. Example 3 nal design for repeated batch processes.

810

J.-K. Kim / Chemical Engineering Journal 172 (2011) 799810 [8] S.J. Doyle, R. Smith, Targeting water reuse with multiple constraints, Trans IChemE: Part B 75 (1997) 181189. [9] B. Galan, I.E. Grossmann, Optimal design of distributed wastewater treatment networks, Ind. Eng. Chem. Res. 37 (1998) 40364048. [10] A. Alva-Algez, A. Kokossis, R. Smith, An Integrated Design Approach for Wastewater Minimisation: Theory and Applications, IChemE Research Event, UK, 1998. [11] G. Huang, C. Chang, H. Ling, C. Chang, A mathematical programming model for water usage and treatment network design, Ind. Eng. Chem. Res. 38 (1999) 26662679. [12] M. Gunaratnam, A. Alva-Argaez, A. Kokossis, J. Kim, R. Smith, Automated design of total water systems, Ind. Eng. Chem. Res. 44 (2005) 588599. [13] Y.P. Wang, R. Smith, Time pinch analysis, Trans. IChemE: Part A 73 (1995) 905914. [14] T. Majozi, C.J. Brouckaert, C.A. Buckley, A graphical technique for wastewater minimisation in batch processes, J. Environ. Manage. 78 (2006) 317 329. [15] D.C.Y. Foo, Z.A. Manan, Y.L. Tan, Synthesis of maximum water recovery network for batch process systems, J. Cleaner Prod. 13 (2005) 13811394. [16] Y. Liu, X. Yuan, Y. Luo, Synthesis of water utilization system using concentration interval analysis method (II) discontinuous process, Chin. J. Chem. Eng. 15 (2007) 369375. [17] C.L. Chen, J.Y. Lee, A graphical technique for the design of water-using networks in batch processes, Chem. Eng. Sci. 63 (2008) 37403754. [18] M. Almato, A. Espuna, L. Puigjaner, Optimisation of water use in batch process industries, Comput. Chem. Eng. 23 (1999) 14271437. [19] J. Kim, R. Smith, Automated design of discontinuous water systems, Process Saf. Environ. Prot. 82 (B3) (2004) 238248. [20] T. Majozi, An effective technique for wastewater minimisation in batch processes, J. Cleaner Prod. 13 (2005) 13741380. [21] J.F. Gouws, T. Majozi, D.C.Y. Foo, C. Chen, J. Lee, Water minimization techniques for batch processes, Ind. Eng. Chem. Res. 49 (2010) 88778893. [22] R. Smith, Chemical Process Design and Integration, Wiley, Chichester, 2005.

6. Conclusions A new systematic targeting and design method for the maximising water re-use in the discontinuous water systems has been developed. First, the time-dependant reusability of water has been screened by obtaining upper bound target and lower bound target. Next, the design is carried out to achieve the lower bound target, by systematically identifying water reuse within and beyond the particular time interval, and the requirement of storage tank for reusing water in the different time intervals. Three examples had been used for illustrating the design methodology developed and demonstrating the robustness and applicability of the method. References
[1] Y.P. Wang, R. Smith, Wastewater minimisation, Chem. Eng. Sci. 49 (1994) 9811006. [2] Y.P. Wang, R. Smith, Design of distributed efuent treatment systems, Chem. Eng. Sci. 49 (1994) 31273145. [3] Y.P. Wang, R. Smith, Wastewater minimisation with owrate constraints, Trans. IChemE: Part A 73 (1995) 889904. [4] W.J. Kuo, R. Smith, Efuent treatment system design, Chem. Eng. Sci. 52 (1997) 42734290. [5] W.J. Kuo, R. Smith, Designing for the interactions between water-use and efuent treatment, Trans. IChemE: Part A 76 (1998) 287301. [6] W.J. Kuo, R. Smith, Design of water-using systems involving regeneration, Trans. IChemE: Part B 76 (1998) 94114. [7] S. Thevendiraraj, J. Klemes, D. Paz, G. Aso, G.J. Cardenas, Water and wastewater minimisation study of a citrus plant, Resour. Conserv. Recycl. 37 (2003) 227250.