Process integration and opportunity for heat pumps in industrial processes

Process integration methods allow one optimizing industrial processes. The main goals are decreasing energy demand and operating costs as well as reduction of pollutants emissions. High fuel costs promote installation of heat pumps. In a heat pump process waste energy is valorized by electrical power to produce higher quality energy. That is used to satisfy a part of the process demand so that less fuel is required and CO2 emission will decrease. This paper presents a methodology, based on pinch analysis, which demonstrates the opportunity of integrating heat pumps in industrial processes. The method considers the whole process including utilities and the energy conversion system. A combined analysis which considers thermal and material streams in the process is realized to optimize the heat recovery and the integration of energy conversion units. By analogy all material streams are listed and the potential of water recuperation is obtained. The combination of appropriate refrigeration and heat pump cycles leads to an important energy saving potential. The respective flow rates are defined by optimization. The application case of a dairy is used to calculate the energy and operating cost savings potential.