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Water integration in industrial zones: a spatial representation with direct recycle applications

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Abstract

This work introduces a representation of spatial aspects within industrial zones, which can be applied to problems involving any type of water integration strategies. The representation is flexible and takes into consideration the respective plant locations, and any barriers that exist in between. Moreover, industrial city corridors that are allocated for water transport have also been accounted for. This allows effective water integration and matching among available water streams using a spatially constrained approach that utilizes the shortest path options available. The proposed representation has been illustrated using direct recycling integration strategies, which in turn are commonly recognized to employ the simplest techniques for water integration, as a first instance. A case study involving several water using and producing processes that belong to a group of plants all operating in a common industrial zone have been carried out as a demonstration, for which several different scenarios were studied. In doing so, cost-effective water network designs that involve attractive wastewater reuse schemes among adjacent and nearby processing facilities have been identified, while considering spatial constraints for water transport.

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Abbreviations

p :

Plant/process

i :

Water source

j :

Water sink

c :

Contaminant

P :

Set of plants/processes in industrial city

SU p :

Set of water sources in plant p

SN p :

Set of water sinks in plant p

C :

Set of contaminants/pollutants

\(z_{cjp}^{ \hbox{min} }\) :

Minimum permissible pollutant c composition in sink j, plant p (ppm)

\(z_{cjp}^{ \hbox{max} }\) :

Maximum permissible pollutant c composition in sink j, plant p (ppm)

\(G_{jp}\) :

Flowrate required in sink j, plant p (kg/h)

\(W_{ip}\) :

Flowrate available in source i, plant p (kg/h)

\(x_{c,ip}^{\text{Source}}\) :

Pollutant c composition in source i, plant p (ppm)

\(x_{c}^{\text{FRESH}}\) :

Pollutant c composition in external freshwater (ppm)

\(\varepsilon\) :

Pipe roughness

\(K_{\text{ex}}\) :

Expansion loss at pipe exit

\(K_{c}\) :

Contraction loss at pipe entrance

\(K_{b}\) :

Loss at pipe elbow/bend

\(\rho\) :

Density (kg/m3)

\(\mu\) :

Viscosity (kg/ms)

a :

Coefficient associated with piping cost calculations

b :

Power coefficient associated with piping cost calculations

\(C^{\text{FRESH}}\) :

Cost of freshwater ($/ton)

\(H_{y}\) :

Operating hours per year (h/year)

\(\gamma\) :

Annualized piping cost factor (year−1)

\(\eta\) :

Efficiency

\(z_{cjp}^{\text{in}}\) :

Pollutant c composition in sink j, plant p

\(M_{ipjp'}\) :

Mass flowrate from source i, plant p to sink j plant p′

\(F_{jp}\) :

External freshwater mass flowrate required in sink j, plant p

\(D_{ip}\) :

Wastewater mass flowrate discharged by source i, plant p

\(L_{ipjp'}\) :

Length of pipe from source i, plant p to sink j plant p′

\(L_{ip}\) :

Length of pipe carrying unused wastewater from source i, plant p to mainstream waste

\(L_{jp}\) :

Length of pipe carrying freshwater from mainstream to sink j, plant p

\({\text{DI}}_{ipjp'}\) :

Calculated diameter of pipe from source i, plant p to sink j plant p′

\({\text{DI}}_{ip}\) :

Calculated diameter of pipe carrying unused wastewater from source i, plant p to mainstream waste

\({\text{DI}}_{jp}\) :

Calculated diameter of pipe carrying freshwater from mainstream to sink j, plant p

\({\text{DI}}_{ipjp'}^{c}\) :

Custom diameter of pipe, based on rounding the calculated value, from source i plant p to sink j plant p′

\({\text{DI}}_{ip}^{c}\) :

Custom diameter of pipe, based on rounding the calculated value, carrying unused wastewater from source i, plant p to mainstream waste

\({\text{DI}}_{jp}^{c}\) :

Custom diameter of pipe, based on rounding the calculated value, carrying freshwater from mainstream to sink j, plant p

\(N_{ipjp'}^{E}\) :

Number of elbows/bends in pipe from source i, plant p to sink j plant p′

\(N_{ip}^{E}\) :

Number of elbows/bends in pipe carrying unused wastewater from source i, plant p to mainstream waste

\(N_{jp}^{E}\) :

Number of elbows/bends in pipe carrying freshwater from mainstream to sink j, plant p

\(N_{{Re_{ipjp'} }}\) :

Reynolds’s number of stream from source i, plant p to sink j plant p′

\(N_{{Re_{ip} }}\) :

Reynolds’s number of stream carrying unused wastewater from source i, plant p to mainstream waste

\(N_{{Re_{jp} }}\) :

Reynolds’s number of stream carrying freshwater from mainstream to sink j, plant p

\(v_{ipjp'}\) :

Velocity of stream from source i, plant p to sink j plant p′

\(v_{ip}\) :

Velocity of stream carrying unused wastewater from source i, plant p to mainstream waste

\(v_{jp}\) :

Velocity of stream carrying freshwater from mainstream to sink j, plant p

\(f_{ipjp'}\) :

Fanning friction factor of stream from source i, plant p to sink j plant p′

\(f_{ip}\) :

Fanning friction factor of stream carrying unused wastewater from source i, plant p to mainstream waste

\(f_{jp}\) :

Fanning friction factor of stream carrying freshwater from mainstream to sink j, plant p

\(A_{ipjp'}\) :

Parameter based on Churchill’s equation for fanning friction factor calculations associated with water stream from source i, plant p to sink j plant p′

\(A_{ip}\) :

Parameter based on Churchill’s equation for fanning friction factor calculations associated with water stream carrying unused wastewater from source i, plant p to mainstream waste

\(A_{jp}\) :

Parameter based on Churchill’s equation for fanning friction factor calculations associated with water stream carrying freshwater from mainstream to sink j, plant p

\(\Delta F_{ipjp'}^{f}\) :

Friction losses associated with pipe carrying water from source i, plant p to sink j plant p′

\(\Delta F_{ip}^{f}\) :

Friction losses associated with pipe carrying unused wastewater from source i, plant p to mainstream waste

\(\Delta F_{jp}^{f}\) :

Friction losses associated with water stream carrying freshwater from mainstream to sink j, plant p

\(\Delta P_{ipjp'}^{\text{Drop}}\) :

Pressure drop due to friction, associated with pipe carrying water from source i, plant p to sink j plant p′

\(\Delta P_{ip}^{\text{Drop}}\) :

Pressure drop due to friction, associated with pipe carrying unused wastewater from source i, plant p to mainstream waste

\(\Delta P_{jp}^{\text{Drop}}\) :

Pressure drop due to friction, associated with pipe carrying freshwater from mainstream to sink j, plant p

\(P_{ip,jp'}^{w}\) :

Shaft power required to overcome pressure drop in pipe carrying water from source i, plant p to sink j plant p′

\(P_{ip}^{w}\) :

Shaft power required to overcome pressure drop in pipe carrying unused wastewater from source i, plant p to mainstream waste

\(P_{jp}^{w}\) :

Shaft power required to overcome pressure drop in pipe carrying freshwater from mainstream to sink j, plant p

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Acknowledgments

This publication was made possible by NPRP Grant No. 4-1191-2-468 from the Qatar National Research Fund (a member of Qatar Foundation). The statements made herein are solely the responsibility of the authors. The authors would like to thank Mason Alnouri for his great assistance and valuable input. Additionally, the authors would like to thank the rest of the research group members in College Station (Mohamed Noureldin and Kerron Gabriel) and Qatar (Sumit Bishnu, Zakarya Othman, and Dhabia Al-Mohannadi).

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Authors and Affiliations

  1. Department of Chemical Engineering, Texas A&M University at Qatar, P.O. Box 23874, Education City, Doha, Qatar

    Sabla Y. Alnouri & Patrick Linke

  2. The Artie McFerrin Department of Chemical Engineering, Texas A&M University, College Station, TX, USA

    Sabla Y. Alnouri & Mahmoud El-Halwagi

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  1. Sabla Y. Alnouri
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  2. Patrick Linke
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  3. Mahmoud El-Halwagi
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Correspondence to Patrick Linke.

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Alnouri, S.Y., Linke, P. & El-Halwagi, M. Water integration in industrial zones: a spatial representation with direct recycle applications. Clean Techn Environ Policy 16, 1637–1659 (2014). https://doi.org/10.1007/s10098-014-0739-2

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