What is PI?
Process Integration is defined as a systematic and general method for designing integrated production systems ranging from individual processes to total sites and with special emphasis on
the efficient use of energy and reducing environmental impacts.
International Energy Agency (IEA)
PI Advantages
General Applicability
Strong Theoretical Basis
Simple Procedure
Cost-Effective Solution
PI techniques can readily be applied to all process industries with no exception
Energy analysis based on fundamental Thermodynamics.
Capital cost analysis based on simple heuristics of known assumptions and limitations
No Mystery ! Simple systematic method Requires engineering common sense
Ensures environmental compliance by increasing your site energy efficiency and reuse of waste
PI Outcomes
Reduced Energy Consumption
Minimize energy consumption of industrial processes and increase energy cost savings up to 50%
Reduced
GHG Emissions
Utilize systematic PI approaches to reduce GHG emission while considering economic impact and design constraints
Reduced Water Consumption
Improve fresh water usage & minimize wastewater production
by water pinch analysis
Improved Profit
Margins
Achieve increased profitability by reducing energy costs and maximizing product recovery
Effective
Asset Utilization
Apply PI techniques for managing energy and material consumption, carbon footprint, waste output in addition to Key Performance Indicators (KPIs)
Operational Excellence
Realize effective monitoring, benchmarking and troubleshooting of process performance
Why Choosing
Alta Process Solutions?
Experienced scientists, engineers, and process design specialists at Alta Process Solutions are dedicated to offer top quality consultancy services to industry, academia and consortia in all areas of the process industries.
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We continue to develop innovative solutions and be at the forefront of process integration technology development and we have achieved excellent results derived from a wide applications.
What We Can Help You With
Our experts from energy and chemical Industry with decades of Process Integration experience can provide insight and guidance on how to evaluate energy conservation and process optimization possibilities, transform your industrial operations and achieve your business goals on performance excellence by implementing Process Integration techniques.
Consulting
Solutions That We Offer
Energy Integration
Energy Integration (EI) is a general concept which provides a holistic view to the generation, allocation, transformation, and exchange of all forms of energy including heat and work (or heat rate and power when the system is studied on a per unit-time basis).
Mass
Integration
Mass integration is a systematic methodology that provides a fundamental understanding of the global flow of mass within a process and employs this holistic understanding in identifying performance targets and optimizing the generation and routing of species through the process.
Equipment Integration
Energy-saving solutions, specially in distillation and heat exchange processes, which may increase capital investment costs. But, various techniques, such as multi-stream HENs, reactive distillation, and vapor recompression-assisted distillation are useful methods to reduce energy consumption and also to save capital and operation costs.
Environmental Protection
Process integration techniques that were previously developed for energy, mass and equipment integration have now been extended to various emission and environmentally-constrained problems, taking into account footprint metrics that measure environmental impacts other than global warming.
Our Unique In-House Software
PILOT™
Our advanced in-house computer software which aims at design and simulation of Heat Exchanger Networks, using Pinch Analysis principles.
With PILOT™ 2.12 you can create rigorous models for Heat Exchanger Network (HEN) design and stand alone shell-and-tube heat exchangers rating and design for grass roots as well as retrofitting projects (energy saving and de-bottlenecking)
Our Partners
Alta Energy
Solutions
Breakwater
Vantage
Thermo Design Engineering
Tridyne
Projects
Our Success Stories
Retrofitting of Crude Oil
Pre-heat Train
Challenge
Reducing energy consumption and operating cost in a refinery with focus on GHG emission reduction mandates.
Solution
Using PINCH technology, the optimum crude oil pre-heat train temperature was determined & increased from 230 C to 251 C.
Results
Retrofitting of Crude Oil Pre-heat Train in a Refinery for Energy Conservation & GHG Emission Reduction
18 %
95k MT/Yr
Energy Saving
GHG Reduction
0.7 MM$/Yr
1.58 MM$
OPEX Saving
Investment
Industry: Crude Oil Refining
Retrofitting of Heat Exchanger Network (HEN)
Challenge
Reducing energy consumption and operating cost by retrofitting an Aromatic Plant in a Petrochemical Complex.
Solution
Applying advanced Process Integration techniques in addition to adding new exchangers to the existing network.
Results
Retrofitting of Heat Exchanger Network (HEN) for Energy Conservation & GHG Emission Reduction
37 %
218k MT/Yr
1.13MM$/Yr
Energy Saving
GHG Reduction
1.56 MM$
OPEX Saving
Investment
Industry: Petrochemicals
Water Consumption Optimization Using Water PA
Challenge
Reducing water consumption and waste water production by using water pinch analysis in a petroleum refining plant.
Solution
Applying advanced water pinch technology led to the optimization of water conservation and waste water production systems.
Results
Water Pinch Analysis for Water Consumption Optimization & Waste Water Production Minimization
38 %
0.1 MM$/Yr
Fresh Water Saving
0 $
OPEX Saving
Investment
Industry: Crude Oil Refining
We work with you to identify suitable and implement Process Integration solutions to your industrial challenges. We believe in the quality of service and the importance of long-term relationships with customers.
Alta Process Solutions has a multidisciplinary and multicultural team consists of scientists, researchers, engineers and chemical process design specialists to bring a complementary approach to projects in any process industry market.