Superstructure optimisation of a water minimisation network with a embedded multicontaminant electrodialysis model

Abstract

The water-energy nexus considers the relationship between water and energy resources. Increases in environmental degradation and social pressures in recent years have necessitated the development of manufacturing processes that are conservative with respect to both these resources, while maintaining financial viability. This can be achieved by process integration (PI); a holistic approach to design which emphasises the unity of processes. Within the realm of PI, water network synthesis (WNS) explores avenues for reuse, recycle and regeneration of effluent in order to minimise freshwater consumption and wastewater production. When regeneration is required, membrane-based treatment processes may be employed. These processes are energy intensive and result in a trade-off between water and energy minimisation, thus creating an avenue for optimisation. Previous work in WNS employed a black box approach to represent regenerators in water minimisation problems. However, this misrepresents the cost of regeneration and underestimates the energy requirements of a system. The aim of the research presented in this dissertation is to develop an integrated water regeneration network synthesis model to simultaneously minimise water and energy in a water network. A novel MINLP model for the design of an electrodialysis (ED) unit that is capable of treating a binary mixture of simple salts was developed from first principles. This ED model was embedded into a water network superstructure optimisation model, where the objective was to minimise freshwater and energy consumption, wastewater productions, and associated costs. The model was applied to a pulp and paper case study, considering several scenarios. Global optimisation of the integrated water network and ED design model, with variable contaminant removal ratios, was found to yield the best results. A total of 38% savings in freshwater, 68% reduction in wastewater production and 55% overall cost reduction were observed when compared with the original design. This model also led to a 80% reduction in regeneration (energy) cost.