PROCESS AND ENERGY INTEGRATION - 2025/6

Module Overview

Process integration is an efficient paradigm, which enables the reduction of capital investment and energy consumption according to the principles of sustainable development applicable for new and retrofit process design. Computer-aided process engineering tools together with mathematical programming enable systematic and simultaneous handling of process integration problems.

This module equips students with the knowledge and skills required to maximise the energy efficiency of existing and new industrial processes while improving process economics and minimising its environmental impact. It introduces a wide range of methods of heat integration of processes within a production site and for total site energy integration. The design of heat exchanger networks (HEN), utility selection, integration of units such as heat engines, heat pumps, and placement of reactors and separators will be addressed. Sequential and simultaneous approaches will be explored utilizing graphical, empirical and mathematical modelling tools. Students will also continue to develop their problem-solving skills and digital capabilities by using state-of-the-art process simulation software.

Module provider

Chemistry and Chemical Engineering

Module Leader

KLYMENKO Oleksiy (Chst Chm Eng)

Number of Credits: 15

ECTS Credits: 7.5

Framework: FHEQ Level 7

Module cap (Maximum number of students): N/A

Module Availability

Semester 2

Prerequisites / Co-requisites

Fundamentals of heat transfer such as ENG2121 HEAT TRANSFER AND LABORATORY and thermodynamics such as ENG2122 CHEMICAL ENGINEERING THERMODYNAMICS or equivalent.

Module content

Indicative content includes:

Introduction: need for process integration, overview of existing methods for unit and total site energy integration.

Pinch Design Method: data extraction from process flowsheets, setting energy targets through thermodynamic principles, construction of the Composite and Grand Composite Curves, utility selection in the overall process context, pinch design method for heat exchanger networks, placement of heat engines, heat pumps, reactors, distillation columns and evaporators, total site energy integration.

Introduction to methods based on mathematical modeling: transshipment model for energy targeting formulated as a linear programing (LP) problem (minimization of the utility cost), superstructural approach to process and total site energy integration (MINLP problem).

Assessment pattern

Alternative Assessment

None

Assessment Strategy

The assessment strategy is designed to provide students with the opportunity to demonstrate

• Learning outcomes 1, 2, 3 in the unseen written examination;


• Learning outcomes 1, 2, a, b, c in Coursework 1;


• Learning outcomes 3, 4, a, b, c in Coursework 2.

• Coursework 1: Homework assignment, approx. 12 hours;


• Coursework 2: Design project with individual report, approx. 20 hours.


• Open-book written examination, 2 hours;

• Class discussions


• Questioning


• Problem solving

Module aims

• - Develop the students' understanding of the area of process integration.
  - Highlight problems faced in the development of solution strategies for the synthesis of energy recovery networks in the context of the overall chemical flowsheet.
  - Develop an understanding of the main approaches to the solution of heat integration problems in process design and available software tools.

Learning outcomes

Methods of Teaching / Learning

The learning and teaching strategy is designed to:

Introduce graphical and mathematical methods of heat integration to students through lectures and working sessions. The methods are then applied in case studies identifying their advantages and disadvantages.

The learning and teaching methods include:

• captured content


• lectures


• tutorials


• supervised computer labs


• independent learning

Indicated Lecture Hours (which may also include seminars, tutorials, workshops and other contact time) are approximate and may include in-class tests where one or more of these are an assessment on the module. In-class tests are scheduled/organised separately to taught content and will be published on to student personal timetables, where they apply to taken modules, as soon as they are finalised by central administration. This will usually be after the initial publication of the teaching timetable for the relevant semester.

Reading list

https://readinglists.surrey.ac.uk
Upon accessing the reading list, please search for the module using the module code: ENGM071

Other information

This module contributes to the student development in the following ways aligned with the five pillars of the Surrey Curriculum Framework:
Digital capabilities: students will be developing their general IT skills by engaging with SurreyLearn and other electronic resources provided to them. They will also learn how to use state-of-the-art process simulation software (Aspen Plus) which is widely used in industry. Students will also be encouraged to use additional software tools such as MS Excel and GAMS to solve heat integration problems.
Employability: the module provides students with knowledge and skills on how to maximise energy efficiency in new and retrofit industrial processes. These are of critical importance for improving process economics as well as reducing green house gas emissions. These skills and understanding the wider context of the knowledge acquired in the module will improve the students’ competitiveness in the job market.
Global and cultural capabilities: the module content is presented in the context of the global challenges, in particular, climate change caused by human activity, which helps students to become well-rounded professionals.
Resourcefulness and resilience: the tutorial problems and coursework assignments are designed to challenge students and develop their reasoning and problem-solving skills, which requires consistent effort throughout the semester and develops their resilience.
Sustainability: this module has sustainability at its core due to the focus on improving energy efficiency of industrial processes. This leads to the development of ‘greener’ processes due to the reduction of associated greenhouse gas emissions and more sustainable production.

Programmes this module appears in

Please note that the information detailed within this record is accurate at the time of publishing and may be subject to change. This record contains information for the most up to date version of the programme / module for the 2025/6 academic year.