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3 OPPORTUNITIES-BARRIERS-PATHWAYS FOR RECOVERY extensively documented. An area that still has room for considerable development is process integration, which can result in a significant amount of energy savings, as described below. An example of process integration is the use of byproduct as feed for a different process [24]. In the production of vinyl chloride, chlorine is combined with ethylene to produce ethylene dichloride, which is pyrolyzed to produce vinyl chloride and HCI. One mole of HCl is produced for every mole of chlorine. The waste HCl is used as a raw material in the oxy-chlorination of ethylene to yield more vinyl chloride. This process would be more efficient if both processes operated together. By expanding this network to include other processes that use chlorine or HCl, the efficiency can be increased further. An example is isocyanate manufacturing, in which Cl2 combines with CO to yield phosgene, which reacts with an amine to produce an isocyanate and HCl. This process sets up a Cl2/HCl network. Cl2 is fed to the isocyanate and vinyl chloride process. The HCl byproduct from the former is sent to the oxychlorination process. The chemical process design engineers should understand their own processes and also processes that supply materials and use their byproducts. Byproducts from chemical processes can also be used as feedstock in other industries (HCl used in steel making) or byproducts from other industries can be used in the chemical industry (HCl from semi- conductor manufacturing). The authors also provided an excellent example of a multi-industry network at Kalundborg, Denmark. An oil refinery, a sulfuric acid plant, a pharmaceutical manufacturer, a coal-burning power plant, a fish farm, and a gypsum board manufacturer form an industrial network. Steam, gas, and cooling water are exchanged between the power plant and refinery. Waste heat from the power plant is used for residential heating and in the greenhouses and fish farm. Ash from coal power plant combustion is used for cement manufacture, while calcium sulfate from the power plant is sent to the gypsum board facility. The refinery sends hot liquid sulfur from de-sulfurization of crude oil to a sulfuric acid manufacturer. In this approach, the power plant and oil refinery are the central facilities, with energy exchange originating or ending at these facilities. In an eco-industrial park in North Texas, the central facility is a steel mill, which uses scrap cars as primary feed to the electric arc furnace. The furnace dust, which has zinc, lead, copper, manganese, zinc, is sent to a cement kiln. One interesting point made by the authors was that about 100 Quads of energy is consumed annually in the U.S., out of which 33 Quads is used for electricity generation. About 22 Quads is lost as heat during electricity generation, which, if captured, can provide 22% of the total annual energy requirement. It should be noted that tri-forming of methane using power plant flue gas, as discussed earlier, is a good example of such use. Some of the new tools that are available for exchange of energy/reactants across various industrial processes are: 71PDF Image | Analysis for Recovering Energy from Industrial Waste Heat
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