Energy Integration and WEP Technical Evaluation of a Large-Scale PVC Production Process

PVC has become an indispensable material worldwide. However, its production method (suspension) presents significant sustainability challenges, such as negative environmental impacts and high operational costs due to energy consumption. For this reason, a combined analysis was conducted involving energy integration using Aspen Energy Analyzer™ V14 software and a technical process analysis. This methodology aims to reduce industrial utility consumption and assess the sustainability performance of this alternative. The integration through pinch analysis revealed that it is possible to reduce the energy consumption of the process by 29% in heating utilities and 6% in cooling utilities. The minimum utility requirements were 21 GJ/h for heating (down from 29 GJ/h) and 131 GJ/h for cooling (down from 139 GJ/h). This reduction resulted in approximately a 41% decrease in utility costs. Additionally, the reduction in burner energy consumption led to lower greenhouse gas emissions, with a decreased natural gas consumption of approximately 279 m3. However, only two streams could be integrated due to technical process limitations; therefore, it is recommended to explore integrations with complex operations such as reactors and phase-change processes. In addition to this, the WEP technical evaluation yielded promising results showing a decrease in the specific energy intensity by 3219.506 MJ/t (being 4681.8 MJ/t), which represents an economic saving in industrial services (energy purposes) of approximately USD 886.000 per year, satisfying the optimization of the process despite the limitations when integrating it energetically. Finally, a more in-depth analysis should be conducted to further integrate other streams of the process to reduce utilities consumption.