In this work, a new simple, yet effective, systematic method to perform retrofit design and analysis is presented. Based on a path flow analysis approach, a set of indicators is calculated in order to pinpoint unnecessary energy and material waste costs and to identify potentially improved retrofit alternatives. The method requires only steady state design data and a database with properties of compounds, including, environmental impact factor related data and safety factor related data. Given a simulation report corresponding to an actual process (or base case design), the method identifies the material and energy path flows and calculates a set of indicators. The most important design variables are then identified through a sensitivity analysis in terms of their effect on the indicator values, which also defines the limiting values of these variables. The generated retrofit (design) alternatives are classified in terms of reduction targets in cost of operation, raw materials, energy consumption, environmental impact and safety. The well-known HDA-process is used as a case study to highlight the main features of the retrofit analysis method.
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