Doing Better

Energy Integration

More Sustainability

In recent decades, the integration of processes has contributed decisively to achieving various objectives linked to the reduction of operating costs and the sustainability of operations. This is because this provides a systematic analysis of the entire industrial process, with the possibility of modifying the process flow diagram, reorganising existing unit operations and redirecting process streams - creating clear economic, environmental and process advantages.

The diversity of chemical processes existing at Bondalti’s facilities are an excellent opportunity to carry out energy integrations with the goal of adopting industrial techniques aimed at applying the reuse of previously underused thermal energy.

And there are plenty of concrete examples. During the reaction to obtain Aniline, a large amount of heat is generated, most of which is eventually released into the environment. On the other hand, there are many processes that require heat in their normal operation. A project has been underway since 2023 with the aim of providing heat to the Soda concentration unit through the Aniline reactors. The advantage is clear. With this integration it is possible to avoid the production of 2.5 t/h of steam that would otherwise be obtained from burning natural gas.  

Another similar integration took place in 2012, involving the Aniline reactors and the Sulphuric Acid concentration stage at the Nitrobenzene factory. With the implementation of this energy integration, 4 t/h of steam was replaced, which was previously obtained by burning natural gas.  

As well as producing steam, Aniline reactors are also fitted with water cooling coils. Since 2008 the design of the Aniline reactors has been changed in order to maximise steam production to the detriment of the water-cooling circuit. In 2000 a hot water circuit was created connecting the Aniline reactors to the Brine heating systems. With this project it was possible to completely stop the existing steam production in the Chlorine plant.

The low-level heat obtained in the production of Aniline can also be used for community purposes (district heating). A challenge that Bondalti will be able to meet in the future.