6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R.

Lewin 1
054402 Design and Analysis II

LECTURE 6: INTRODUCTION TO
HEAT EXCHANGER NETWORK
SYNTHESIS

Daniel R. Lewin
Department of Chemical Engineering
Technion, Haifa, Israel


6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 2
Schedule Introduction to HEN Synthesis
Unit 1. Introduction: Capital vs. Energy
What is an optimal HEN design
A Simple Example (Class Exercise 1)
Setting Energy Targets
Unit 2. The Pinch and MER Design
The Heat Recovery Pinch
HEN Representation
Class Exercise 2
Unit 3. The Problem Table
Class Exercises 3 and 4
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 3
Schedule Advanced HEN Synthesis
Unit 4. Loops and Splits
Minimum Number of Units by Loop Breaking
Class Exercise 5
Stream Split Designs
Class Exercise 6
Unit 5. Threshold Problems
Class Exercise 7


6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 4
Schedule Heat and Power Integration
Unit 6. Data Extraction
Class Exercise 8
Unit 7. Heat Integration in Design
Grand Composite Curve
Heat-integrated Distillation
Heat Engines
Heat Pumps



6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 5
Part One: Objectives
The first part of this three-part Unit on HEN synthesis
serves as an introduction to the subject, and covers:
The pinch
The design of HEN to meet Maximum Energy Recovery (MER)
targets
The use of the Problem Table to systematically compute MER
targets
Instructional Objectives:
Given data on hot and cold streams, you should be able to:
Compute the pinch temperatures
Compute MER targets
Design a simple HEN to meet the MER targets


6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 6
A Short Bibliography...
Early pioneers:
Rudd@Wisconsin (1968)
Hohmann@USC (1971)
Central figure:
Linnhoff@ICI/UMIST (1978)
Currently: President, Linnhoff-March
Recommended texts:
Seider, Seader and Lewin (1999): Process Design Principles,
Wiley and Sons, NY
Linnhoff et al. (1982): A User Guide on Process Integration
for the Efficient Use of Energy, I. Chem. E., London
Most up-to-date review:
Gundersen, T. and Naess, L. (1988): The Synthesis of Cost
Optimal Heat Exchanger Networks: An Industrial Review of
the State of the Art, Comp. Chem. Eng., 12(6), 503-530
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 7
UNIT 1: Introduction - Capital vs. Energy
The design of Heat Exchanger Networks deals with the
following problem:
Given:
N
H
hot streams, with given heat capacity flowrate, each having
to be cooled from supply temperature T
H
S
to targets T
H
T
.
N
C
cold streams, with given heat capacity flowrate, each having
to be heated from supply temperature T
C
S
to targets T
C
T
.
Design:
An optimum network of heat exchangers, connecting between
the hot and cold streams and between the streams and
cold/hot utilities (furnace, hot-oil, steam, cooling water or
refrigerant, depending on the required duty temperature).
What is optimal?
Implies a trade-off between CAPITAL COSTS (Cost of
equipment) and ENERGY COSTS (Cost of utilities).
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 8
Example
Network for minimal
energy cost ?
Network for minimal
equipment cost ?
H H H
C
C
C
Cooling
Water
Steam
T
in
T
in
T
in
T
in
T
in
T
in
T
out
T
out
T
out
T
out
T
out
T
out
Cooling
Water
Steam
T
in
T
in
T
in
T
in
T
in
T
in
T
out
T
out
T
out
T
out
T
out
T
out
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 9
Numerical Example
Design B:
E(AREA) = 13.3
Design A:
E(AREA) = 20.4
[ A = Q/UAT
lm
]
Cooling
Water (90-110
o
F)
Cooling
Water (90-110
o
F)
Steam (400
o
F)
300
o
300
o
50
0
50
0
150
o
200
o
200
o
150
o
150
o
200
o
200
o
200
o
200
o
100 100
100 100
100 100
300
o
300
o
300
o
300
o
50
0
50
0
50
0
50
0
CP = 1.0 CP = 1.0
CP = 1.0 CP = 1.0
CP = 1.0 CP = 1.0
CP = 1.0 CP = 1.0 CP = 1.0
100 100 100
300
o
300
o
50
0
50
0
150
o
200
o
200
o
150
o
150
o
200
o
200
o
200
o
200
o
300
o
300
o
300
o
300
o
50
0
50
0
50
0
50
0
CP = 1.0 CP = 1.0
CP = 1.0 CP = 1.0
CP = 1.0 CP = 1.0
CP = 1.0 CP = 1.0 CP = 1.0
100
100
100
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 10
Some Definitions
T
H
AH
T
S
T
T
AT
T
S
= Stream supply temperature (
o
C)
T
T
= Stream target temperature (
o
C)
H = Stream enthalpy (MW)
CP = (MW/
o
C)
= Heat capacity flowrate (MW/
o
C)
= Stream flowrate specific heat capacity
Cp m

6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 11

Which of the two counter-current heat exchangers
illustrated below violates AT > 20
o
F (i.e. AT
min
= 20
o
F) ?
100
o
60
o
50
o
80
o
100
o
60
o
40
o
70
o
A B
Clearly, exchanger A violates the AT
min
constraint.
20
o
10
o

20
o
30
o

AT
min
- Example
AT
min
= Lowest permissible temperature difference
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 12
Definitions (Contd)
100
o
60
o
40
o
T
1
= 70
o
OK
OK
Exchanger Duty.
Data: Hot stream CP = 0.3 MW/
o
C
Cold stream CP = 0.4 MW/
o
C

Check: T
1
= 40 + (100 - 60)(0.3/0.4) = 70
o
C

Q = 0.4(70 - 40) = 0.3(100 - 60) = 12 MW
Heat Transfer Area (A): A = Q/(UAT
lm
)
Data: Overall heat transfer coefficient, U=1.7 kW/m
2

o
C
(Alternative formulation in terms of film coefficients)
AT
lm
= (30 - 20)/log
e
(30/20) = 24.66

So, A = Q/(UAT
lm
) = 12000/(1.724.66) = 286.2 m
2
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 13
Reb
Cond
R1
R2
AH=162
120
o
30
o
180
o
80
o
60
o
100
o
130
o
40
o
AH=160
AH=180
AH=100
C1
Stream
T
S
(
o
C)
T
T
(
o
C)
AH
(kW)
CP
(kW/
o
C)
H1 180 80 100 1.0
H2 130 40 180 2.0
C1 60 100 160 4.0
C2 30 120 162 1.8

Utilities. Steam@150
o
C, CW@25
o
C

Design a network of steam heaters,
water coolers and exchangers for the
process streams. Where possible, use
exchangers in preference to utilities.
.
AT
min
= 10
o
C
Class Exercise 1
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 14
Setting Energy Targets

Summary of proposed design:





Are 60 kW of Steam
Necessary?
Reb
Cond
R1
R2
120
o
30
o
180
o
80
o
60
o
100
o
130
o
40
o
C1
H
100
60
162
18
C
Steam CW Units
60 kW 18 kW 4

6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 15
The Temperature-Enthalpy Diagram
One hot stream
AH=180
130
o
C
40
o
C
T
H
200
o
C
100
o
C
T
H
AH=100
AH=300
Two hot streams
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 16
The Temperature-Enthalpy Diagram
Correlation between AT
min
, Q
Hmin
and Q
Cmin

More in, More out! Q
Hmin
+ x Q
Cmin
+ x
AT
min
= 10
Steam
CW
C
H
110
o
C
100
o
C
T
H
Q
Cmin
= 30
Q
Hmin
= 50
Steam
CW
AT
min
= 20
Steam
CW
C
H
120
o
C
100
o
C
T
H
Q
Cmin
= 50
Q
Hmin
= 70
Steam
CW
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 17
The Composite Curve
Hot Composite Curve
Reb
Cond
R1
R2
AH=162
120
o
30
o
180
o
80
o
60
o
100
o
130
o
40
o
AH=160
AH=180
AH=100
C1
180
o
C
AH interval
50
130
o
C
80
o
C
40
o
C
80
150
CP=1.0
CP=2.0
180
o
C
50
130
o
C
80
o
C
40
o
C
80
150
CP=1.0
CP=2.0
CP=3.0
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 18
The Composite Curve (Contd)
Cold Composite Curve
Reb
Cond
R1
R2
AH=162
120
o
30
o
180
o
80
o
60
o
100
o
130
o
40
o
AH=160
AH=180
AH=100
C1
120
o
C
AH interval
36
100
o
C
60
o
C
30
o
C
54
232
CP=1.8
CP=4.0
CP=1.8
CP=5.8
120
o
C
36
100
o
C
60
o
C
30
o
C
54
232
CP=1.8
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 19
The Composite Curve (Contd)
Method: manipulate hot and cold composite curves until
required AT
min
is satisfied.
This defines hot and cold pinch temperatures.
130
o
C
100
o
C
80
o
C
60
o
C
AT
min
= 10
o
C
H
T
Q
Cmin
= 6
Q
Hmin
= 48
130
o
C
80
o
C
60
o
C
AT
min
= 20
o
C
H
T
Q
Cmin
= 12
Q
Hmin
= 54

Result:
Q
Cmin
and Q
Hmin
for
desired AT
min

MER Target

Here,
hot pinch is at 70
o
C,
cold pinch is at 60
o
C
Q
Hmin
= 48 kW and
Q
Cmin
= 6 kW



6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 20
UNIT 2: The Pinch
The pinch separates the HEN problem into two parts:
Heat sink - above the pinch, where at least Q
Hmin
utility must be
used
Heat source - below the pinch, where at least Q
Cmin
utility must be
used.
H
T
Q
Cmin
Q
Hmin
PINCH
H
T
Q
Cmin
Q
Hmin
Heat
Source
Heat
Sink
AT
min
+x
x
+x
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 21
Significance of the Pinch
Do not transfer heat across pinch
Do not use cold utilities above the pinch
Do not use hot utilities below the pinch

Reb
Cond
R1
R2
C1
100
49
111
7 C
H
62
Summary of modified design:
Steam CW Units
~49 kW ~7 kW 5

6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 22
HEN Representation
Reb
Cond
R1
R2
C1
100
49
111
7 C
H
62
80
o
C
180
o
C
30
o
C 40
o
C
120
o
C
130
o
C
100
o
C
60
o
C
H1
H2
C1
C2
180
o
C
80
o
C
130
o
C
100
o
C
120
o
C
40
o
C
60
o
C
30
o
C
111
H
49
62
7
C
100
Where is the pinch ?
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 23
HEN Representation with the Pinch
The pinch divides the HEN into two parts:
the left hand side (above the pinch)
the right hand side (below the pinch)
At the pinch, ALL hot streams are hotter than ALL cold
streams by AT
min
.
H1
H2
C1
C2
T
hot
H
C
T
hot
T
cold
T
hot
T
cold
T
cold
T
cold
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 24
Class Exercise 2
140
o
320
o
480
o
500
o
200
o
290
o
240
o
320
o
CP = 1.0
CP = 1.5
CP = 2.0 CP = 1.8
C1
H2 H1
C1
C2
CW
S
210
50
170
100
116
For this network, draw the
grid representation
Given pinch temperatures at
480
o
C /460
o
C, and MER
targets: Q
Hmin
= 40, Q
Cmin
=
106, redraw the network
separating the sections above
and below the pinch.
Why is Q
H
> Q
Hmin
?
H1
H2
C1
C2
320
o
C
200
o
C
480
o
C
500
o
C
320
o
C
290
o
C
240
o
C
140
o
C
CP
1.8
2.0
1.0
1.5
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 25
Class Exercise 2 - Solution
140
o
320
o
480
o
500
o
200
o
290
o
240
o
320
o
CP = 1.0
CP = 1.5
CP = 2.0 CP = 1.8
C1
H2 H1
C1
C2
CW
S
210
50
170
100
116
H1
H2
C1
C2
320
o
C 200
o
C
500
o
C
320
o
C
290
o
C
240
o
C
140
o
C
CP
1.8
2.0
1.0
1.5
460
o
C
480
o
C
H
40
H
10 210
170 100
C
116
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 26
Class Exercise 2 - Solution (Contd)
H1
H2
C1
C2
320
o
C
200
o
C
480
o
C
500
o
C
320
o
C
290
o
C
240
o
C
140
o
C
210
H
40
170
116
C
100
450
o
CP
1.8
2.0
1.0
1.5
H
10
H1
H2
C1
C2
320
o
C
200
o
C
480
o
C
500
o
C
320
o
C
290
o
C
240
o
C
140
o
C
220
H
40
160
106
C
110
460
o
CP
1.8
2.0
1.0
1.5
This can be fixed by reducing the cooling duty by 10 units, and
eliminate the excess 10 units of heating below the pinch.
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 27
Design for Maximum Energy Recovery(MER)
Step 1: MER Targeting.
Pinch at 90
o
(Hot) and 80
o
(Cold)
Energy Targets:
Total Hot Utilities: 20 kW
Total Cold Utilities: 60 kW
H1
H2
C1
C2
170
o
C
60
o
C
150
o
C
135
o
C
140
o
C
30
o
C
20
o
C
80
o
C
CP
3.0
1.5
2.0
4.0
Example
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 28
Design for MER (Contd)
Step 2: Divide the problem at the pinch
H1
H2
C1
170
o
C
60
o
C
150
o
C
135
o
C
140
o
C
30
o
C
20
o
C
80
o
C
CP
3.0
1.5
2.0
4.0 C2
80
o
C 80
o
C
90
o
C 90
o
C
90
o
C 90
o
C
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 29
Design for MER (Contd)
Step 3: Design hot-end, starting at the pinch:
Pair up exchangers according to CP-constraints.
Immediately above the pinch, pair up streams
such that: CP
HOT
s CP
COLD

(This ensures that T
H
T
C
> AT
min
)
H1
H2
C1
CP
3.0
1.5
2.0
4.0 C2
Violates ATmin constraint
H1
H2
C1
CP
3.0
1.5
2.0
4.0 C2
Meets ATmin constraint
AT
min
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 30
Design for MER (Contd)
Step 3 (Contd): Complete hot-end design, by ticking-off
streams.
H1
H2
C1
CP
3.0
1.5
2.0
4.0 C2
170
o
150
o
135
o
140
o
90
o
90
o
80
o
80
o

90
240


H
Add heating utilities as needed (MER target)
Q
Hmin
= 20 kW

20
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 31
Design for MER (Contd)
Step 4: Design cold-end, starting at the pinch:
Pair up exchangers according to CP-constraints.
Immediately above the pinch, pair up streams
such that: CP
HOT
> CP
COLD

(This ensures that T
H
T
C
> AT
min
)
H1
H2
C1
CP
3.0
1.5
2.0
Violates AT
min
constraint
H1
H2
C1
CP
3.0
1.5
2.0
Meets AT
min
constraint
AT
min
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 32
H1
H2
C1
CP
3.0
1.5
2.0
90
o
90
o
80
o
20
o
60
o
30
o
Design for MER (Contd)
Step 4 (Contd): Complete cold-end design, by ticking-off
streams.

C
Add cooling utilities as needed (MER target)
Q
Cmin
= 60 kW
30 90
60

35
o


6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 33
Design for MER (Contd)
Completed Design:
H1
H2
C1
CP
3.0
1.5
2.0
4.0
C2
170
o
150
o
135
o
140
o
90
o
90
o
80
o
80
o
240
90
20
H
125
o
90 30
60
35
o
70
o
20
o
60
o
30
o
C
Note that this design meets the MER targets:
Q
Hmin
= 20 kW and Q
Cmin
= 60 kW
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 34
Design for MER (Contd)
Design for MER - Summary:
MER Targeting. Define pinch temperatures, Q
hmin
and Q
Cmin

Divide problem at the pinch
Design hot-end, starting at the pinch: Pair up exchangers
according to CP-constraints. Immediately above the pinch, pair up
streams such that: CP
HOT
s CP
COLD.
Tick off streams in order to
minimize costs. Add heating utilities as needed (up to Q
Hmin
). Do
not use cold utilities above the pinch.
Design cold-end, starting at the pinch: Pair up exchangers
according to CP-constraints. Immediately below the pinch, pair up
streams such that: CP
HOT
> CP
COLD.
Tick off streams in order to
minimize costs. Add heating utilities as needed (up to Q
Cmin
). Do
not use hot utilities below the pinch.
Done!
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 35
H1
H2
C1
180
o
C
80
o
C
130
o
C
100
o
C
120
o
C
40
o
C
60
o
C
CP
1.0
2.0
4.0
1.8 C2
60
o
C
70
o
C
60
o
C
30
o
C
Class Exercise 3
Stream
T
S
(
o
C)
T
T
(
o
C)
AH
(kW)
CP
(kW/
o
C)
H1 180 80 100 1.0
H2 130 40 180 2.0
C1 60 100 160 4.0
C2 30 120 162 1.8

Design a network of steam heaters,
water coolers and exchangers for
the process streams. Where
possible, use exchangers in
preference to utilities.
AT
min
= 10
o
C.
Utilities:
Steam@150
o
C, CW@25
o
C
Q
Hmin
=48
Q
Cmin
=6
80
o
C
H
54

C
120

43
o
C
6


100
H
8
40




6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 36
UNIT 3: The Problem Table
Stream
T
S
(
o
F)
T
T
(
o
F)
AH
(kBtu/h)
CP
(kBtu/h
o
F)
H1 260 160 3000 30
H2 250 130 1800 15
C1 120 235 2300 20
C2 180 240 2400 40

AT
min
= 10
o
F.
Example:
Step 1: Temperature Intervals
(subtract AT
min
from hot temperatures)
Temperature intervals:
250F 240F 235F 180F 150F 120F
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 37
UNIT 3: The Problem Table (Contd)
Step 2: Interval heat balances
For each interval, compute:
AH
i
= (T
i
T
i+1
)(ECP
Hot
ECP
Cold
)
Interval
T
i
T
i
T
i+1
ECP
Hot
ECP
Cold
AH
i
1 250 10 30 300
2 240 5 5 25
3 235 55
15 825
4 180 30 25 750
5 150 30
5 150
6 120

6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 38
UNIT 3: The Problem Table (Contd)
Step 3: Form enthalpy
cascade. T
1
= 250
o
F
AH = 300
Q
H
Q
H
AH = 300
T
1
= 250
o
F
AH = 25
Q
1
T
2
= 240
o
F
AH = -825
Q
2
T
3
= 235
o
F
AH = 750
Q
3
T
4
= 180
o
F
AH = -150
Q
4
T
5
= 150
o
F
Q
C
T
6
= 120
o
F
Assume
Q
H
= 0
300
325
-500
250
100
Eliminate infeasible
(negative) heat transfer
Q
H
= 500
800
825
0
750
600
This defines:
Cold pinch temp. = 180
o
F
Q
Hmin
= 500 kBtu/h
Q
Cmin
= 600 kBtu/h
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 39
Class Exercise 4 - Now try again!
Stream
T
S
(
o
C)
T
T
(
o
C)
AH
(kW)
CP
(kW/
o
C)
H1 180 80 100 1.0
H2 130 40 180 2.0
C1 60 100 160 4.0
C2 30 120 162 1.8

Calculate the Problem Table.
Predict Q
Hmin
and Q
Cmin
.
Draw the Enthalpy Cascade.
AT
min
= 10
o
C.
Step 1: Temperature Intervals
(subtract AT
min
from hot temperatures)
Temperature intervals:

6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 40
Class Exercise 4 (Contd)
Step 2: Interval heat balances
For each interval, compute:
AH
i
= (T
i
T
i+1
)(ECP
Hot
ECP
Cold
)
Interval
T
i
T
i
T
i+1
ECP
Hot
ECP
Cold
AH
i
1
2
3
4
5
6

6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 41
Class Exercise 4 (Contd)
Step 3: Form enthalpy
cascade.
Q
H
Q
H
AH =
T
1
=
T
2
=
Q
1
AH =
Q
2
AH =
T
3
=
AH =
Q
3
T
4
=
Q
4
AH =
T
5
=
Q
C
Q
C
T
6
=
Assume
Q
H
= 0
Eliminate infeasible
(negative) heat transfer
Q
H
=
This defines:
Cold pinch temp. =
o
C
Q
Hmin
= kW
Q
Cmin
= kW
6 - Intro HEN Synthesis DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 42
Introduction to HEN Synthesis - Summary
Unit 1. Introduction: Capital vs. Energy
What is an optimal HEN design
Setting Energy Targets
Unit 2. The Pinch and MER Design
The Heat Recovery Pinch
HEN Representation
MER Design: (a) MER Target; (b) Hot- and cold-side designs
Unit 3. The Problem Table
for MER Targeting

Next week: Advanced HEN Synthesis