ApplicationofPDMforMERHENsynthesis

Module05

Lecture28

Module05:PinchDesignMethodforHENsynthesis
Lecture28:ApplicationofPDMforMERHENsynthesis
Keywords:PDM,HEN
InthislecturePinchDesignMethoddevelopedinLecture26&27areappliedonasamplefour
stream problem as shown in Table 5.3 is considered. The stream diagram of the problem is
showninFig.5.20.

Table5.3AfourstreamproblemforTmin=10C
Stream Stream Heat
Capacity Source
Target
Number Type
FlowRate
Temperature
Temperature
0
0

(kW/ C)
( C)
(0C)
1
HOT
3
200
65
2
HOT
6
90
30
3
COLD
3.5
30
142
4
COLD
4
25
130

Fig.5.20StreamdiagramforprobleminTable5.3

Forthegivenproblem:QHmin =87kW,QCmin=40kW,HotPinchtemperature=90Candcold
pinchtemperature=80C

HotEnd(abovepinch)design

ApplicationofPDMforMERHENsynthesis

Module05

Pinch

162.33
200
90
1
1

Tmin=10C

142
142
80

1
3

217kW

130

80
4

87kW
(a1)

133.33
90
1 200
1

Tmin=10C

142
80
3

130

1 80
4

200kW

(b1)

Pinch

162.33
90
1 200
2
1

Tmin=10C

142
142
80
3

217kW

(b)
130
108.25
80
2
4

113kW

(a2)

133.33

90
1 200
2
1

Tmin=10C

142
117.14
80
3
2

130kW

130
1 80
4

CPH,kW
3

3.5

(b2)

200kW

217

AbovePinch(HotEnd)

4.0

200

CPH,kW
3

330

3.5

Design2

Design2

330

Design1

Design1

Lecture28

217

4.0

200

NHNCEq.5.2
CPH CPCEq.5.4
3
3.5

4.0
HOT
COLD

HOTEND
DESIGN
Step1

CPH,kW
3

330

3.5

217

AbovePinch(HotEnd)

4.0

200

CPH,kW
3

330

3.5

217

4.0

200

NHNCEq.5.2
CPH CPCEq.5.4
3
3.5

4.0
HOT
COLD

HOTEND
DESIGN
Step2

ApplicationofPDMforMERHENsynthesis

1 200

162.33

142

CPH,kW

90

142

Design1

80

217kW

108.25

87kW

80

113kW
(a3)

130

Umin =3+11=3

Design2
(b3)

3.5

217

AbovePinch(HotEnd)

4.0

200

CPH,kW

133.33
90
1 200
2
1

Tmin=10C
142
117.14
80
3
H
2

87kW
130kW
4

330

130

Lecture28

Pinch

Tmin=10C
3

Module05

1 80
200kW

330

217

HOTEND
DESIGN
Step3

200

Umin =3+11=3

3.5

4.0

NHNCEq.5.2
CPH CPCEq.5.4
3
3.5

4.0
HOT
COLD

Fig.5.21Differentsteps(a1) to(a3)forfeasibledesign1and &(b1)to(b3)for

Design1

Fig.5.21(a1)showstheplacementofheatexchangerbetweenstream1andstream3.Asthe
CP of stream3 is 3.5 and that of stream1 is 3.0, the CP of stream3 > to CP of stream1(
requiredbyPDM)andthus,amatchcanbeplacedbetweenthesestreams.Pleasenotethatthis
exchangerisapinchexchanger.Asperthetickoffrulethismatchcanbemaximizedto217
kWsothatthestream3istickedoffasindicatedbythesignplacedonthestream.IntheCP
tablethismatchisshownbyasolidline.

ThesecondmatchwhichisshowninFig.5.21(a2)andisnotapinchmatch,isplacedbetween
stream1andstream4asCPofstream4>CPofstream1.Thismatchisfortheremainingduty
ofstream1whichis113kW.ThismatchisshowninCPtableofFig.5.21(a2)bysolidline.With
this match stream1 is ticked off. Now the only stream whose heat load is not satisfied is
stream4.Tosatisfytheheatloadaheaterof87kWisplacedonthisstream.Bydoingsothe
stream4istickedoff.Further,forthispartofproblemnumberofcoldstreamisgreaterthan
numberofhotstreamasrequiredbyPDMandthusnostreamsplittingisrequiredtocomplete
the design. Fig.5.21(a3) shows the complete hot end design of the problem in Table 5.3.

ApplicationofPDMforMERHENsynthesis

Module05

Lecture28

Numberofunitsforthisdesignisequalto3.Thisisasperthenumberofunittargetappliedto
hotendoftheproblemasshowninFig.5.21(a3).

Design2

The design2 provides an alternate design to design1 following the PDM showing that many
alternate feasible designs can be developed for the same problem. The placement of heat
exchangerbetweenstream1andstream3isshowninFig.5.21(b1).AstheCPofstream4is4
andthatofstream1is3.0,theCPofstream4>toCPofstream1(asrequiredbyPDM)and
thus,amatchisplaced.Pleasenotethatthisexchangerisapinchexchanger.Asperthetick
offrulethismatchcanbemaximizedto200kWtotickoffstream4asindicatedbythesign
placedonthestream.IntheCPtablethismatchisshownbyadottedline.

Thesecondmatch,anonpinchexchanger,asshowninFig.5.21(b2)isplacedbetweenstream
1 and stream3 as CP of stream3 > CP of stream1. This match is for the remaining duty of
stream1whichis130kW.ThismatchisshowninCPtableofFig.5.21(b2)bydottedline.With
this match stream1 is ticked off. Now the only stream whose heat load is not satisfied is
stream3.Tosatisfytheheatloadofstream3aheaterof87kWisplacedonthisstream.By
doingsothestream3isalsotickedoff.Further,forthispartofproblemnumberofcoldstream
is greater than number of hot stream as required by PDM and thus no stream splitting is
required to complete the design. Fig.5.21(b3) shows the complete hot end design of the
probleminTable5.3.Numberofunitsforthisdesignisequalto3.Thisisasperthenumberof
unittargetappliedtohotendoftheproblemasshowninFig.5.21(b3).

ThefinalhotenddesignisshowninFig.5.21(a3)forfeasibledesign1andin(b3)forfeasible
design2.Bothedesigns,design1anddesign2arecorrectasfarasPDMisconcerned.Boththe
designsareapartofMERdesignastheseconsumethetargetedminimumhotutilitydemands.
Howeverthesemaydifferintotalareaoftheheatexchangernetworkandthusfixedcost.

Coldend(belowpinch)Design

Asshowninhotenddesign,twodesignsnamelydesign1anddesign2havebeenproposedfor
cold end design also as shown below. Both designs are feasible as far as PDM is concerned.
These also consume the minimum cold utility demand and thus are a part of MER design.
However,thesedesignswillrequiredifferentnetworkareaandthusfixedcost.

Thedesignofcoldismorecomplexthanhotendasappearsfromthedesign.AsperthePDMas
no.ofhotstreamisequaltono.ofcoldstreams,streamsplittingisnotrequired.However,the
designcompulsionsrequiredstreamsplittingofahotaswellasacoldstream.Inthiscasealso
thedesignisconductedindifferentstepsstartingfromstep1tostep3.

AspertheCPtableandPDMonlyonestraightforwardmatchispossiblebetweenstream2and
stream4.ThenumberofunitstargetshowsthatUmin=4.Thusthedesignstrategyhastobe
changedtoput4matchestomaintainheatbalancebetweenhotandcoldstreamsaswellas
coldutility.

ApplicationofPDMforMERHENsynthesis

Module05

Lecture28

Design1
Fordesign1thestreamNo.3issplitintotwopartstoofferapossibilityformatchingofstream
1withapartofstream3.Thus,stream3issplitinsuchawaythatonepartofitwilltickoff
stream1.Therefore,stream3issplitintotwopartshavingCPsequalto1.5and2.Thestream
having CP equal to 1.5 will offer a load of 75 kW. Now stream1 is matched with a part of
stream3havingCPequalto1.5.Thistickedoffstream1aswellasapartofstream3havingCP
equalto1.5ascanbeseenfromFig.5.22(a1).ThismatchingisshowninCPtablebybluesolid
line.
As wehaveonlyonehotstream(stream2)isleft,thecoolerhastobeplacedonit.Thusa
coolerisplacedawayfromthepinchpointonthisstreamasshowninFig.5.22(a2).Theloadof
thecooleris40kWasreportedintheproblem(QCmin=40kW).Asimplecomputationshowsthat
theinputtemperaturetocoolerwillbe36.66C.

Nowstream2issplitintwopartstoprovidebalancedheat(aftercooler)tosatisfytheheatload
ofstream4andsplitpartofstream3havingCPequalto2.AstheCPofstream4is4.0,oneof
the split part of the stream2 should have a CP equal to 4.0 to match CP criterion. Thus the
otherpartwillhaveaCPof2(=64).Accordinglythestream2issplitasshowninFig.5.22(a3).

The exchanger2 having load 220 kW is now placed between split part of stream2 having CP
equalto4andstream4andtheexchanger3havingload100kWisplacedbetweensplitpart
of stream3 having CP equal to 2 and the split part of stream2 having CP equal to 2. All
matchings are shown in CP table with blue bold lines. Temperatures after each matching is
computedandplacedintheHENtoshowthatnoviolationofTminoccursduringdesign.The
finaldesignforcoldendisshowninFig.5.22(a3).

H,kW CP Pinch

75
3
90

360
4.0

90

1.5

80
175
2

80
220
4.0

H,kW CP Pinch

75
65
90

75
3
1

2.5

360
3.5
90

80
175
3.5

1.5
1

80
220
2.5

65

30 2
1
75

30
30

30

Design1

25

BelowPinch(ColdEnd)
NHNCEq.5.2
CPHCPCEq.5.4

1.5 3.5
3

2 2
6
4.0
4

HOT
COLD

(a1)
65

Design2

30 2
30

300

(b1)

25

BelowPinch(Cold End)
NHNCEq.5.2
CPHCPCEq.5.4

33.5
2.51.5

6
4

3.52.5

HOT
COLD

COLDENDDESIGNStep1

ApplicationofPDMforMERHENsynthesis

H,kW
CP Pinch

75
3
90

360
4.0
90

1.5

80
175
2

80
220
4.0

H,kW CP Pinch
75

65
90
75
3
1

2.5
360
3.5
90

80
3.5
175

1.5
1

80
220
2.5

Module05

Lecture28

65

1
36.66
1
75

30

30 2

C
40

30

30

Design1

25

BelowPinch(ColdEnd)
NHNCEq.5.2
CPHCPCEq.5.4

1.5
3
3.5

2
2
6
4.0
4

HOT
COLD

(a2)
65

Design2
36.66

C
40

30
300

(b2)

30 2

BelowPinch(Cold End)
NHNCEq.5.2
CPHCPCEq.5.4
33.5

30

25

2.51.5

6
4

3.52.5

HOT
COLD

COLDENDDESIGNStep2

ApplicationofPDMforMERHENsynthesis

Module05

Lecture28

H,kW
CP Pinch

65
1 Below Pinch(ColdEnd)
75 3
1
90

90
NHNCEq.5.2
40
2
3

CP
HCPCEq.5.4
360 4.0
90
30 2
35 36.66
2
C

1.5 3.5
1.5
1 30

3
40
80
30
175 2

3
3 75 30
2 2

6
4.0
50
100

80
25
220 4.0
COLD
4 HOT

(b)
220
Umin =4+1 1 =4

H,kW
CP Pinch
75

65
65
90
BelowPinch(ColdEnd)
1
75
3
1

NHNCEq.5.2

40
90
2.5
2

CPHCPCEq.5.4
40
40
360
3.5
90
30 2

4 C
3

33.5
40

80
30
75
175
3.5
3
3

2.51.5
30

175

6
4
1.5

3.52.5

0
80
25

220
2.5
30
4
2
4

20

125
HOT
COLD

Design1

Design2

Umin=5
COLDENDDESIGNStep3
(b)

Fig.5.22Differentsteps(a1)to(a3)forfeasibledesign1and &(b1)to(b3)for

feasibledesign2ofthecoldenddesignforprobleminTable5.3.

Design2
Fordesign2thestreamNo.4issplitintotwopartstoofferapossibilityformatchingofstream
1withapartofstream4.Thus,stream4issplitinsuchawaythatonepartofitwilltickoff
stream1. Therefore, stream4 is split into two parts having CPs equal to 1.5 and 2.5. The
streamhavingCPequalto1.5willofferaloadof75kW.Nowstream1ismatchedwithapartof
stream4havingCPequalto1.5.Thistickedoffstream1aswellasapartofstream4havingCP
equal to 1.5 as can be seen from Fig.5.22 (b1). A heat balance shows that the initial
temperature of the split stream should be 30C to offer 75 kW load. Accordingly the initial
temperatureofthisstreamismarkedas30CintheHEN.ThismatchingisshowninCPtableby
redsolidline.
As wehaveonlyonehotstream(stream2)isleft,thecoolerhastobeplacedonit.Thusa
coolerisplacedawayfromthepinchpointonthisstreamasshowninFig.5.22(b2).Theloadof

ApplicationofPDMforMERHENsynthesis

Module05

Lecture28

thecooleris40kWasreportedintheproblem(QCmin=40kW).Asimplecomputationshowsthat
theinputtemperaturetocoolerwillbe36.66C.

Now stream2 is split in two parts to provide balanced heat (after cooler) to satisfy the heat
loadofsplitpartofstream4havingCPequalto2.5andstream3havingCPequalto3.5.Asthe
CP of stream 3 is 3.5, one of the split part of the stream2 should have a CP equal to 3.5 to
matchCPcriterion.ThustheotherpartwillhaveaCPof2.5(=63.5).Accordinglythestream2
issplitasshowninFig.5.22(b3).

The exchanger3 having load 175 kW is now placed between split part of stream2 having CP
equalto3.5andstream3andtheexchanger2havingload125kWisplacedbetweensplitpart
ofstream4havingCPequalto2.5andthesplitpartofstream2havingCPequalto2.5.Finally
tomaintainheatbalancebetweenstream2andstream4,heatexchanger4withload20units
isplaced.
Allmatchings areshowninCPtablewithredbold lines. Temperaturesaftereachmatchingis
computedandplacedintheHENtoshowthatnoviolationofTminoccursduringdesign.The
finaldesignforcoldendisshowninFig.5.22(b3).

FinalDesign

ThefinalMERdesignoftheHENisachievedbyjoiningtheHotenddesignwithcoldenddesign.
For the present case as two designs are proposed for hot as well as cold end a total of four
feasiblefinaldesignispossible.Thisisduetothefactsthathotendaswellascoldenddesignis
inbalanceasfarasloadisconcerned.

Table5.4AlternatefinaldesignsforHEN
Feasible
HEN HotEndDesign
ColdEndDesign No.ofUnits.
configurations
1.
Design1
Design1
07
2.
Design2
Design2
08
3.
Design1
Design2
08
4.
Design2
Design1
07

Aminimumunitstargetappliedtothecompleteproblem(Table5.3)showsthatthenumberof
units should be five ( =4+21). Thus there is a scope to decrease number of units by two.
InvariablythetotalnumberofunitsinaMERdesignliketheabovehasmorenumberofunits
due to the presence of loops in the HEN design. Thus the removal of loops from the design
offersascopetodecreasenumberofunitsandtoreducethefixedcost.Butthisdecreaseis
achieved at the cost of increased utility cost as during this process heat flows through pinch
pointandthedesignnomoreremainsMER.

Thefinaldesignforhenconfiguration1isshowninFig.5.23.

ApplicationofPDMforMERHENsynthesis

200
1

Tmin=10C

142

130

Lecture28

Pinch
2

162.33

90

142
1
217kW
2

113kW

Design1

80

40

35

1
75

80 80

80

65

90
90
90

108.25

87kW

Module05

3
100kW

36.66

30

C
40

30

30

50
25

2
220kW

30 2

Design1

Fig5.23completedesignofHENforprobleminTable5.3

After demonstrating the PDM with a sample problem, three design problems will be taken
through lecture29, 30 & 31 to demonstrate design of problems such as Threshold problem,
Singlepinchandmultiplepinchrespectively.

References

1. AngelMartn*,FidelA.Mato,Hint:Aneducationalsoftwareforheatexchanger
networkdesignwiththepinchmethod,educationforchemicalengineers3(2008)e6
e14
2. Linnhoff,B.andFlower,J.R.,1978,Synthesisofheatexchangernetworks,AIChEJ,24(4):
633.
3. Linnhoff,B.andHindmarsh,E.,1983,Thepinchdesignmethodforheatexchanger
networks,ChemEngSci,38(5):745.
4. Linnhoff,B.,Townsend,D.W.,Boland,D.,Hewitt,G.F.,Thomas,B.E.A.,Guy,A.R.and
Marsland,R.H.,1994,AUserGuideonProcessIntegrationfortheEfficientUseof
Energy.(TheInstitutionofChemicalEngineers,Rugby,Warks,UK).
5. Smith,R.2005,ChemicalProcess:DesignandIntegration(seconded.),(J.Wiley,JWiley.