Heat exchanger network I Heat exchanger network I Heat exchanger network I Heat exchanger network I

Composite curves Composite curves Composite curves Composite curves

Copyright@Dominic Foo H82PLD - Plant Design CC - 2
The The The The Onion diagram Onion diagram Onion diagram Onion diagram
Reactor
Separation &
recycle
Heat exchange
network
Utilities
(Linnhoff et al., 1982)
Copyright@Dominic Foo H82PLD - Plant Design CC - 3
Lecture outline Lecture outline Lecture outline Lecture outline
Single heat transfer unit vs. a
network (multiple units)
Heat transfer composite curves
Hot & cold utility targets
The famous name pinch
analysis
Copyright@Dominic Foo H82PLD - Plant Design CC - 4
Recommended texts Recommended texts Recommended texts Recommended texts
Smith, R. (2005). Chemical Process Design and Integration. New York: John
Wiley & Sons (heat exchanger network synthesis).
Linnhoff, B., Townsend, D. W., Boland, D., Hewitt, G. F., Thomas, B. E.
A., Guy, A. R., & Marshall, R. H. (1982). A User Guide on Process
Integration for the Efficient Use of Energy. Rugby: IChemE (latest edition
by Ian Kemp).
Copyright@Dominic Foo H82PLD - Plant Design CC - 5
Evolution of heat recovery Evolution of heat recovery Evolution of heat recovery Evolution of heat recovery
pinch analysis pinch analysis pinch analysis pinch analysis
1970s Minimum hot and cold utility targeting
1990 Energy-area trade off (Supertargeting)
1984 Surface area targeting
1993 Distillation column integration
1993 Total site analysis
1983 The pinch design method (PDM)
1989 Heat integration for batch processes
Copyright@Dominic Foo H82PLD - Plant Design CC - 6
Some important terms Some important terms Some important terms Some important terms
Hot streams
Stream to be cooled
Sources of heat
Cold streams
Stream to be heated
Sinks of heat
Supply temp initial T
Target temp final T
Supply T
Q
T
Supply T
Hot stream
Target T
Cold stream
Target T
Copyright@Dominic Foo H82PLD - Plant Design CC - 7
2 stream heat recovery 2 stream heat recovery 2 stream heat recovery 2 stream heat recovery
12 40 160 Hot 2
14 110 40 Cold 1
H
(MW)
Target temp, T
T
(C)
Supply temp,
T
S
(C)
Type Steam
Utility available for use:
Steam @ 180C
Cooling water @ 20C
Without heat recovery:
Heat Stream 1 with steam: 14 MW
Cold Stream 2 with cooling water: 12 MW
Comment: high energy cost!
Copyright@Dominic Foo H82PLD - Plant Design CC - 8
2 stream heat recovery 2 stream heat recovery 2 stream heat recovery 2 stream heat recovery
12 40 160 Hot 2
14 110 40 Cold 1
H
(MW)
Target temp, T
T
(C)
Supply temp,
T
S
(C)
Type Steam
T
min
= 10C
Q
Hmin
= 3
Q
Cmin
= 1
Q
REC
= 11
Copyright@Dominic Foo H82PLD - Plant Design CC - 9
Larger value of Larger value of Larger value of Larger value of T TT T
min min min min
Important features:
Vertical shifting is prohibited
Horizontal shifting is allowed
Energy targets:
Minimum hot utility: Q
Hmin
Minimum cold utility: Q
Cmin
Q
Hmin
= 4
Q
Cmin
= 2
Q
REC
= 10
T
min
= 20C
Copyright@Dominic Foo H82PLD - Plant Design CC - 10
A more complex problem A more complex problem A more complex problem A more complex problem
30.0
27.0
31.5
32.0
H
(MW)
0.20 180 20 Cold 1. Reactor 1 feed
0.15 40 250 Hot 2. Reactor 1 product
0.25 80 200 Hot 4. Reactor 2 product
0.30 230 140 Cold 3. Reactor 2 feed
Heat capacity
flowrate, CP
(MW.K
-1
)
Target
temp,
T
T
(C)
Supply
temp,
T
S
(C)
Type Steam
Reactor 1
Feed 1
20C
Reactor 2
Feed 2
140C
Off gas, 40C
Product 1, 40C
180C
40C
250C
230C 200C Product 2
80C
Note: Heat capacity flowrate, CP = m.C
p
( )
S T p p
T T mC T mC Q = =
Copyright@Dominic Foo H82PLD - Plant Design CC - 11
Hot composite curve Hot composite curve Hot composite curve Hot composite curve
H (MW)
T (C)
31.5 30.0
250
200
80
40
T (C)
48 7.5
250
200
80
40
6
61.5
H (MW)
61.5
C
P

=

0
.
1
5
C
P

=

0
.
2
5
C
P

=

0
.
1
5
C
P

=

0
.
1
5
C
P

=

0
.
4
Copyright@Dominic Foo H82PLD - Plant Design CC - 12
Cold composite curve Cold composite curve Cold composite curve Cold composite curve
C
P

=

0
.
2
C
P

=

0
.
3
230
180
140
20
32 27
59
T (C)
H (MW)
T (C)
20 15 24
H (MW)
59
C
P

=

0
.
2
C
P
=

0
.
5
230
180
140
20
C
P

=

0
.
3
Copyright@Dominic Foo H82PLD - Plant Design CC - 13
Hot & cold composite curves Hot & cold composite curves Hot & cold composite curves Hot & cold composite curves
H (MW)
T (C)
Q
REC
= 51.1 Q
Hmin
= 7.5 Q
Cmin
= 10
T
min
= 10C
Pinch
230
20
250
40
Copyright@Dominic Foo H82PLD - Plant Design CC - 14
With larger With larger With larger With larger T TT T
min min min min
Q
Hmin
= 7.5
Q
Cmin
= 10
T
min
= 10C
Q
Hmin
= 11.5
Q
Cmin
= 14
T
min
= 20C
Copyright@Dominic Foo H82PLD - Plant Design CC - 15
T TT T
min min min min
& economic trade & economic trade & economic trade & economic trade- -- -off off off off
H
T
H
T
H
T
T
min
Cost
Total
Energy
Capital
min
T UA Q =
Copyright@Dominic Foo H82PLD - Plant Design CC - 16
A note on A note on A note on A note on T TT T
min min min min
Care should be taken not to ignore practical
constraints in setting T
min
To achieve pure T
min
requires heat exchangers
that exhibit pure countercurrent flow
Shell-and-tube: not possible T
min
< 10C should be
avoided
Plate heat exchanger: T
min
~ 5C or less
Copyright@Dominic Foo H82PLD - Plant Design CC - 20
Additional task Additional task Additional task Additional task
Proof that the CP for composite curve is the
summation of CP of individual streams.
Locate the new energy targets for the following
value of T
min
:
30C
50C
Copyright@Dominic Foo H82PLD - Plant Design CC - 22
The heat recovery pinch The heat recovery pinch The heat recovery pinch The heat recovery pinch
H (MW)
T (C)
T
min
Pinch
Q
Hmin
Q
Cmin
Heat
sink
Heat
source
Copyright@Dominic Foo H82PLD - Plant Design CC - 23
Possible heating Possible heating Possible heating Possible heating
H (MW)
T (C)
Pinch
Heat
source
Possible
Copyright@Dominic Foo H82PLD - Plant Design CC - 24
Impossible heating Impossible heating Impossible heating Impossible heating
H (MW)
T (C)
Pinch
Heat
source
Impossible
Copyright@Dominic Foo H82PLD - Plant Design CC - 25
Heat transfer across pinch Heat transfer across pinch Heat transfer across pinch Heat transfer across pinch
H (MW)
T (C)
Q
Hmin
+XP
Q
Cmin
+XP
Heat
sink
Heat
source
XP
Copyright@Dominic Foo H82PLD - Plant Design CC - 26
Cold above the pinch Cold above the pinch Cold above the pinch Cold above the pinch
H (MW)
T (C)
Q
Hmin
+XP
Q
Cmin
Heat
sink
Heat
source XP
Copyright@Dominic Foo H82PLD - Plant Design CC - 27
Heat below the pinch Heat below the pinch Heat below the pinch Heat below the pinch
H (MW)
T (C)
Q
Hmin
Q
Cmin
+XP
Heat
sink
Heat
source
XP
Copyright@Dominic Foo H82PLD - Plant Design CC - 28
Heuristic Heuristic Heuristic Heuristic
To achieve energy targets, must not transfer heat
across the pinch by:
Process-process heat transfer
Inappropriate use of utility
DONT COLD ABOVE THE PINCH!
DONT HEAT BELOW THE PINCH!