CHAPTER 3

PROCESS INTEGRATION

3.1 INTRODUCTION

Generally, heat or energy integration is an important part in chemical process plant

design. Energy integration is a technique to match hot and cold streams in a plant to
achieve heat transfer to reduce hot and cold utility consumption. Before we proceed
to design the heat exchanger network, first, the base case process flow heat
exchanger should be known of its heat exchanger area and energy utilities
consumption, in order to compare it with the utility consumption after heat
integration. These energy utilities should be optimized in order to reduce the utilities
consumption of the process which will affect the operating cost of this plant.
This chapter determines the heat exchanger network by using the heat
integration method in order to determine whether the plant is economic in terms of
energy usage and also optimises the use of energy by heat recovery. Heat recovery
systems are designed to conserve energy by reusing available waste heat. Energy
conservation does not only reduce steam cost but it also helps to reduce cooling
water cost. Although the capital cost may increase because more units of heat
exchanger are needed, but the utilities cost will decrease tremendously and is more
economical in the long term of view. The area and utility consumption of the base
case process flow heat exchanger should be known for comparison after heat
integration.
 3-2

One of the most successful and generally useful techniques in process

integration is pinch technology. The term derives from the fact that in a plot of the
system temperatures versus the heat transferred, a pinch usually occurs between
the hot stream and cold stream curves. The pinch represents a distinct
thermodynamic break in the system and that, for minimum energy requirement, heat
should not be transfer across the pinch. Three rules were deduced: composite
curves, problem table algorithm and HEN (Heat Exchanger Network).

3.2 Pinch Analysis

Pinch analysis is a methodology for minimizing energy consumption of

processes by calculating thermodynamically feasible energy targets, which is
minimum energy consumption, and achieving them by optimizing heat recovery
systems, energy supply methods and process operating conditions. It is also known
as "process integration", "heat integration", "energy integration" or "pinch
technology".

The techniques were first developed in the early 1980s by teams led by
Professor Bodo Linnhoff at University of Manchester (UK). In France, Jean-Paul
Gourlia also contributed to popularize this approach with several reference papers
on this topic. Many refinements have been developed since and used in wide range
of industries. Pinch Analysis has been extended beyond energy applications. There
are many advantages using this approach which include:

1. It is mainly a graphical method which allows engineer to keep

physical approach of involved phenomenon while other optimization
techniques are purely numerical.
2. It takes into account the whole process or the whole plant, providing
a systematic approach instead of focusing on a specific unit or
equipment.
3. It is demonstrated that its use can reduce both capital and operating
costs. Emissions are consequently also minimized.
4. The energy minimization is performed without any knowledge of the
heat exchanger network which is design afterwards.
 3-3

5. A very deep knowledge of the analysed process is not required to

apply the method and retrieve substantial savings.

In any Pinch Analysis problem, whether a new project or a retrofit situation, a

well-defined stepwise procedure is followed in the step shown in Figure 6.1. It
should be noted that these steps are not necessarily performed on a once-through
basis, independent of one another.

Figure 3.1: Steps of Pinch Analysis

 3-4

3.3 HEAT RECOVERY AND HEAT EXCHANGE

3.3.1 Basic Concepts of Heat Exchange

Any flow which requires to be heated or cooled, but does not change in composition
is defined as a stream. The feed, which starts cold and needs to be heated up, is
known as a cold stream. Conversely, the hot product which must be cooled down is
called a hot stream. Conversely, the reaction process is not a stream, because it
involves a change in chemical composition; and the make-up flow is not a stream,
because it is not heated or cooled. To perform the heating and cooling, a steam
heater could be placed on the cold stream and a water cooler on the hot stream.
Energy consumption can be reduced by recovering some heat from the hot stream
and use it to heat the cold stream in a heat exchanger, less steam and water will be
required to satisfy the remaining duties.

3.3.2 Temperature and Enthalpy

For each hot, cold and utility stream identified, the following thermal data is
extracted from the process material and heat balance flow sheet:

1. Supply temperature, Ts (K) is the temperature at which the stream is

available.
2. Target temperature, Tt (K) is the temperature the stream must be taken to.
3. Heat capacity flow rate, CP (kW/K) the product of flow rate and specific
heat.

CP = m x Cp

4. Enthalpy Change, H (kW) associated with a stream passing through the

exchanger is given by the First Law of Thermodynamics.

First Law energy equation: H = Q W

In a heat exchanger, no mechanical work is being performed: W = 0 (zero)

 3-5

The above equation simplifies to: H = Q

Q represents the heat supply or demand associated with the stream. It is given
by the relationship: Q = CP x (Ts Tt)

There is a correlation between the value of Tmin in the exchanger and the total
utility load on the system. This means that by choosing a value of Tmin, an energy
target for how much heating and cooling should be used if the heat exchanger is
designed correctly can be obtained.

3.3.3 Composite Curves

Composite curve mainly is a graph of temperature versus enthalpy (T vs H).

Composite curves have been used for many years to set energy targets ahead of
design. Composite curves consist of temperature (T) enthalpy (H) profiles of heat
availability in the process (the hot composite curve) and heat demands in the
process (the cold composite curve) together in a graphical representation.

For heat exchange to occur from the hot stream to the cold stream, the hot
stream cooling curve must lie above the cold stream-heating curve. Because of the
kinked nature of the composite curves, they approach each other most closely at
one point defined as the minimum approach temperature which is Tmin. Tmin can
be measured directly from the T-H profiles as being the minimum vertical difference
between the hot and cold curves. At a particular Tmin value, the overlap shows the
maximum possible scope for heat recovery within the process. The hot end and
cold end overshoots indicate minimum hot utility requirement (QH min) and minimum
cold utility requirement (QC min), of the process for the chosen Tmin.

From composite curves, the energy requirement for a process is supplied via
process to process heat exchange and/or exchange with several utility levels such
as steam levels, refrigeration levels, hot oil circuit, and furnace flue gas.
 3-6

3.3.4 A Targeting Procedure: The Problem Table

In principle, the composite curves described in the previous sub-section could be

used for obtaining energy targets at given value of Tmin. However, it would require
a graph paper and scissors approach (for sliding the graphs relative to one
another) which would be messy and imprecise. Instead, an algorithm for setting the
targets algebraically, the Problem Table can be used.

With the Problem Table algorithm, the engineer has a powerful targeting
technique at his or her fingertips. Data can be quickly extracted from flowsheets and
analysed to see whether the process is nearing optimal, or whether significant scope
for energy saving exists. The targets are easily obtained and provide enormous
stimulus to break away from the learning curve. A step-by-step algorithm for
calculating the Problem Table is given below:

1. Select a global Tmin for the calculation.

2. Substract Tmin/2 from all hot stream temperatures TH and add
Tmin/2 to all cold stream temperatures TC to give the shifted
temperatures S for each stream.
3. Make a list of all the shifted temperatures S at which streams (hot or
cold) begin, end or change heat capacity flowrate CP.
4. Rank the list of shifted temperatures in descending order (highest
temperature at the top).
5. In each temperature interval i between two shifted temperatures, add
together the heat capacity flowrates of all the hot streams which exist
in that temperature interval and substract the heat capacity flowrates
of all the cold streams, to give a net heat capacity flowrate CPnet.
6. Multiply CPnet for each interval by the temperature range of the
interval to give the net heat released (positive) or required (negative)
in the interval.
7. Starting from a zero input at the highest temperature, work down the
table, adding on the net heat change in each temperature interval to
give a heat cascade (cumulative heat passing through at a given
shifted temperature).
 3-7

8. The cascade in step 7 normally contains negative heat flows and in

thermodynamically infeasible. Take the minimum net heat flow in the
table (-Qmin largest negative value, or zero) and add this amount of
heat Qmin as hot utility to the first interval in the cascade. All the net
heat flows in the cascade now increase by this amount, and the
minimum value becomes zero. This is the feasible heat cascade, or
Problem Table.
9. The heat added to the first interval is the hot utility requirement
(target) QHmin. The heat removed from the final interval is the cold
utility target QCmin. The point(s) at which there is zero net heat flow in
the cascade is the pinch. The plot of the net heat flow in the cascade
is the pinch. The plot of the net heat flow (horizontal axis) against the
shifted temperature (vertical axis) is the GCC.

3.3.5 The Grand Composite Curve (GCC)

The GCC shows the variation of heat supply and demand within the
process. Using GCC diagram, the designer can find which utilities are to be used.
The designer aims to maximize the use of the cheaper utility levels and minimize the
use of the expensive utility levels. Low-pressure steam and cooling water are
preferred instead of high-pressure steam and refrigeration, respectively.

The information required for the construction of the GCC comes directly from the
Problem Table Algorithm (PTA). The vertical axis on the shifted composite curves
shows process interval temperature. In other words, the curves are shifted by
subtracting part of the allowable temperature approach from the hot stream
temperatures and adding the remaining part of the allowable temperature approach
to the cold stream temperatures. The result is a scale based upon process
temperature having an allowance for temperature approach (Tmin). The GCC is
then constructed from the enthalpy (horizontal) differences between the shifted
composite curves at different temperatures. On the GCC, the horizontal distance
separating the curve from the vertical axis at the top of the temperature scale shows
the overall hot utility consumption of the process.

In summary, the GCC is one of the most basic tools used in pinch analysis for
the selection of the appropriate utility levels and for targeting of a given set of
multiple utility levels. The targeting involves setting appropriate loads for the various
 3-8

utility levels by maximizing the least expensive utility loads and minimizing the loads
on the most expensive utilities. The pinch is also easily visualized, being the point
where net heat flow is 0 and the GCC touches the axis. Moreover, we can see
whether the pinch occurs in the middle of the temperature range or at one end (a
threshold problem), and identify other regions of low net heat flow, or even double
or multiple pinches.

3.4 PINCH AND ITS SIGNIFICANCE

Above the pinch (i.e. in the region to the right) the hot composite transfers all its
heat into the cold composite, leaving utility heating only required. The region above
the pinch is therefore a net heat sink, with heat flowing into it but no heat flowing out.
It involves heat exchange and hot utility, but no cold utility. Conversely below the
pinch cooling only is required and the region is therefore a net heat source, requiring
heat exchange and cold utility but no hot utility. Heat QHmin flows into the problem
above the pinch and QCmin out of the problem below, but the heat flow across the
pinch is zero.

It follows that any network design that transfers an amount of heat across the
pinch must, by overall enthalpy balance, require an amount more than minimum
from hot and cold utilities. Any utility cooling the amount of heat above the pinch
must incur extra hot utility of the same amount and vice versa below the pinch. This
gives three golden rules to produce a design achieving minimum utility targets:

1. Dont transfer heat across the pinch.

2. Dont use cold utilities above the pinch.
3. Dont use hot utilities below the pinch.

Conversely, if a process is using more energy than its thermodynamic targets, it

must be due to one or more the golden rules being broken.
 3-9

3.5 HEAT EXCHANGER NETWORK DESIGN

3.5.1 Network Grid Representation

In history, the most helpful representation is the grid diagram introduced by

Linnhoff and Flower (1978). The streams are drawn as horizontal lines, with high
temperatures on the left and hot streams at the top; heat exchange matches are
represented by two circles joined by a vertical line. The grid represents the
countercurrent nature of the heat exchange, making it easier to check exchanger
temperature feasibility.

In normal case (where pinch point exist), the heat exchanger network is designed
according to pinch technology to gain maximum energy recovery. In this case,
where the pinch point does not exist, therefore, the heat exchanger network is
treated as a design of below the pinch point. In the process of matching between hot
and cold streams, there are several considerations that must be take into account,
which are:

o Each match should not violate the rules of thermodynamics where the
achieved temperature profile of each streams have a minimum difference
of Tmin.
o The matching process should start at the pinch point since the pinch is
the most constrained part of the network.

3.5.2 Design for Maximum Energy Recovery (MER)

Above the pinch, no utility cooling should be used; hence all hot streams must be
brought to pinch temperature by interchange against cold streams. Therefore, the
design must start at the pinch, finding matches that fulfill this condition. In design
immediately above the pinch, the following criterion must be met:

CPHOT CPCOLD

Having found a feasible pinch design it is necessary to decide on the match

heat loads. The recommendation is maximize the heat load so as to completely
 3-10

satisfy one of the streams. This ensures the minimum number of heat exchange
units is employed. In design immediately below the pinch, the following criterion
must be met:

CPHOT CPCOLD

In cases where CP inequality exists for a match, the match would still be considered
as feasible because it is away from the pinch. Summarising, the design for an MER
network can be produced by:

1. Dividing the problem at the pinch and designing each part separately.
2. Starting the design at the pinch and moving away.
3. Immediately adjacent to the pinch, obeying the constraints:

CPHOT CPCOLD (above) for all hot streams

CPHOT CPCOLD (below) for all cold streams

4. Maximising exchanger loads.

5. Supplying external heating only above the pinch and external cooling
only below the pinch.

3.6 PROCEDURES OF HEAT INTEGRATION

In order to synthesis HEN, it is desirable to determine the Maximum Energy

Recovery (MER) target in term of minimum hot and cool utilities (Qhmin and Qcmin),
hot pinch temperature and cool pinch temperature, process composite curve was
constructed. Then, Problem Table Algorithm was used to verify the results of
composite curve more accurately. A brief description of the Pinch analysis applied
in the heat integration of this plant is as follows:

i) Identification of the cold and hot streams

ii) Labelling of stream properties such as H and FCp.
iii) Assume Tmin = 10 K
iv) Construction of process composite curve by a plot of temperature versus
enthalpy for cool stream and hot stream.
 3-11

v) Determination of the MER target.

vi) Verification the result through Problem Table Algorithm by first determine
the shifted temperatures (Ts)

, = , +
2

, = ,
2

vii) Process Heat Cascading to determine the MER target.

viii) Stream Matching Analysis above and below Pinch Region. The following
term FC p,out>FCp,in is applied.
ix) Comparison of heat utilization efficiency before and after heat integration.
x) Design the heat exchanger network (HEN).

3.6.1 Stream Identification

Pinch Analysis begins with the process of screening plant flow sheet for a set of hot
and cold streams having potential for heat interchange. These stream data can be
obtained directly from the simulation results.

Table 3.1 and 3.2 below indicates the summary of the hot and cold streams
in our ethanol plant, which are used to obtain the maximum energy recovery for the
plant for heat integration for the sake of saving utilities cost. The value of heat flow
rate, CP is obtained from the energy balance summary, where it is equal to the ratio
of H/T.
Table 3.1: Summary of hot streams
CP
EQUIPMENT STREAM Tsupply (K) Ttarget (K) T (K)
(kW/C)

K-100 (heater) 1 -58.83 86.8 145.63 1.648

E-100 (heater) 6 67.3 161.4 94.1 6.432

E-101 (heater) 7 161.4 300 138.6 5.882

 3-12

Table 3.2: Summary of Cold streams

CP
EQUIPMENT STREAM Tsupply (K) Ttarget (K) T (K)
(kW/C)

E-102 (cooler) 14 146.7 40 106.7 5.675

E-100 (cooler) 9 320.00 158.9 161.1 2.584

Stream selection is done by selecting all the streams attached to all of the heat
exchangers. By having it manipulated by a process stream, multiple problems could
arise in the event of a process upset occurring either at downstream or upstream.

3.6.2 Selection of initial Tmin value

The design of any heat transfer equipment must always adhere to the Second Law
of Thermodynamics that prohibits any temperature crossover between the hot and
the cold stream. Therefore, a minimum heat transfer driving force must always be
allowed for a feasible heat transfer design. Thus, the temperature of the hot and
cold streams at any point in the heat exchanger must always have a minimum
temperature difference (Tmin). This Tmin value represents the bottleneck in the heat
recovery. A few values based on Linnoff Marchs application experience are
tabulated below for shell and tube heat exchangers.

Table 3.3: Minimum Temperature Difference (Tmin) Values for Shell and Tube
Heat Exchangers Based on Linnoff Marchs Application Experience

No Industrial Sector Experience Tmin Values

1 Oil Refining 20 C 40 C
2 Petrochemical 10 C 20 C
3 Chemical 10 C 20 C
4 Low Temperature Processes 3 C 5 C
 3-13

When carrying out problem using Problem Table Algorithm (PTA), the
temperatures were shifted according to Tmin/2 being added to the cold streams and
subtracted from the hot streams. This value of Tmin/2 can be considered to be a
contribution to the overall Tmin between the hot and the cold streams. Rather than
making the Tmin contribution equal for all streams, it could be made stream-specific
(Robin Smith (2005), Chemical Process Design and Integration):

As an example, suppose that liquid streams are assigned a contribution of 5C

and gas streams 10C. Then a liquid/liquid match has a T min of 5 + 5 = 10C, a
liquid/gas match has a Tmin of 5 + 10 = 15C and a gas/gas match has a Tmin of 10
+ 10 = 20C. The same values of Tmin will be used as above in the composite
curves, where the location of the pinch and Tmin at the pinch would depend on
which kind of streams were located in the region of the point of closest approach
between the composite curves.

The same values of Tmin will be used as above in the composite curves, where
the location of the pinch and Tmin at the pinch would depend on which kind of
streams were located in the region of the point of closest approach between the
composite curves.

In the process of ethanol production, based on the streams extracted in Table

3.1 and Table 3.2, Tmin = 10C was used to obtain both Problem Table Algorithm
(PTA) and Grand Composite Curves.

3.6.3 Shifting Temperatures

For hot stream: T*supply/target = Tsupply/target + Tmin/2

For cold stream: T*supply/target = Tsupply/target - Tmin/2

Table 3.4 shows the Shifted hot and cold streams supply and target temperatures.

Table 3.4: Shifted hot and cold streams supply and target temperatures

EQUIPMENT STREAM Tsupply (C) Ttarget (C) T*supply (C) T*target (C)
K-100 (heater) 1 -58.83 86.8 -53.83 91.8
E-100 (heater) 6 67.30 161.4 72.3 166.4
E-101 (heater) 7 161.40 300.0 166.4 305
E-102 (cooler) 14 146.70 40.0 141.7 35
E-100 (cooler) 9 320.00 158.9 315 153.9
 3-14

3.6.3.1 Rank order of interval temperature

Interval temperatures are ranked in order of magnitude, representing the duplicate

temperatures only once in the order and interval temperature differences are
calculated in table 3.5.

Table 3.5: Rank order of interval temperature

Rank order of temperature

Stream in
Rank Tn
interval
320
300 20 7
161.4 138.6 6,7
158.9 2.5 9
146.7 12.2 14
86.8 59.9 1
67.3 19.5 6
40 27.3 14
-58.83 98.83 1

3.6.4 Temperature Intervals and Heat Load

1. Heat balance of each shifted temperature interval is calculated according to

the equation below

= ( ) ( )

Where:

= net heat required in the interval

= Sum of the heat capacities of all cold streams in the interval

= Sum of the heat capacities of all hot streams in the interval

= interval temperature difference

The temperature interval and heat load for Ethanol Production is shown in table 6.6.
 3-15

Table 3.6: Temperature intervals and heat load for Ethanol Production
process

Interval Rank Tn(C) CPc - CPh Hload (kw) Accumulate H

d H (kW) (kW)
320 0 34.285
1 300 20 -5.882 -117.64 117.64 151.925
2 161.4 138.6 0.55 76.23 41.41 75.695
3 158.9 2.5 2.584 6.46 34.95 69.235
4 146.7 12.2 5.675 69.235 -34.285 0
5 86.8 59.9 -1.648 -98.7152 64.4302 98.7152
6 67.3 19.5 -6.432 -125.424 189.8542 224.139
7 40 27.3 5.675 154.9275 34.9267 69.212
8 -58.83 98.83 -1.648 -162.8718 197.79854 232.084

3.6.5 Heat Cascade

Heat cascade for ethanol production process is shown in table 3.7.

Table 3.7: Heat cascade for ethanol production process

Infeasible Heat Cascade Feasible Heat Cascade

T* (C) Hot utility H (kW) T* (C) Hot utility H (kW)
320 0 34.285 320 0 34.285
300 117.64 151.925 300 117.64 151.925
161.4 41.41 75.695 161.4 41.41 75.695
158.9 34.95 69.235 158.9 34.95 69.235
146.7 -34.285 0 146.7 -34.285 0
86.8 64.4302 98.7152 86.8 64.4302 98.7152
67.3 189.8542 224.139 67.3 189.8542 224.139
40 34.9267 69.212 40 34.9267 69.212
-58.83 197.79854 232.084 -58.83 197.79854 232.084
 3-16

From the heat cascade performed above, several data are obtained:

Pinch temperature, Tpinch = 146.7C

Since Tmin = 10C;

Tpinch, hot = [146.7 + (10/2)] = 151.7C

Tpinch, cold = [146.7 (10/2)] = 141.7C

Minimum heating requirement, QH,min = 331.14 kW

Minimum cooling requirement, QC,min = 624.15 kW

 3-17

3.6.6 Grand Composite Curve

The data for plotting the grand composite curve is shown in table 3.8.

Table 3.8: Data for plotting the grand composite curve

H (kW) T* (C)
34.285 320
151.925 300
75.695 161.4
69.235 158.9
0 146.7
98.7152 86.8
224.139 67.3
69.2117 40
232.084 -58.83

Grand Composite Curve

350

300

250

200
T* (C)

150

100

50

0
0 50 100 150 200 250
H (kW)

Figure 3.2: The grand composite curve for ethanol production process
 3-18

3.6.7 Design above the pinch

The criteria for the design above the pinch, Cp hot Cp cold. It will be easier for the
heat transferred from hot stream to the cold stream. Note that the streams that
present at the pinch temperature are considered. The design above temperature
diagram is shown in Figure 3.3. Stream 9 and stream 7 are chosen to be above the
pinch because the values of temperatures are above the pinch temperature.

Figure 3.3: The design above the pinch diagram

 3-19

3.6.8 Design below the pinch

Since Cp cold Cp hot, there is a hot stream that has a heat to be transfer. For
stream 6 and 14, considered as at 146.7 C because it is below the pinch. The
Figure 3.4 shows the design of the below pinch diagram. Stream 1, 6 and 14 are
chosen to be below the pinch because the values of these temperatures are below
the pinch temperature.

Figure 3.4: The design below the pinch diagram

 3-20

3.6.9 Minimum Number of Units and Comparison

The minimum number of units can be determined using equation:

= ( 1) + ( 1)

where S is the number of stream at a corresponding pinch inclusive of utilities.

The completed design is shown in Figure 6.3 and 6.4. The minimum number of units
for this problem is therefore:

= (2 1) + (3 1)

= 3

The design in Figure 6.3 is seen to achieve the minimum number of unit
targets. However, the number of heat exchanger before and after heat integration
remains the same as the number of heat exchanger based on utilities alone are 3
which is similar to that of after integration. In terms of energy and cost saving, there
is indeed an improvement over the unintegrated complex.

The need for heating utilities is completely eliminated as in the case of the cold
streams that have been chosen to be integrated. As much as 1660.49 kW of energy
that could have been supplied by high pressure steam is instead being supplied by
the hot stream, particularly one that is coming out of the heat exchanger. This value
is calculated by multiply the value of CP and T. As example for hot stream,

Stream 1: CP x T: 1.648 kW/oC x (86.8 58.83)oC: 240 kW,

Stream 6: CP x T: 6.432 kW/oC x (161.4 67.3) oC: 605.25 kW,

Stream 7: CP x T: 5.882 kW/oC x (300 161.4) oC: 815.25 kW

Total: 240 kW + 605.25 kW + 815.25 kW: 1660.49 kW

 3-21

This lowers the dependence of the plant on HPS for heating purposes, thus
as an alternative the surplus HPS can be sold to other adjacent plants that might
require them.

The same idea applies to the cooling utilities as the need for them is lowered
as in the case of the hot streams that have been chosen to be integrated. As much
as 1021.80 kW of energy that could have been needed for the cooling to take place
is saved by the presence of the four cold streams that act as a substitute to the
cooling organic gas mixture required whereby these cold streams will receive the
heat from the hot stream, consequently leads to a lower demand for cooling water.
This value is calculated by multiply the value of CP and T. As example for cold
stream,

Stream 14: CP x T: 5.675 kW/oC x (146.7 40) oC: 605.52 kW,

Stream 9: CP x T: 2.584 kW/oC x (320 158.9) oC: 416.28 kW

Total: 605.52 kW + 416.28 kW: 1021.8 kW

Table 3.9 shows the summary of the energy requirement before the
integration and energy savings after the integration.

Table 3.9: Comparison of energy requirement before and after heat

integration

Utilities Before After Integration Energy

Integration, (kW) (kW) Savings (%)
Cold (gas
QC = 1021.80 QCmin = 624.15 38.92%
mixture)
Hot (gas
QH = 1660.49 QHmin = 331.14 80.06%
mixture)
Total QT = 2682.29 QT(hot+cold) = 955.29 64.39%

From Table 3.9, it can be seen that the heat integration was performed on the plant
has indeed reduced some requirements on both the cooling organic gas mixture for
cooling purposes and high pressure steam for heating purposes with each
contributing to 38.92% and 80.06% in energy savings respectively. With this in mind,
 3-22

it is decided that the plant should undergo integration so as to reduce the annual
operational cost.
 3-23

E-100 T-102
P-100 P-101 MIX-100 MIX-101 MIX-102 K-101 E-101 E-102 TEE-101 CRV-100 T-100 P-102 VLV-100 T-101 K-102
HEAT DISTILLATION
PUMP PUMP MIXER MIXER MIXER EXPANDER HEATER COOLER SPLITER REACTOR ABSORBER PUMP VALVE SEPARATOR COMPRESSOR
EXCHANGER COLUMN
25.08 25.08
7000 7000 7000
25.08

23 21 22

6900
320 35.20 7000
3950 25.08

240 kW TEE-100
9
18 20
1000 7000
-58.3 86.80
7000 7000 7000
45.23 27.36
6950
300 K-102
130.4
81.25 30
1 3
4000 3950
P-28
5 6 7 8
7000
K-100 30.68 16 16.1
P-68
101.3
4
30 E-100 E-101
MIX-100 MIX-101 605.25 kW
10 E-104
2 416.28 kW
30.48
30.48
162.8 P-69
815.25 kW 3950
5000 CRV-100
P-100 5000
101.3
30 T-101 19
12
13
P-17
11

6850 5000 5000

P-101 159.2 147 40
214.6
MIX-102 500

14 15
4500 800 800
37.27 15.70 -50 26

E-102
K-101 T-100
17 24 25

VLV-100
605.52 kW E-103

5000
171.3 5000
171.3
170.4
800
31 T-102
29 28
TEE-101 27

171.3
500
P-102
30

Figure 3.5: Process flow diagram before integration

 3-24

E-100 T-102
K-100 P-100 P-101 MIX-100 MIX-101 MIX-102 K-101 E-101 E-102 TEE-101 CRV-100 T-100 P-102 VLV-100 T-101 K-102
HEAT DISTILLATION
COMPRESSOR PUMP PUMP MIXER MIXER MIXER EXPANDER HEATER COOLER SPLITER REACTOR ABSORBER PUMP VALVE SEPARATOR COMPRESSOR
EXCHANGER COLUMN
25.08 25.08
7000 7000 7000
25.08

331.14 kW 23 21 22

6900
320 35.20 7000
3950 25.08

TEE-100
9
18 20
1000 7000
-58.3 86.80
7000 7000 7000
45.23 27.36
6950
300 K-102
130.4
81.25 30
1 3
4000 3950
P-28
5 6 7 8
7000
K-100 30.68 16 16.1
101.3
4
30 E-100 E-101
MIX-100 MIX-101
10 E-104
2

30.48
30.48
162.8 CRV-100 3950
5000
P-100 5000
101.3
624.15 kW
30 T-101 19
12
13
P-17
11

6850 5000 5000

P-101 159.2 147 40
214.6
MIX-102 500

14 15
4500 800 800
37.27 15.70 -50 26

E-102
K-101 T-100
17 24 25

VLV-100
E-103

5000
171.3 5000
171.3
170.4
800
31 T-102
29 28
TEE-101 27

171.3
500
P-102
30

Figure 3.6: Process flow diagram after integration

 3-25

REFERENCES

R. K. Shah and D. P. Sekulic, Fundamental Of Heat Exchanger Design, John

Wiley & sons, 2003.

Perry R.H and Green, Don, Perrys Chemical Engineers Handbook, 7th Edition,
McGraw-Hill Book Company, Singapore, 1999.

Sinnott, R. K., Coulson & Richardson, Chemical Engineering Design, Butterworth

Heinemann, 1999.