Lecture 7 - HEN I - CC

The Onion diagram
diagram
Reactor
Heat exchanger network I

Composite curves
Separation &
recycle
Heat exchange
network
Utilities
(Linnhoff et al., 1982)
Copyright@Dominic Foo
Lecture outline
H82PLD - Plant Design
CC - 2
Recommended texts
Single heat transfer unit vs. a

network (multiple units)
Heat transfer composite curves
Hot & cold utility targets
The famous name pinch
analysis
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).
CC - 3
CC - 4
Evolution of heat recovery

pinch analysis
Some important terms
1970s
Minimum hot and cold utility targeting
1983
The pinch design method (PDM)
1984
Surface area targeting
Stream to be cooled
Sources of heat
Heat integration for batch processes
1990
Energy-area trade off (Supertargeting)
1993
Distillation column integration
1993
Total site analysis
Target T
Stream to be heated
Sinks of heat
Target T
Cold stream
Supply temp initial T

Target temp final T
CC - 5
2 stream heat recovery
Supply T
Hot stream
Cold streams
1989
Hot streams
Supply T
CC - 6
2 stream heat recovery
Steam
Type
Supply temp,
TS (C)
Target temp, TT
(C)
H
(MW)
Steam
Type
Supply temp,
TS (C)
Target temp, TT
(C)
H
(MW)
Cold
40
110
14
Cold
40
110
14
Hot
160
40
12
Hot
160
40
12
QHmin = 3
Utility available for use:

Steam @ 180C
Cooling water @ 20C
QCmin = 1
QREC = 11
Without heat recovery:

Heat Stream 1 with steam: 14 MW
Cold Stream 2 with cooling water: 12 MW
Comment: high energy cost!

Tmin = 10C
CC - 7
CC - 8
A more complex problem
Larger value of Tmin
Feed 2
Important features:
Energy targets:
Vertical shifting is prohibited

Horizontal shifting is allowed
230C
Reactor 2
140C
Minimum hot utility: QHmin

Minimum cold utility: QCmin
180C
Feed 1
20C
Reactor 1
Product 2
200C
80C
250C
Off gas, 40C
40C
Q = mC p T = mC p (TT TS )
QHmin = 4
Product 1, 40C
Supply
Target
H Heat capacity
temp,
temp,
flowrate, CP
(MW) (MW.K-1)
TS (C)
TT (C)
1. Reactor 1 feed
Cold
20
180
32.0
0.20
2. Reactor 1 product
Hot
250
40
31.5
0.15
3. Reactor 2 feed
Cold
140
230
27.0
0.30
4. Reactor 2 product
Hot
200
80
30.0
0.25
Note: Heat capacity flowrate, CP = m.Cp
QCmin = 2
Steam
QREC = 10
Tmin = 20C
CC - 9
Type
Hot composite curve
Cold composite curve
T (C)
T (C)
30.0
H (MW)
61.5
48
61.5
7.5 H (MW)
CP
0 .3
32
27
H (MW)
24
59
CC - 11
.5
=0
20
20
31.5
CP
=
CP
40
0 .1
40
180
140
140
80
230
CP
80
0.3
0.
CP
CP
180
.4
=0
CP
=
CP
2
0.
230
CP
200
T (C)
0.
2
200
CP
=
250
0.1
5
250
0.1
5
T (C)
CC - 10
20
15 H (MW)
59
CC - 12
Hot & cold composite curves
With larger Tmin

QHmin = 7.5
T (C)
Tmin = 10C
250
230
Pinch
QHmin = 11.5
Tmin = 10C
QCmin = 10
40
20
Tmin = 20C
QCmin = 10
QREC = 51.1
QHmin = 7.5
H (MW)
QCmin = 14
CC - 13
Tmin & economic tradetrade-off

T
CC - 14
A note on Tmin
Care should be taken not to ignore practical
constraints in setting Tmin
To achieve pure Tmin requires heat exchangers

that exhibit pure countercurrent flow
H
Cost
Total
Shell-and-tube: not possible Tmin < 10C should be

avoided
Plate heat exchanger: Tmin ~ 5C or less
Energy
Capital
Q = UATmin
Tmin
CC - 15
CC - 16
Additional task
The heat recovery pinch
Proof that the CP for composite curve is the

summation of CP of individual streams.
QHmin
T (C)
Locate the new energy targets for the following

value of Tmin:
Pinch
Heat
sink
30C
50C
Heat
source
Tmin
H (MW)
QCmin
CC - 20
Possible heating
Impossible heating
T (C)
T (C)
Impossible
Possible
Pinch
Pinch
Heat
source
Heat
source
H (MW)
CC - 22
H (MW)
CC - 23
CC - 24
Heat transfer across pinch
Cold above the pinch
QHmin +XP
T (C)
XP
QHmin +XP
T (C)
Heat
sink
Heat
sink
Heat
source
Heat
source
H (MW)
QCmin+XP
CC - 25
CC - 26
To achieve energy targets, must not transfer heat

across the pinch by:
Process-process heat transfer
Inappropriate use of utility
Heat
sink
DONT COLD ABOVE THE PINCH!

DONT HEAT BELOW THE PINCH!
Heat
source
H (MW)
QCmin+XP
Heuristic
QHmin
XP
H (MW)
QCmin
Heat below the pinch

T (C)
XP
CC - 27
CC - 28

Lecture 7 - HEN I - CC

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Lecture 7 - HEN I - CC

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The Onion diagram

Heat exchanger network I

H82PLD - Plant Design

Single heat transfer unit vs. a

Wiley & Sons (heat exchanger network synthesis).

H82PLD - Plant Design

H82PLD - Plant Design

Evolution of heat recovery

Some important terms

Minimum hot and cold utility targeting

The pinch design method (PDM)

Surface area targeting

Heat integration for batch processes

Energy-area trade off (Supertargeting)

Distillation column integration

Total site analysis

Supply temp initial T

H82PLD - Plant Design

2 stream heat recovery

H82PLD - Plant Design

2 stream heat recovery

Utility available for use:

Without heat recovery:

Comment: high energy cost!

H82PLD - Plant Design

H82PLD - Plant Design

A more complex problem

Larger value of Tmin

Vertical shifting is prohibited

Minimum hot utility: QHmin

Off gas, 40C

H82PLD - Plant Design

H82PLD - Plant Design

Hot composite curve

Cold composite curve

H82PLD - Plant Design

Hot & cold composite curves

With larger Tmin

H82PLD - Plant Design

Tmin & economic tradetrade-off

H82PLD - Plant Design

To achieve pure Tmin requires heat exchangers

Shell-and-tube: not possible Tmin < 10C should be

H82PLD - Plant Design

H82PLD - Plant Design

The heat recovery pinch

Proof that the CP for composite curve is the

Locate the new energy targets for the following

H82PLD - Plant Design

H82PLD - Plant Design

H82PLD - Plant Design

H82PLD - Plant Design

Heat transfer across pinch

Cold above the pinch

H82PLD - Plant Design

H82PLD - Plant Design

To achieve energy targets, must not transfer heat

DONT COLD ABOVE THE PINCH!

Heat below the pinch

H82PLD - Plant Design

H82PLD - Plant Design

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