Biegler/Grossmann/Westerberg:

Systematic Methods of Chemical Process Design

Synthesis of
Heat Exchanger Networks
Cheng-Liang Chen
PSE
LABORATORY
Department of Chemical Engineering
National TAIWAN University
Chen CL 1
Heat Exchanger Network Synthesis
Given a minimum temperature approach, the exact
amount for minimum utility consumption can be
predicted prior to developing the network structure
Based on the pinch temperature for minimum utility
consumption, the synthesis of the network can be
decomposed into subnetworks
It is possible to develop good a priori estimates of the
minimum total area of heat exchange in a network
Q: explicit procedure for deriving conguration of
a heat exchanger network ?
Chen CL 2
An optimal or near optimal network exhibits the
following characteristics:
Rule 1: minimum utility cost
Rule 2: minimum number of units
Rule 3: minimum investment cost
Chen CL 3
Sequential Synthesis: Min Utility Cost
FCp (MW/C) T
in
(C) T
out
(C)
H1 1.0 400 120
H2 2.0 340 120
C1 1.5 160 400
C2 1.3 100 250
Steam: 500
o
C, CW: 20 30
o
C, Min recovery app temp = 20
o
C
Chen CL 4
Heat Cascade Diagram
Chen CL 5
Heat Balances around each temp interval
R
1
+ 30 = Q
s
R
2
+ 90 = R
1
+ 60
R
3
+ 357 = R
2
+ 480
Q
w
+ 78 = R
3
+ 180 (4 eq.s, 5 var.s)
LP Transshipment Problem:
min Z = Q
s
+Q
w
s.t. R
1
Q
s
= 30
R
2
R
1
= 30
R
3
R
2
= 123
Q
w
R
3
= 102
Q
s
, Q
w
, R
1
, R
2
, R
3
0
Q
s
= 60 MW, Q
w
= 225 MW
R
1
= 30, R
2
= 0, R
3
= 123
a pinch at temp interval 340
o
320
o
C
Chen CL 6
Note:
min Z = Q
s
+Q
w
s.t. R
1
Q
s
= 30
R
2
R
1
= 30
R
3
R
2
= 123
Q
w
R
3
= 102

min Z = Q
s
+Q
w
= 2Q
s
+ 165 (?)
s.t. R
1
= Q
s
30 0
R
2
= R
1
30 = Q
s
60 0
R
3
= R
2
+ 123 = Q
s
+ 63 0
Q
w
= R
3
+ 102 = Q
s
+ 165 0

Q
s
= 60
Qw = 225
R
1
= 30
R
2
= 0
R
3
= 123
Chen CL 7
General Transshipment Model for
Predicting Min Utility Cost
Sets
H
k
= {i| hot stream i supplies heat to interval k (k = 1, , K)}
C
k
= {j| cold stream j demands heat from interval k}
S
k
= {m| hot utility m supplies heat to interval k}
W
k
= {n| cold utility n extracts heat from interval k}
Par.s
Q
H
ik
, Q
C
jk
heat content of hot/cold streams i/j in interval k
c
m
, c
n
unit cost of hot utility m and cold utility n
Var.s
Q
S
m
, Q
W
n
heat load of hot utility m and cold utility n
R
k
heat residual exiting interval k
Chen CL 8
Heat Flows in Interval k
Chen CL 9
LP Transshipment Model for Predicting Min Utility
Cost
minZ =

mS
c
m
Q
S
m
+

nW
c
n
Q
W
n
s.t. R
k
R
k1

mS
k
Q
S
m
+

nW
k
Q
W
n
=

iH
k
Q
H
ik

jC
k
Q
C
jk
k = 1, , K
Q
S
m
, Q
W
n
, R
k
0, k = 1, , K 1
R
0
= R
K
= 0
Chen CL 10
Transshipment Model: Example
FCp (MW/K) T
in
(K) T
out
(K)
H1 2.5 400 320
H2 3.8 370 320
C1 2.0 300 420
C2 2.0 300 370
HP Steam: 500K, $80/kW yr, LP Steam: 380K, $50/kW yr
CW: 300K, $20/kW yr, Min recovery app temp = 10K
Chen CL 11
min Z = 80000Q
HP
+ 50000Q
LP
+ 20000Q
CW
s.t. R
1
Q
HP
= 60
R
2
R
1
= 10
R
3
R
2
Q
LP
= 15
R
3
+Q
CW
= 75
R
1
, R
2
, R
3
, Q
HP
, Q
LP
, Q
CW
0
Z = $6, 550, 000/yr
Q
HP
= 60, Q
LP
= 5, Q
CW
= 75 MW
R
1
= 0, R
2
= 10, R
3
= 0 (two pinches)
sub-network 1: above 400 390 K
sub-network 2: betwn 400 390 K and 370 360 K
sub-network 3: below 370 360 K
Chen CL 12
Expanded Transshipment Model:
Min Utility Cost with Constrained Matches
Constrained Matches:
too far apart streams, for operational considerations,
Expanded Transshipment Model:
Single overall heat residual R
k
exiting at each temp interval k
individual heat residuals R
ik
, R
mk
for each hot stream i and
each hot utility m that are present at or above that
temp interval k
Dene variable Q
ijk
to denote heat exchange between hot
stream i and cold stream j (and also Q
Sjk
, Q
iWk
)
Chen CL 13
Expanded Transshipment Model for Previous Example
Chen CL 14
Interval k for Expanded Transshipment Model
Chen CL 15
Chen CL 16
The Expanded LP Transshipment Model:
H

k
= {i| hot stream i is present at interval k or at a higher interval}
S

k
= {m| hot utility m is present at interval k or at a higher interval}
Q
ijk
exahange of heat of hot stream i and cold stream j at interval k
Q
mjk
exahange of heat of hot utility m and cold stream j at interval k
Q
ink
exahange of heat of hot stream i and cold utility m at interval k
R
ik
heat residual of hot stream i exiting interval k
R
mk
heat residual of hot utility m exiting interval k
Chen CL 17
minZ =

mS
c
m
Q
S
m
+

nW
c
n
Q
W
n
s.t. R
ik
R
i,k1
+

jC
k
Q
ijk
+

nW
k
Q
ink
= Q
H
ik
i H

k
R
mk
R
m,k1
+

jC
k
Q
mjk
= Q
S
m
m S

iH
k
Q
ijk
+

mS
k
Q
mjk
= Q
C
jk
j C
k

iH
k
Q
ink
= Q
W
n
n W
k
, k = 1, , K
R
ik
, R
mk
, Q
ijk
, Q
mjk
, Q
ink
, Q
S
n
, Q
W
n
0
R
i0
= R
iK
= 0
Q
L
ij

K

k=1
Q
ijk
Q
U
ij
Chen CL 18
Expanded LP Transshipment Model with
Restricted Match: Example
FCp (MW/C) T
in
(C) T
out
(C)
H1 1.0 400 120
H2 2.0 340 120
C1 1.5 160 400
C2 1.3 100 250
Steam: 500
o
C, CW: 20 30
o
C, Min recovery app temp = 20
o
C
Note: match for H1 and C1 is forbidden (Q
112
= Q
113
= 0)
Minimum utility cost Z = $9, 300, 000/yr $15, 300, 000/yr
Heating utility load Q
S
= 60 MW 120 MW
Cooling utility load Q
W
= 225 MW 285 MW
Chen CL 19
Chen CL 20
Prediction of Matches for Minimizing
Number of Units
q subnetworks, K
1
temperature intervals in subnetwork q
y
q
ij
=

1 hot stream i, cold stream j exchange heat

0 hot stream i, cold stream j do not exchange heat
min

iH

jC
y
q
ij
R
ik
R
i,k1
+

jC
k
Q
ijk
= Q
H
ik
i H

k
, k = 1, , K
q

iH
k
Q
ijk
= Q
C
jk
j C
k
K
q

k=1
Q
ijk
U
ij
y
q
ij
0 R
ik
, Q
ijk
0
Chen CL 21
Matches for Minimizing Number of Units:
Example
FCp (MW/C) T
in
(C) T
out
(C)
H1 1.0 400 120
H2 2.0 340 120
C1 1.5 160 400
C2 1.3 100 250
Steam: 500
o
C, CW: 20 30
o
C, Min recovery app temp = 20
o
C
Q
S
= 60, Q
W
= 225 MW
Chen CL 22
Chen CL 23
Chen CL 24
Results:
Above Pinch:
Match Steam-C1 60 MW y
A
S1
= 1, Q
S11
= 30, Q
S12
= 30
Match H1-C1 60 MW y
A
11
= 1, Q
112
= 60
Below Pinch:
Match H1-C1 25 MW y
B
11
= 1, Q
113
= 25
Match H1-C2 195 MW y
B
12
= 1, Q
123
= 117, Q
124
= 78
Match H2-C1 215 MW y
B
21
= 1, Q
213
= 215
Match H2-CW 225 MW y
B
2W
= 1, Q
2W4
= 225
Chen CL 25
Alternative Structure: if let y
B
11
= 0 (forbit H1-C1 below
pinch)
Above Pinch:
Match Steam-C1 60 MW y
A
S1
= 1, Q
S11
= 30, Q
S12
= 30
Match H1-C1 60 MW y
A
11
= 1, Q
112
= 60
Below Pinch:
Match H1-C2 195 MW y
B
12
= 1, Q
123
= 117, Q
124
= 78
Match H2-C1 240 MW y
B
21
= 1, Q
213
= 240
Match H1-CW 25 MW y
B
1W
= 1, Q
1W4
= 25
Match H2-CW 225 MW y
B
2W
= 1, Q
2W4
= 200
Chen CL 26
Chen CL 27
Alternative Structure:
if without partitioning into subnetworks
match H1-C1 is denoted by y
11
, Q
112
+Q
113
220y
11
0
Match Steam-C1 60 MW
Match H1-C1 85 MW
Match H1-C2 195 MW
Match H2-C1 215 MW
Match H2-CW 225 MW
Chen CL 28
Automatic Derivation of Network
Structures
Superstructure of A 1H2C Example
Chen CL 29
Alternatives Embedded in Previous
Superstructure
Chen CL 30
Variables for Superstructure with Two
Matches
Chen CL 31
Objective and Constraints
minC = C
1
A

11
+C
2
A

12
= C
1

Q
11
U
11
[
1
1

1
2
(
1
1
+
1
2
) /2]
1/3

+ C
2

Q
12
U
12
[
2
1

2
2
(
2
1
+
2
2
) /2]
1/3

Mass balance for initial splitter

F
1
+F
2
= F
Chen CL 32
Mass and heat balances for mixers at inlet of two units
F
1
+F
8
F
3
= 0
F
1
T
in
+F
8
T
78
F
3
T
3
= 0
F
2
+F
6
F
4
= 0
F
2
T
in
+F
6
T
56
F
4
T
4
= 0
Mass balances for splitters at outlet of exchangers
F
3
F
6
F
5
= 0 F
4
F
7
F
8
= 0
Heat balances in exchangers
Q
11
F
3
(T
3
T
56
) = 0 Q
12
F
4
(T
4
T
78
) = 0
Chen CL 33
Temperature dierences

1
1
= T
3
t
out
1

1
2
= T
56
t
in
1

2
1
= T
4
t
out
2

2
2
= T
78
t
in
2
Feasibility constraints for temperatures

1
1
,
1
2
,
2
1
,
2
2
T
min
Nonnegativity conditions on heat capacity ow rates
F
j
0 j = 1, , 8
Chen CL 34
Automatic Derivation of Network
Structures: Example
FCp (kW/K) T
in
(K) T
out
(K) h (kW/m
2
K) Cost ($/kW-yr)
H1 22. 440 350 2.0 -
C1 20. 349 430 2.0 -
C2 7.5 320 368 .67 -
S1 500 500 1.0 120
W1 300 320 1.0 20
Min recovery app temp = 1 K
Exchanger Cost = 6, 600 + 670(area)
0.83
Chen CL 35
Chen CL 36
Simultaneous Optimization Model for
Heat Exchanger Network Synthesis
One Problem with 2-Hot-2-Cold Streams
Stream T
in
T
out
FCp (kW/K) h (KW/m
2
K) Cost ($/KW-yr)
H1 650 370 10.0 1.0 -
H2 590 370 20.0 1.0 -
C1 410 650 15.0 1.0 -
C2 353 500 13.0 1.0 -
S1 680 680 5.0 80
W1 300 320 1.0 15
Assume T
min
= 10K, Exchanger cost = $5500 + 150A (area, m
2
)
Chen CL 37
HENS: Simultaneous Optimization
A Typical Stage-wise Superstructure
Chen CL 38
HENS: Simultaneous Optimization
Indices and Sets
i = index for hot process stream
j = index for cold process stream
k = index for superstructure stage
HP = {i|i is a hot process stream}
CP = {j|j is a cold process stream}
HU = {h|h is a hot utility}
CU = {c|c is a cold utility}
ST = {k|k is a stage in the superstructure, [ST] = N
s
or NOK}
Chen CL 39
HENS: Simultaneous Optimization
Parameters
T
in
i
, T
in
j
: inlet temperature of hot (cold) stream i (j)
T
out
i
, T
out
j
: outlet temperature of hot (cold) stream i (j)
F
i
, F
j
: heat capacity ow rate for hot (cold) stream i (j)
T
in
HU
: inlet temperature of hot utility
T
out
HU
: outlet temperature of hot utility
T
in
CU
: inlet temperature of cold utility
T
out
CU
: outlet temperature of cold utility
: upper bound for heat exchange
: upper bound for temperature dierence
C, B : area cost coecient and exponent
CF : xed charge for exchangers
Chen CL 40
HENS: Simultaneous Optimization
Variables
dt
ijk
: temperature approach (TA) for match (i, j) at stage k
dtcu
i
: TA for match of hot stream i and cold utility
dthu
j
: TA for match of cold stream j and hot utility
qcu
i
: heat exchanger between hot stream i and cold utility
qhu
j
: HE between cold stream j and hot utility
q
ijk
: HE between hot stream i, cold stream j, stage k
t
ik
: temperature of hot stream i at hot end of stage k
t
jk
: temperature of cold stream j at hot end of stage k
z
ijk
: {0, 1} denoting existence of match (i, j) in stage k
zcu
i
: {0, 1} denoting cold utility exchanges heat with stream i
zhu
j
: {0, 1} denoting hot utility exchanges heat with stream j
Chen CL 41
HENS: Simultaneous Optimization
Constraints
Overall heat balance for each stream:
(T
in
i
T
out
i
)F
i
=

kST

jCP
q
ijk
+qcu
i
i HP
(T
out
j
T
in
j
)F
j
=

kST

iHP
q
ijk
+qhu
j
j CP
Heat balance at each stage:
(t
ik
t
i,k+1
)F
i
=

jCP
q
ijk
k ST, i HP
(t
jk
t
j,k+1
)F
j
=

iHP
q
ijk
k ST, j CP
Chen CL 42
HENS: Simultaneous Optimization
Constraints
Assignment of superstructure inlet temperature:
T
in
i
= t
i1
T
in
j
= t
j,N
s
+1
Feasibility of temperatures:
t
ik
t
i,k+1
k ST, i HP
t
jk
t
j,k+1
k ST, j CP
T
out
i
t
i,N
s
+1
i HP
T
out
j
t
j1
j CP
Chen CL 43
HENS: Simultaneous Optimization
Constraints
Hot and cold utility load:
(t
i,N
s
+1
T
out
i
)F
i
= qcu
i
i HP
(T
out
j
t
j1
)F
j
= qhu
j
j CP
Logical constraints:
q
ijk
z
ijk
0 i HP, j CP, k ST
qcu
i
zcu
i
0 i HP
qhu
j
zhu
j
0 j CP
z
ijk
, zcu
i
, zhu
j
{0, 1}
Chen CL 44
HENS: Simultaneous Optimization
Constraints
Calculation of approach temperatures:
dt
ijk
t
ik
t
jk
+ (1 z
ijk
) i HP, j CP, k ST
dt
ij,k+1
t
i,k+1
t
j,k+1
+ (1 z
ijk
) i HP, j CP, k ST
dtcu
i
t
i,N
s
+1
T
out
CU
+ (1 zcu
i
) i HP
dthu
j
T
out
HU
t
j1
+ (1 zhu
j
) j CP
dt
ijk
T
min
i HP, j CP, k ST
dtcu
i
T
min
i HP
dthu
j
T
min
j CP
Chen CL 45
Avoid stream splits (optional)

iHP
z
ijk
1 j CP, k ST

jCP
z
ijk
1 i HP, k ST
Chen CL 46
HENS: Simultaneous Optimization
Objective: Minimum Utility Cost
MILP Problem:
min
x
J =

iHP
CCUqcu
i
+

jCP
CHUqhu
j
x

z
ijk
, zcu
i
, zhu
j
,
t
ik
, t
jk
, dt
ijk
, dtcu
i
, dthu
j
,
q
ijk
, qcu
i
, qhu
j
;
i HP, j CP, k ST

Chen CL 47
=

(T
in
i
T
out
i
)F
i
=

kST

jCP
q
ijk
+qcu
i
(T
out
j
T
in
j
)F
j
=

kST

iHP
q
ijk
+qhu
j
(t
ik
t
i,k+1
)F
i
=

jCP
q
ijk
(t
jk
t
j,k+1
)F
j
=

iHP
q
ijk
T
in
i
= t
i,1
T
in
j
= t
j,1
t
ik
t
i,k+1
t
jk
t
j,k+1
T
out
i
t
i,N
s
+1
T
out
j
t
j1
(t
i,N
s
+1
T
out
i
)F
i
= qcu
i
(T
out
j
t
j1
)F
j
= qhu
j
q
ijk
z
ijk
0
qcu
i
zcu
i
0
qhu
j
zhu
j
0
dt
ijk
t
ik
t
jk
+ (1 z
ijk
)
dt
ij,k+1
t
i,k+1
t
j,k+1
+ (1 z
ijk
)
dtcu
i
t
i,N
s
+1
T
out
CU
+ (1 zcu
i
)
dthu
j
T
out
HU
t
j1
+ (1 zhu
j
)
dt
ijk
, dtcu
i
, dthu
j
T
min

Chen CL 48
HENS: Simultaneous Optimization
Objective: Min (Utility + Fixed + Area) Cost
MINLP Problem:
min
x

iHP
CCUqcu
i
+

jCP
CHUqhu
j
+

iHP

jCP

kST
CF
ij
z
ijk
+

iHP
CF
i,CU
zcu
i
+

jCP
CF
j,HU
zhu
j
+

iHP

jCP

kST
C
ij
(A
ijk
)
B
ij
+

iHP
C
i,CU
(A
i,CU
)
B
i,CU
+

jCP
C
j,HU
(A
j,HU
)
B
j,HU
Chen CL 49
where
A
ijk
=
q
ijk
U
ij

(dt
ijk
) (dt
ij,k+1
)

dt
ijk
+dt
ij,k+1
2

1/3
1
U
ij
=
1
h
i
+
1
h
j
Chen CL 50
HENS: Simultaneous Optimization
Optimal Network Structure
155, 000/yr total cost
(71, 400 for utility cost and 83, 600 for capital cost)
Chen CL 51
Simultaneous MINLP Model: Example
FCp (kW/K) T
in
(K) T
out
(K) h (kW/m
2
K) Cost ($/kW-yr)
H1 22. 440 350 2.0 -
C1 20. 349 430 2.0 -
C2 7.5 320 368 .67 -
S1 500 500 1.0 120
W1 300 320 1.0 20
Min recovery app temp = 1 K
Exchanger Cost = 6, 600 + 670(area)
0.83
Chen CL 52
Chen CL 53
Simultaneous MINLP Model: Same
Example with No Stream Splitting