Introduction to Heat Exchanger Network Synthesis

LECTURE SEVEN
054402 Design and Analysis

LECTURE 7: INTRODUCTION TO
HEAT EXCHANGER NETWORK (HEN)
SYNTHESIS
Daniel R. Lewin
Department of Chemical Engineering
Technion, Haifa, Israel
1
DESIGN AND ANALYSIS - (c) Daniel R. Lewin
7 - Intro HEN Synthesis
Schedule Introduction to HEN Synthesis

Unit 1. Introduction: Capital vs. Energy
What is an optimal HEN design
A Simple Example (Class Exercise 1)
Setting Energy Targets
Unit 2. The Pinch and MER Design

The Heat Recovery Pinch
HEN Representation
Class Exercise 2
Unit 3. The Problem Table

Class Exercises 3 and 4
Daniel R. Lewin, Technion
LECTURE SEVEN
Schedule Advanced HEN Synthesis

Unit 4. Loops and Splits
Minimum Number of Units by Loop Breaking

Class Exercise 5
Stream Split Designs
Class Exercise 6
Unit 5. Threshold Problems

Class Exercise 7
Schedule Heat and Power Integration

Unit 6. Data Extraction
Class Exercise 8
Unit 7. Heat Integration in Design
Grand Composite Curve

Heat-integrated Distillation
Heat Engines
Heat Pumps
LECTURE SEVEN
Part One: Objectives

The first part of this three-part Unit on HEN synthesis
serves as an introduction to the subject, and covers:
The pinch
The design of HEN to meet Maximum Energy Recovery (MER)
targets
The use of the Problem Table to systematically compute MER
targets
Instructional Objectives:
Given data on hot and cold streams, you should be able to:
Compute the pinch temperatures
Compute MER targets
Design a simple HEN to meet the MER targets
UNIT 1: Introduction - Capital vs. Energy

The design of Heat Exchanger Networks deals with the
following problem:
Given:
NH hot streams, with given heat capacity flowrate, each having
to be cooled from supply temperature THS to targets THT.
NC cold streams, with given heat capacity flowrate, each having
to be heated from supply temperature T CS to targets TCT.
Design:
An optimum network of heat exchangers, connecting between

the hot and cold streams and between the streams and
cold/hot utilities (furnace, hot-oil, steam, cooling water or
refrigerant, depending on the required duty temperature).
What is optimal?
Implies a trade-off between CAPITAL COSTS (Cost of
equipment) and ENERGY COSTS (Cost of utilities).
6
LECTURE SEVEN
Example
out
out
Steam
Cooling
Water
out
C T
out
Tin
Tin
Tin
Tin
Tout
Tin
Tin
Network for minimal

equipment cost ?
out
Tout
Tout
Steam
Tout
Cooling
Water
Tout
Tin
Network for minimal

energy cost ?
Tin
Tout
Tin
Tout
Tin
Tin
Tin
Numerical Example
150o
150o
100
100
150o
CP = 1.0
300
Cooling
Water (90-110oF)
100
o
CP = 1.0 300
CP = 1.0
Steam (400oF)
100
200o
100
200o
100
200o
300o
500
500
CP = 1.0
CP = 1.0
Design B:
(AREA) = 13.3
Design A:
(AREA) = 20.4
[ A = Q/UTlm ]
150o
500
150o
CP = 1.0
o
CP = 1.0 300
CP = 1.0
CP = 1.0
300
200o
100
300
100
CP = 1.0
200o
100
o
500
500
150o
CP = 1.0
200
500
CP = 1.0
LECTURE SEVEN
Some Definitions
T
T
TS
TT
H
CP
TS
H
= Stream supply temperature (oC)

= Stream target temperature (oC)
= Stream enthalpy (MW)
= m
Cp (MW/ oC)
= Heat capacity flowrate (MW/ oC)
= Stream flowrate specific heat capacity
Tmin
- Example
Tmin = Lowest permissible temperature difference

Which of the two counter-current heat exchangers
illustrated below violates T 20 oF (i.e. Tmin = 20 oF) ?
70o
80o
60o
100o
50o
A
10
60o
100o
40o
B
LECTURE SEVEN
Definitions (Contd)
OK
Exchanger Duty.
Data:
Hot stream CP = 0.3 MW/ oC

Cold stream CP = 0.4 MW/ oC
T1 = 70o
60o
100o
Check: T1 = 40 + (100 - 60)(0.3/0.4) = 70oC ;
40o
OK
Q = 0.4(70 - 40) = 0.3(100 - 60) = 12 MW

Heat Transfer Area (A): A = Q/(UTlm)
Data: Overall heat transfer coefficient, U=1.7 kW/m2 oC
(Alternative formulation in terms of film coefficients)
Tlm = (30 - 20)/loge(30/20) = 24.66
So, A = Q/(UTlm) = 12000/(1.724.66) = 286.2 m2
11
Class Exercise 1
Cond
C1
80
H=100
180
60o
Tmin = 10 oC
R2
H=160
Reb
100o
40o
12
TS
( C)
TT
(oC)
H1
H2
C1
C2
180
130
60
30
80
40
100
120
CP
H
o
C)
(kW/
(kW)
100
1.0
180
2.0
160
4.0
162
1.8
Utilities. Steam@150 oC, CW@25oC
130o
H=180
R1
Stream
120o
H=162
Design a network of steam heaters,

water coolers and exchangers for the
30o process streams. Where possible, use
exchangers in preference to utilities.
LECTURE SEVEN

Cond
C1
180o
60o
Summary of proposed design:
100
80o
R2
60
H
Reb
130o
Steam
CW
Units
60 kW
18 kW
R1
100o
Are 60 kW of Steam
Necessary?
120
o
162
C 18
30o
40o
13
The Temperature-Enthalpy Diagram

T
T
130oC
200oC
40oC
100oC
H=180
One hot stream
14
H=300
H=100
Two hot streams
LECTURE SEVEN
The Temperature-Enthalpy Diagram

CW
Steam
Tmin = 20
10
Steam
120oC
110oC
100oC
CW
30
QCmin = 50
QHmin = 50
70
Correlation between Tmin, QHmin and QCmin

More in, More out! QHmin + x QCmin + x
15
The Composite Curve

Hot Composite Curve
Cond
C1
80
H=100
60
H interval
180oC
180o
CP=1.0
50
130 C
150
80oC
R2
CP=2.0
40oC
80
H=160
Reb
100o
40o
16
180oC
o
120 130 C
130o
H=180
R1
o
H=162
CP=1.0
CP=3.0
150
80oC
30o
40oC
50
CP=2.0
80
LECTURE SEVEN
The Composite Curve (Contd)
Cold Composite Curve
H interval
120oC
H=100
Cond
C1
80
60
180
CP=1.8
100oC
232
60oC
R2
CP=4.0
30oC
H=160
Reb
100o
130o
40
120oC
R1
CP=1.8
100oC
120o
H=180
60 C
30
17
CP=5.8
H=162
36
36
232
54
CP=1.8
30oC
54
The Composite Curve (Contd)

T
Result:
QCmin and QHmin for
desired Tmin
QHmin = 54
48
130oC
100oC
MER Target
80 C
20ooC
T
=
Tmin
min = 10 C
60oC
QQ
Cmin
Cmin==6 12
Here,
hot pinch is at 70 oC,
cold pinch is at 60 oC
QHmin = 48 kW and
QCmin = 6 kW
Method: manipulate hot and cold composite curves until

required Tmin is satisfied.
This defines hot and cold pinch temperatures.
18
LECTURE SEVEN
UNIT 2: The Pinch

QHmin
T
Heat
Source
QHmin
+x
Tmin
Heat
Sink
PINCH
x
QCmin
+x
The pinch separates the HEN problem into two parts:

Heat sink - above the pinch, where at least Q Hmin utility must be
used
Heat source - below the pinch, where at least QCmin utility must be
used.
19
Significance of the Pinch

Do not transfer heat across pinch
Do not use cold utilities above the pinch
Do not use hot utilities below the pinch
Cond
100
Summary of modified design:

R2
C1
Steam
CW
Units
~49 kW
~7 kW
R1
Reb
H 49
111
62
C 7
20
10
LECTURE SEVEN
HEN Representation
Cond
C1
100
o
60 C
180oC
80oC
H1
R2
H2
130oC
100oC
o
100 C
Reb
130oC
H 49
111
R1
120 C
40 C
C 7
49
111
100
40oC
60oC
C1
30 C
C2
62
Where is the pinch ?
30oC
21
C
7
120oC
62
o
80oC
180oC
HEN Representation with the Pinch

Thot
H1
H2
H
Thot
Thot
Tcold
Tcold
Tcold
Tcold
C1
C2
The pinch divides the HEN into two parts:

the left hand side (above the pinch)
the right hand side (below the pinch)
At the pinch, ALL hot streams are hotter than ALL cold
streams by Tmin.
22
11
LECTURE SEVEN
Class Exercise 2
For this network, draw the

grid representation
Given pinch temperatures at
480 oC /460 oC, and MER
targets: QHmin= 40, QCmin=
106, redraw the network
separating the sections above
and below the pinch.
Why is QH > QHmin ?
H2
H1
320o
o
C1 240
o
C2 140
480o
210
100
170
CW
320
CP = 1.0
CP = 1.5
CP
o
480 C
500oC
200 C
1.8
290oC
2.0
240oC
C1
1.0
C2
1.5
320 C
23
500o
290o
200o
CP = 1.8 CP = 2.0
H2
50
116
320oC
H1
140 C
Class Exercise 2 - Solution
24
12
LECTURE SEVEN
Design for Maximum Energy Recovery(MER)

Example
CP
170oC
60 C
3.0
150oC
30oC
1.5
H1
H2
135oC
20oC
C1
2.0
C2
4.0
140 C
80 C
Step 1: MER Targeting.

Pinch at 90o (Hot) and 80o (Cold)
Energy Targets:
Total Hot Utilities:
20 kW
Total Cold Utilities:
60 kW
25
Design for MER (Contd)

Step 2: Divide the problem at the pinch
170oC
H1
3.0
1.5
90 C
90 C
30oC
135oC
80oC
80oC
20oC
140oC
80oC
150 C
CP
60oC
H2
13
90oC
26
90oC
C2
C1
2.0
4.0
LECTURE SEVEN

Step 3: Design hot-end, starting at the pinch:
Pair up exchangers according to CP-constraints.
Immediately above the pinch, pair up streams
such that: CPHOT CPCOLD
(This ensures that TH TC Tmin)
CP
H1
3.0
H2
1.5
C1
2.0
C2
4.0
Tmin
Meets Tmin
Violates
Tminconstraint
constraint
27

Step 3 (Contd): Complete hot-end design, by ticking-off
streams.
CP
H1
QHmin = 20 kW 9
H2
150o
90o
170o
90
135o
140
H
20
80o
90
3.0
80
1.5
C1
2.0
C2
4.0
240
Add heating utilities as needed (MER target)
28
14
LECTURE SEVEN

Step 4: Design cold-end, starting at the pinch:
Pair up exchangers according to CP-constraints.
Immediately below the pinch, pair up streams
such that: CPHOT CPCOLD
(This ensures that TH TC Tmin)
CP
H1
3.0
H2
1.5
C1
Tmin
2.0
Violates
Meets
TT
constraint
constraint
minmin
29

Step 4 (Contd): Complete cold-end design, by ticking-off
streams.
CP
H1
H2
90
60
90o
C
60
80o
35o
90
30o
20o
C1
3.0
1.5
QCmin = 60 kW 9
2.0
30
Add cooling utilities as needed (MER target)
30
15
LECTURE SEVEN

Completed Design:
CP
o
H1
H2
170
90
140
60
90o
150o
135o
H
20
70o
80o
125o
90
35o
90
30
C
60
20o
80o
30o
3.0
1.5
C1
2.0
C2
4.0
240
Note that this design meets the MER targets:

QHmin = 20 kW and QCmin = 60 kW
31

Design for MER - Summary:
n MER Targeting. Define pinch temperatures, Qhmin and QCmin
o Divide problem at the pinch
p Design hot-end, starting at the pinch: Pair up exchangers

according to CP-constraints. Immediately above the pinch, pair up
streams such that: CPHOT CPCOLD. Tick off streams in order to
minimize costs. Add heating utilities as needed (up to Q Hmin). Do
not use cold utilities above the pinch.
q Design cold-end, starting at the pinch: Pair up exchangers
according to CP-constraints. Immediately below the pinch, pair up
streams such that: CPHOT CPCOLD. Tick off streams in order to
minimize costs. Add cooling utilities as needed (up to Q Cmin). Do
not use hot utilities below the pinch.
Done!
32
16
LECTURE SEVEN
Class Exercise 3
Stream
TS
(oC)
TT
(oC)
H1
H2
C1
C2
180
130
60
30
80
40
100
120
CP
H
o
(kW) (kW/ C)
100
1.0
180
2.0
160
4.0
162
1.8
Tmin = 10 oC.
Utilities:
Steam@150 oC, CW@25oC
Design a network of steam heaters,
water coolers and exchangers for
the process streams. Where
possible, use exchangers in
preference to utilities.
CP
180oC
H1
80oC
70oC
40 C
100 C
60oC
60oC
120oC
60oC
30oC
QHmin=48
H2
130 C
33
1.0
2.0
C1
4.0
C2
1.8
QCmin=6
UNIT 3: The Problem Table

Example:
Stream
TS
(oF)
TT
(oF)
(kBtu/h)
(kBtu/h oF)
H1
H2
C1
C2
260
250
120
180
160
130
235
240
3000
1800
2300
2400
30
15
20
40
CP
Tmin = 10 oF.
Step 1: Temperature Intervals
(subtract Tmin from hot temperatures)
Temperature intervals:
250F 240F 235F 180F 150F 120F
34
17
LECTURE SEVEN
UNIT 3: The Problem Table (Contd)

Step 2: Interval heat balances
For each interval, compute:
Hi = (Ti Ti+1)(CPHot CPCold )
H1 H2 C1
Interval
1
2
3
4
5
6
35
C2 Ti Ti+1
250
240
235
180
150
120
10
5
55
30
30
CPHot
CPCold
H i
30
5
15
25
5
300
25
825
750
150
UNIT 3: The Problem Table (Contd)

Step 3: Form enthalpy
cascade.
T1 = 250oF
QH
Assume
QH = 0
Eliminate infeasible
(negative) heat transfer
QH = 500
H = 300
o
Q1
300
800
325
825
-500
250
750
100
600
T2 = 240 F
H = 25
o
Q2
T3 = 235 F
H = -825
o
Q3
T4 = 180 F
H = 750
This defines:
Cold pinch temp. = 180 oF
QHmin = 500 kBtu/h
QCmin = 600 kBtu/h
36
18
Q4
T5 = 150 F
H = -150
T6 = 120oF
QC
LECTURE SEVEN
Class Exercise 4 - Now try again!

Stream
TS
(oC)
TT
(oC)
H1
H2
C1
C2
180
130
60
30
80
40
100
120
CP
H
o
(kW) (kW/ C)
100
1.0
180
2.0
160
4.0
162
1.8
Tmin = 10 oC.
Calculate the Problem Table.
Predict QHmin and QCmin.
Draw the Enthalpy Cascade.
Step 1: Temperature Intervals

(subtract Tmin from hot temperatures)
Temperature intervals:
37
Class Exercise 4 (Contd)

Step 2: Interval heat balances
For each interval, compute:
Hi = (Ti Ti+1)(CPHot CPCold )
Interval
Ti
Ti Ti+1
CPHot
CPCold
Hi
1
2
3
4
5
6
38
19
LECTURE SEVEN
Class Exercise 4 (Contd)

Step 3: Form enthalpy
T
cascade.
QH
Eliminate infeasible
(negative) heat transfer
QH =
Assume
QH = 0
=
H =
Q1
T2 =
H =
Q2
T3 =
H =
Q3
T4 =
H =
This defines:
Cold pinch temp. =
kW
QHmin =
kW
QCmin =
39
Q4
T5 =
oC
H =
QC
QC
T6 =
Introduction to HEN Synthesis - Summary

Unit 1. Introduction: Capital vs. Energy
What is an optimal HEN design
Unit 2. The Pinch and MER Design

The Heat Recovery Pinch
HEN Representation
MER Design: (a) MER Target; (b) Hot- and cold-side designs
Unit 3. The Problem Table

for MER Targeting
Next week: Advanced HEN Synthesis
40
20

Introduction to Heat Exchanger Network Synthesis

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LECTURE SEVEN

054402 Design and Analysis

054402 Design and Analysis

DESIGN AND ANALYSIS - (c) Daniel R. Lewin

7 - Intro HEN Synthesis

Schedule Introduction to HEN Synthesis

Unit 2. The Pinch and MER Design

Unit 3. The Problem Table

DESIGN AND ANALYSIS - (c) Daniel R. Lewin

7 - Intro HEN Synthesis

Daniel R. Lewin, Technion

054402 Design and Analysis

Schedule Advanced HEN Synthesis

Minimum Number of Units by Loop Breaking

Unit 5. Threshold Problems

DESIGN AND ANALYSIS - (c) Daniel R. Lewin

7 - Intro HEN Synthesis

Schedule Heat and Power Integration

Unit 7. Heat Integration in Design

Grand Composite Curve

DESIGN AND ANALYSIS - (c) Daniel R. Lewin

7 - Intro HEN Synthesis

Daniel R. Lewin, Technion

054402 Design and Analysis

Part One: Objectives

DESIGN AND ANALYSIS - (c) Daniel R. Lewin

7 - Intro HEN Synthesis

UNIT 1: Introduction - Capital vs. Energy

An optimum network of heat exchangers, connecting between

DESIGN AND ANALYSIS - (c) Daniel R. Lewin

7 - Intro HEN Synthesis

Daniel R. Lewin, Technion

054402 Design and Analysis

Network for minimal

Network for minimal

DESIGN AND ANALYSIS - (c) Daniel R. Lewin

7 - Intro HEN Synthesis

DESIGN AND ANALYSIS - (c) Daniel R. Lewin

7 - Intro HEN Synthesis

Daniel R. Lewin, Technion

054402 Design and Analysis

= Stream supply temperature (oC)

DESIGN AND ANALYSIS - (c) Daniel R. Lewin

7 - Intro HEN Synthesis

Tmin = Lowest permissible temperature difference

DESIGN AND ANALYSIS - (c) Daniel R. Lewin

7 - Intro HEN Synthesis

Daniel R. Lewin, Technion

054402 Design and Analysis

Hot stream CP = 0.3 MW/ oC

Check: T1 = 40 + (100 - 60)(0.3/0.4) = 70oC ;

Q = 0.4(70 - 40) = 0.3(100 - 60) = 12 MW

DESIGN AND ANALYSIS - (c) Daniel R. Lewin

7 - Intro HEN Synthesis

Utilities. Steam@150 oC, CW@25oC

Design a network of steam heaters,

DESIGN AND ANALYSIS - (c) Daniel R. Lewin

7 - Intro HEN Synthesis

Daniel R. Lewin, Technion

054402 Design and Analysis

Setting Energy Targets

Summary of proposed design: