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HEAT INTEGRATIONS
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Learning Outcomes
After studying this topic, participants should be able to:
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• This topic will cover:
– 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
A Short Bibliography...
• Early pioneers:
– Rudd@Wisconsin (1968)
– Hohmann@USC (1971)
• Central figure:
– Linnhoff@ICI/UMIST (1978)
– Currently: President, Linnhoff-March
• Recommended texts:
– Seider, Seader and Lewin (1999): Process Design Principles,
Wiley and Sons, NY
– Linnhoff et al. (1982): A User Guide on Process Integration for the
Efficient Use of Energy, I. Chem. E., London
• Most up-to-date review:
– Gundersen, T. and Naess, L. (1988): “The Synthesis of Cost
Optimal Heat Exchanger Networks: An Industrial Review of the
State of the Art”, Comp. Chem. Eng., 12(6), 503-530
Introduction - Capital vs. Energy
• The design of HEN for heat integration deals with the following problem:
• Given:
• Number of hot streams (NH), with given heat capacity flowrate (C=mCp),
each having to be cooled from supply temperature THS to targets THT.
• Number of cold streams (NC), with given heat capacity flowrate (C),
each having to be heated from supply temperature TCS 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).
A Distillation Train –
Design Without Process/Heat Integration
Inspect scope for energy saving
through heat recovery/integration...
A stream
that needs
cooling
KEY
NO. OF HEATERS = 3
NO. OF COOLERS = 2
A stream
that needs
heating
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A Heat Recovery/Integration Problem
Consider heat exchange between the process streams to save hot utility
(steam) and cold utility (cooling water).
Some Definitions
T
ΔH = mCpΔT
= mCP (Tt - Ts)
A Heater - Use Medium Pressure Steam = 2.0 (130°C - 40 °C)
= 180 MW
(release/given/donate heat)
Note: This example only involves heat, and Cp is constant
How Much Cooling Is Needed?
Q = mCpΔT
= mCP (Tt - Ts)
= 1.0 (50°C - 200 °C)
A Cooler - Use Cooling Water = -150 MW
(adsorbs/receive/require heat)
Heat Exchange Between Process Streams
KEY
NO. OF HEATERS = 1
NO. OF COOLERS = 0
Many
Hot
Streams
Many
Cold
Streams
Heat Exchanger Network
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Tout Tout Tout Steam
Cooling Without heat integration.
H H H Water
Tin C T
out Auxiliary network of
HEX for minimal
Tin
C Tout equipment cost ?
Tin C Tout
Tin Tin Tin
Tout Tout Tout Steam
Cooling
Water
Tin Tout
With heat integration. Tin
Tout
Interior network of
Tin Tout
HEX for minimal
energy cost ? Tin Tin Tin
Numerical Example
150o 150o 150 o Steam (400oF)
Cooling Design I:
Water (90-110oF)
o
100 100 100
Area= 20.4
CP = 1.0 300 100 200o
300o
CP = 1.0 100 200o
300o
CP = 1.0 100 200o
150o 150o 150o
0 0 0
50 50 50
CP = 1.0 CP = 1.0 CP = 1.0
o
CP = 1.0 300 100 200o
300o
CP = 1.0 100 200o
300o
CP = 1.0 100 200o
Pinch Technology!!
Pinch Technology
HEN Design;
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steam = 1722 MW
cooling = 654 MW
water
FLASH
5
6 number of unit = 6
FEED 3 2
PRODUCT
Pinch design (with MER targets),
REACTOR Targets
RECYCLE achieved
4 steam = 1068 MW
cooling
FLASH
1 = 0 MW
water
number of unit = 4
2
3
FEED PRODUCT
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Consider the following streams
C1
120oF 235oF
C2
180oF 240oF
H1
160oF 260oF
H2
130oF 250oF
104 Btu/hr.oF
C1 120 235 2 230
C2 180 240 4 240
H1 260 160 3 300
H2 250 130 1.5 180
6 HEX
(3 interior HEX and
3 auxiliary HEX)
Qsteam = 30+27.5
= 57.5x104Btu/hr
QCW = 67.5x104Btu/hr
Note,
Q = Qsteam-QCW
=10x104Btu/hr
So, does not violate 1st Law.
Questions:
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Method 1 : In total with 9 steps to be discussed . . . .
Step 1: Arbitrarily adjust Ts and Tt using Δtmin. This is to
avoid temperature violation of Δtmin in the subsequent
calculations. Here adjustment is by reducing only the hot
streams temperature by Δtmin=10oF
adjusted adjusted
C1 120 120 235 235
C2 180 180 240 240
H1 260 250 160 150
H2 250 240 130 120
Stream Ts(oF) Ts(oF) Tt(oF) Tt(oF)
adjusted adjusted
C1 120 120 235 235
C2 180 180 240 240
H1 260 250 160 150
H2 250 240 130 120
250=T0
240=T1 Interval 1=T0-T1=250-240
240
235=T2 Interval 2=T1-T2=240-235
180=T3 Interval 3=T2-T3=235-180
150=T4 Interval 4=T3-T4=180-150
120=T5 Interval 5=T4-T5=150-120
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Step 3: Identify streams within each interval.
Streams in this interval
250oF
Interval 1=T0-T1=250-240 Only H1
240
Interval 2=T1-T2=240-235 H1, H2,C2
235
180
Interval,i ΔT (ΣCh-ΣCc) ΔH
104Btu/hr.oF 104Btu/hr
1 (250-240) 10 3 30
4 (180-150) 30 3+1.5-2=2.5 75
e.g. R1=ΔH1+Qsteam
R2=ΔH2+R1
Step 6:
Set Qsteam equal the
largest negative residual
i.e. add energy at T>250oF using
low pressure steam
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So, MER targets:
Qsteam = 57.5x104Btu/hr
QCW = 67.5x104Btu/hr
1 250-260 3 30 240-250 0 0
2 245-250 3+1.5 22.5 235-240 4 20
3 190-245 3+1.5 247.5 180-235 4+2 330
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Revisit our previous example
Let’s start designing the HEN on Hot side Cold side
the hot side starting at pinch (Cc≥ Ch )
and working outwards.
Matching H1:
Since CH1=3, the only choice of cold
stream is C2 where CC2 = 4.
Matching H2:
Since CH2=1.5, we could use
stream C1 where CC1 = 2.
Note: 2(235-225)=20
Matching C1:
Since CC1=2, the only choice of hot
stream is H1 where CH1 = 3.
Note: 1.5(170-130)=60
Stream matching is
complete!
Complete stream matching at MER
Cold side
HEN after stream matching at MER
THANK YOU
Note:
For system involving phase change and variable
heat capacity see example 10.5.
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Tutorial/Assignment
The following figure is proposed for HEN between four
streams. Determine if the network has the minimum utility
requirements. If not, design a network with the minimum
utility requirements. Use ΔTmin=20 for all HEX.
H2(C=8KW/oC) H1 (C=2.5KW/oC)
90oC 150oC
25oC 70oC 100oC
C2 1 2
(C=3KW/oC)
135KW 90KW
73.125oC 114C
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THANK YOU
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