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4.1 Introduction
Heat integration is a technique in designing a process to reduce the consumption of energy as
well as to maximize heat recovery. This chapter focuses on the heat integration work done
based on the design of the plant. Heat integration is done using pinch technology which enables
process designers to determine the best arrangement of heat exchange to achieve maximum
heat recovery. Once the pinch is determined, the hot and cold utilities are calculated, and the
heat exchanger network is drafted on the process flow diagram.
Pinch technology establishes a temperature difference, designated as the pinch point, which
separates the overall operating temperature region observed in the process into two temperature
regions. Once the pinch point is identified, heat from external sources that must be supplied to
the process at temperatures above the pinch whereas heat removed from the process by cooling
media at temperatures below the pinch can all be determined. This analysis approach
maximizes heat recovery in the process with the establishment of a heat exchanger network.
After the analysis, an engineer must decide on the trade-off between the energy recovered and
the capital cost involved in the heat recovery system in order to maximize economic potential.
The objective of pinch technology is to develop a heat exchanger network (HEN) in a plant to
optimize the use of energy, thus minimizing the operating cost. The concepts behind pinch
technology that should be abided when performing pinch design are:
1. Common values of ΔTmin in the industry:
a) Oil refining = 20 – 40°C
b) Petrochemical = 10 – 20°C
c) Chemical = 10 – 20°C
d) Low temperature processes = 3 – 5°C
2. The minimum heating requirement, ǪHmin and minimum cooling requirement, ǪCmin
and the pinch temperature are determined from the cascade diagram.
3. When performing pinch design, there are two pinches known as above pinch, the
Cp,cold should always be greater than or equivalent to Cp,hot. Do the same vice-versa
for below pinch design. The stream pairing should always start with the biggest Cp
value.
4. Comparison of utility consumption before and after maximum energy recovery (MER)
is done in order to determine the MER efficiency (Towler & Sinnott, 2013)
This step is essential as it provides the data required for the following step which is to construct
the temperature interval diagram. The table below shows the data acquired from the shifting of
stream table.
Table 4.2 Shifted stream table
COLD HOT
Temperature
(celcius) E-101 E-104 E-107 E-106 E-107 E-109 E-110 E-102 E-103 E-105 COLD HOT COLD - HOT SURPLUS/DEFICIT
410 22.26
0 2960.01 -2960.008459
277 7.14
0 1969.51 -1969.512081 SURPLUS
210
727 1322.81 -595.8066216 SURPLUS
165 16.16
0 29.3957 -29.3957027 SURPLUS
164 8.46
0 530.047 -530.0467128 SURPLUS
150
0 189.302 -189.3023974 SURPLUS
145
107.933 378.605 -270.6720676 SURPLUS
135 3.2
97.1395 369.544 -272.4048609 SURPLUS
126 0.6
215.865 833.21 -617.3441352 SURPLUS
106 2.32
388.558 1583.22 -1194.659443 SURPLUS
70
107.933 439.783 -331.8498454 SURPLUS
60
64.7596 260.27 -195.5099072 SURPLUS
54 2.69
43.1731 175.002 -131.828827 SURPLUS
50
59.3746 218.752 -159.3777838 SURPLUS
45
59.3746 153.602 -94.22778381 SURPLUS
40
59.3746 42.3239 17.05072971 DEFICIT
35 10.79
102.757 804.154 -701.3970446 SURPLUS
-60
97.3485 0 97.3485 DEFICIT
4.2.2.6 Construction of Cascade Diagram
The cascade diagram is illustrated in Figure 4.3. The net amount of energy in each temperature
interval is presented in the previous step. If there is excess energy in a given temperature
interval, this energy can be cascaded down to the next temperature level. The heat flow showed
in this cascade diagram has to be positive throughout the course, if negative value is present
along the cascade diagram, normalization is required to convert the negative flow to positive
flow.
Temperature COLD - HOT (kW) Normalize (kW)
(oC)
410 0
-2960.008459
277 2960.008459
-1969.512081
210 4929.520541
-595.8066216
165 5525.327162
-29.3957027
164 5554.722865
-530.0467128
150 6084.769578
-189.3023974
145 6274.071975
-270.6720676
135 6544.744043
-272.4048609
126 6817.148904
-617.3441352
106 7434.493039
-1194.659443
70 8629.152482
-331.8498454
60 8961.002328
-195.5099072
54 9156.512235
-131.828827
50 9288.341062
-159.3777838
45 9447.718846
-94.22778381
40 9541.94663
17.05072971
35 9524.8959
-701.3970446
-60 10226.29294
97.3485
-150 10128.94444
1
𝑇ℎ𝑜𝑡 𝑝𝑖𝑛𝑐ℎ = 𝑃𝑖𝑛𝑐ℎ 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 + ∆𝑇𝑚𝑖𝑛 Eq. 4.4
2
1
𝑇𝑐𝑜𝑙𝑑 𝑝𝑖𝑛𝑐ℎ = 𝑃𝑖𝑛𝑐ℎ 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 − ∆𝑇𝑚𝑖𝑛 Eq. 4.5
2
Figure 4.5 illustrates the heat integration performed on heat exchanger network of Liquid
Fuel production plant which obeys the stated rules of thumb.
HEAT DUTY,kW EQUIPMENT PINCH POINT Cp, kW/k
30.3781
30.3781 E-106 45 C 54 420 3.42
39.596
39.596 E-107 60 C 126 420 0.6
287.765
287.765 E-109 45 C 135 420 3.2
1657.31
1657.31 E-110 45 C 277 420 7.14
6320.35 kW
8234.61 E-102 50 C 420 22.2557
1679.78 kW
1896.11 E-103 -50 C 174 420 8.464777
83.44
83.44 E-105 80 C 116 420 2.317778
Table 4.4 Summary of heat equipment duties before and after HEN
Table 4.5 shows that 100.00% and 16.74% of energy are saved from hot and cold utilities
respectively.
All sizing affected by the newly proposed HEN were revised and re-updated for all
equipment. The latest process flow diagram after heat exchanger network analysis has been
done can give a better heat recovery, and will minimum consumption and cost of hot and cold
utilities.