Bag A Jew I CZ Heat Integration

PART 1
PINCH AND MINIMUM UTILITY USAGE
WHAT IS THE PINCH?

The pinch point is a temperature. Typically, it divides the temperature range into two regions. Heating utility can be used only above the pinch and cooling utility only below it.
WHAT IS A PINCH DESIGN

A heat exchanger network obtained using the pinch design method is a network where no heat is transferred from a hot stream whose temperature is above the pinch to a cold stream whose temperature is below the pinch.
IS PINCH TECHNOLGY CURRENT?

YES and NO. It is a good first approach to most problems. Pinch technology is at the root of many other heat integration technologies. It is impossible to understand them without the basic concepts of pinch technology.
TEMPERATURE-ENTHALPY (T-H) DIAGRAMS

Assume one heat exchanger. These are alternative representations T
H,in
TC,in
TC,out
TH,in TC,out
TH, out TH,in TH, out TH, out
TC,in
Slopes are the inverse of F*Cp. Recall that Q=F Cp T
TC,out Q
TC,in
T-H DIAGRAMS
Assume one heat exchanger and a heater
TH,in
TC,in
Q TH, out
QH
TC,out
TH,in TC,out
TH, out TH,in TH, out
TC,in
H QH
TC,out
H QH
TC,in Q
T-H DIAGRAMS
Assume one heat exchanger and a cooler
TH,in
TC,in
TC,out T TH,in TC,out
QC TH, out TH,in C

QC
TH, out TH, out
TC,in
H
TC,out Q
TC,in
QC
T-H DIAGRAMS
Two hot-one cold stream
TH1,in TH2,in Q1 TH2,out TH1,in TH2,in TH1,out TH2, out Q2 TC,out
TC,in
T TH1,in
TH2,in
TH2,out TH1,out
TC,out TH2,out
TC,in
H Q2
TC,out
Q2 Q1
TC,in
Q1
Notice the vertical arrangement of heat transfer
T-H DIAGRAMS
Composite Curve
Obtained by lumping all the heat from different streams that are at the same interval of temperature.
T T
Remark: By constructing the composite curve we loose information on the vertical arrangement of heat transfer between streams
T-H DIAGRAMS
Moving composite curves horizontally
T T
Cooling
Heating
Smallest T H Smallest T H
TH1,in TC,in
Q1
TH2,in
Q2
TH1,in
Q1
QC
TH2,in
Q2
QH
TC,in
TC,out
TC,out
TH1,out TH2,out
TH2,out TH1,out
T-H DIAGRAMS
T
Moving the cold composite stream to the right

Cooling Heating Increases heating and cooling BY THE SAME AMOUNT Increases the smallest T Decreases the area needed A=Q/(U* T ) Notice that for this simple example the smallest T takes place in the end of the cold stream
Smallest T TC,in
TH1,in
Q1
QC
TH2,in
Q2
QH
TC,out
TH2,out TH1,out
T-H DIAGRAMS
T
Cooling Heating
In general, the smallest T can take place anywhere. We call the temperature at which this takes place THE PINCH.
H
TEMPERATURE-ENTHALPY DIAGRAMS
T
Cooling
Heating
H
From the energy point of view it is then convenient to move the cold stream to the left. However, the area may become too large. To limit the area, we introduce a minimum approach Tmin
GRAPHICAL PROCEDURE
Fix Tmin Construct the hot and cold composite curve Draw the hot composite curve and leave it fixed Draw the cold composite curve in such a way that the smallest T=Tmin The temperature at which T=Tmin is the PINCH The non-overlap on the right is the Minimum Heating Utility and the non-overlap on the left is the Minimum Cooling Utility
HANDS ON EXERCISE
H=27 MW T=140 0C T=230 0C REACTOR 2 T=200 C
0
H=-30 MW T=80 0C
H=32 MW T=20 0C REACTOR 1 T=180 0C
H=-31.5 MW T=40 0C
T=250 0C
Stream
Reactor 1 feed Reactor 1 product Reactor 2 feed Reactor 1 product Tmin=10 oC
Type
Cold Hot Cold Hot
Supply T
(oC) 20 250 140 200
Target T
(oC) 180 40 230 80
H
(MW) 32.0 -31.5 27.0 -30.0
F*Cp
(MW oC-1) 0.2 0.15 0.3 0.25
Answer: Hot Streams

250
FC p= 0.2 5
p=0 .
250 200
p FC .4 =0
15
200
FCp=0.15
FC
80 40 31.5 30
H
80 40 FCp=0.15 6 48 7.5 H
Answer: Cold Streams

230 180 140
p C F
=0 .2
.3 0 =
230 180 140

FC p= 0.2
0.5 = Cp
.3 0 p= C F
20 32 27
H
FC p
20 24 20 15
H
Answer: Both Curves Together.

250 230 200 180 140 80 40 20 10 51.5 7.5
H
Pinch
T= Tmin
Important observation: The pinch is at the beginning of a cold stream or at the beginning of a hot stream.
UTILITY COST vs. Tmin

There is total overlap for some values of Tmin
T
COST
Utility
T
TOTAL OVERLAP
Tmin
PARTIAL OVERLAP
Note: There is a particular overlap that requires only cooling utility
PROBLEM TABLE
Composite curves are inconvenient. Thus a method based on tables was developed. STEPS:
1. 2. 3. 4. Divide the temperature range into intervals and shift the cold temperature scale Make a heat balance in each interval Cascade the heat surplus/deficit through the intervals. Add heat so that no deficit is cascaded
PROBLEM TABLE
We now explain each step in detail.
Consider the example 1.1
Stream
Type
Cold Hot Cold Hot
Supply T
(oC)
Target T
(oC)
H
(MW)
F*Cp
(MW oC-1)
20 250 140 200
180 40 230 80
32.0 -31.5 27.0 -30.0
0.2 0.15 0.3 0.25
PROBLEM TABLE
1.
250 230 200 180 140 80 40 20 Hot streams Cold streams
Divide the temperature range into intervals and shift the cold temperature scale
250 240 200 190 150
80 40 30 Hot streams Cold streams
Now one can make heat balances in each interval. Heat transfer within each interval is feasible.
PROBLEM TABLE
2. Make a heat balance in each interval. (We now turn into a table format distorting the scale)
Tinterval
250 F Cp=0.15 240 200 190 150 80 40 30 Hot streams F Cp=0.2 Cold streams F Cp=0.3 F Cp=0.25 10 40 10 40 70 40 10
Hinterval
1.5 - 6.0 1.0 -4.0 14.0 -2.0 - 2.0
Surplus/Deficit?
Surplus Deficit Surplus Deficit Surplus Deficit Deficit
PROBLEM TABLE
3.
1.5
Cascade the heat surplus through the intervals. That is, we transfer to the intervals below every surplus/deficit.
1.5
- 6.0
1.0
This interval has a surplus. It should transfer 1.5 to interval 2. This interval has a deficit. After using the 1.5 cascaded it transfers 4.5 to interval 3.
1.5 - 6.0 -4.5 1.0 -3.5 -4.0 -7.5 14.0 6.5
The largest deficit transferred is -7.5. Thus, 7.5 MW of heat need to be added on top to prevent any deficit to be transferred to lower intervals
-4.0
14.0
- 2.0
-2.0 4.5
-2.0
- 2.0 2.5
PROBLEM TABLE
4. Add heat so that no deficit is cascaded.
7.5 1.5 1.5 - 6.0 -4.5 1.0 -3.5 -4.0 -7.5 14.0 6.5 -2.0 4.5 -2.0 2.5 -2.0 10.0 -2.0 12.0 14.0 14.0 -4.0 0.0 1.0 4.0 - 6.0 3.0 1.5 9.0
This is the minimum heating utility This is the position of the pinch
This is the minimum cooling utility
IMPORTANT CONCLUSION
7.5 +
DO NOT TRANSFER HEAT ACROSS THE PINCH

THIS IS A GOLDEN RULE OF PINCH TECHNOLOGY. WE WILL SEE LATER HOW THIS IS RELAXED FOR DIFFERENT PURPOSES WHEN THIS HAPPENS IN BADLY INTEGRATED PLANTS THERE ARE HEAT EXCHANGERS WHERE SUCH TRANSFER ACROSS THE PINCH TAKES PLACE
1.5 9.0 + - 6.0 3. 0 + 1.0 4. 0 + -4.0 0. 0 + 14.0 14. 0 + -2.0 12. 0 + -2.0 10. 0 +
Heating utility is larger than the minimum
Heat is transferred across the pinch

Cooling utility is larger by the same amount
PROBLEM TABLE
Heating utility of smaller temperature.
7.5 1.5 9.0 - 6.0 3.0 1.0 4.0 -4.0 0.0 14.0 14.0 -2.0 12.0 -2.0 10.0 -2.0 10.0 -2.0 12.0 14.0 14.0 -4.0 0.0 1.0 1.0 + 3.0 - 6.0 0.0 1.5 1.5 + 4.5 0.0
Heating utility at the largest temperature is now zero.
These are the minimum values of heating utility needed at each temperature level.
MATHEMATICAL MODEL
0
q1 q2
1
Let q i be the surplus or demand of heat in interval i . It is given by:
qi =
k iH
H k
cp kH (Ti 1 Ti )
siC
C s
cp sC (Ti 1 Ti )
The minimum heating utility is obtained by solving the following linear programming (LP) problem
qi qi+1
i i+1
S min = Min 0 s. t
i = i 1 + q i i 0
i = 1,... mI
qn
n
PART 2
TOTAL AREA TARGETING

In this part we will explore ways to predict the total area of a network without the need to explore specific designs. Because A=Q/(U*Tml), one can calculate the area easily in the following situation.
T TH1 TC2 TH2
Tml=
(TH1-TC2)-(TH2-TC1) ln (TH1-TC2) (TH2-TC1)
TC1
H
Q

Since area=Q/(U Tml), the composite curve diagram provides one way of estimating the total area involved. Isolate all regions with a pair of straight line sections and calculate the area for each.
T
Heating utility, steam or furnace.
Cooling water
A1 A2 A3 A4 A5 A6
The above scheme of heat transfer is called VERTICAL HEAT TRANSFER
EXERCISE
Calculate the values of Q in each interval and estimate the corresponding area. Use U= 0.001 MW m-2 oC
T
Furnace (300 oC)
250 230 200 180 Pinch 140 80 40 20

H
T= Tmin
Obtain the total area estimate
Cooling Water
Q1 Q2
Q3
Q4
Q5 Q6
EXERCISE
COMPOSITE CURVE
300 250 200
Furnace (300 oC)
II
III
IV V
T= Tmin
Pinch Cooling Water
T, C
150 100 50 0 0 10 20 30 40 50 60
VI
70
80
90
Q, MW
HOT COLD
Units: Q= MW T=
oC
A= m2
Interval I II III IV V VI
Q
6 4 24 20 7.5 7.5
TH1 80 90 150 200 250 300
TH2 40 80 90 150 200 250
TC1 15 20 20 140 180 205
TC2 20 30 140 180 205 230
EXERCISE
Interval
I II III IV V VI
Q
6 4 24 20 7.5 7.5
TH1
80 90 150 200 250 300
TH2
40 80 90 150 200 250
TC1
15 20 20 140 180 205
TC2
20 30 140 180 205 230
Tml
40.0 60.0 30.8 14.4 30.8 81.9
A
150.1 66.7 778.4 1386.3 243.3 91.6 2716.3
Total Area
Units: Q= MW
T= oC
, A=
m2
U= 0.001 MW m-2 oC

Drawbacks Fixed costs associated with the number of units are not considered.
We will see later how the number of units can be calculated
QUESTIONS FOR DISCUSSION

Is the total area predicted this way, realistic? That is, is it close enough to a value that one would obtain in a final design? Is the estimate, realistic or not, conservative? That is, is it larger than the one expected from a final design? How complex is a design built using the vertical transfer?
ANSWERS
Is the total area predicted this way, realistic? That is, is it close enough to a value that one would obtain from a final design?
YES, Within 10-15%
ANSWERS
Is the estimate, realistic or not, conservative? That is, is it larger than the one expected from a final design?
The area obtained is actually the minimum area needed to perform the heat transfer.
ANSWERS
How complex is a design built using the vertical transfer?
Very Complex. Take for example interval 4. There are four streams in this interval.
Stream (MW
oC-1)
Type
Supply T
Target T (oC) (oC) 180 150 180 150
F*Cp (MW) 8.0 0.2 0.15 0.3 0.25
Reactor 1 feed Reactor 1 product Reactor 2 feed Reactor 1 product
Cold Hot Cold Hot
140 200 140 200
-7.5 12.0 -12.5
This implies at least three heat exchangers, just in this interval.
HEAT EXCHANGER NETWORK

300 40 80 90 150 200 250 300
FCp=0.16
FCp=0.09
R1 prod, FCp=0.15
R2 prod, FCp=0.25
FCp=0.1875
R1 feed, FCp=0.2 R2 feed, FCp=0.3

FCp=0.1125
I 15 20
II 30 20
III 140
IV
VI
180 205 230
HEAT EXCHANGER NETWORK

40 80 90 150 200 250 300 300 R1 prod, FCp=0.15
FCp=0.16
R2 prod, FCp=0.25
20
FCp=0.075
R1 feed, FCp=0.2
R2 feed, FCp=0.3
FCp=0.1125
I 15 20
II 30
III 140
IV
VI
180 205 230
TOTAL= 10 Exchangers
Called Spaghetti design
PREDICTING THE NUMBER OF UNITS

We can anticipate very simply how many exchangers we should have!!! Consider the following warehouses, each containing some merchandise that needs to be delivered to the row of consumer centers. What is the minimum number of trucks needed?
Warehouses
30
50
17
Consumer Centers
25
16
56
ANSWER
You need five trucks, possibly less in some other cases. Here is how you solve the problem specifically.
30
50
17
25
11
39
17
25
16
56
The general answer is N=S-1 . When does one need less?
ANSWER
When there is an exact balance between two streams or a subset of streams.
25 55 17
25
16
39
17
25
16
56
The general answer is N=S-P . P is the number of independent subsystems. (Two in this case)
GENERAL FORMULA FOR UNIT TARGETING

Nmin= (S-P)above pinch+ (S-P)below pinch
If we do not consider two separate problems, above and below the pinch we can get misleading results.
SUPERTARGETING
Economy of the system is dependent on Tmin
COST Total Utility Capital
Optimum
Tmin
SPECIAL CASES
There is total overlap for some values of Tmin
T
COST
Total Utility
T
TOTAL OVERLAP
Capital
H
PARTIAL OVERLAP
Tmin Note: There is a particular overlap that requires only cooling utility
PART 3
DESIGN OF MAXIMUM ENERGY RECOVERY NETWORKS
MER NETWORKS
Networks featuring minimum utility usage are called MAXIMUM ENERGY RECOVERY (MER) Networks.
PINCH DESIGN METHOD

RECALL THAT No heat is transferred through the pinch. This makes the region above the pinch a HEAT SINK region and the region below the pinch a HEAT SOURCE region.
Heat Sink
Heat is obtained from the heating utility
7.5 1.5 9.0 -6.0 3.0 1.0 4.0 -4.0 0.0 14.0 14.0 -2.0 12.0
Minimum heating utility
Pinch
H
-2.0
Heat Source
Heat is released to cooling utility
10.0
Minimum cooling utility
CONCLUSION
One can analyze the two systems separately, that is, Heat exchangers will not contain heat transfer across the pinch.
PINCH MATCHES
Consider two streams above the pinch
TH,in Tp TC,out= Tp- Tmin + Q/FCpC TH,in= Tp+Q/FCpH But TH,in> TC,out+ Tmin.
Q/FCpH > Q/FCpC
Thus replacing one obtains TC,out

Q
Tp- Tmin
FCpH < FCpC
Golden rule for pinch matches above the pinch.
Tmin
Tmin
Violation when FCpH > FCpC
PINCH MATCHES
Consider two streams below the pinch
Tp TH,out TC,in= Tp- Tmin - Q/FCpC TH,out= Tp-Q/FCpH But TH,out> TC,in + Tmin.
Thus replacing one obtains Tp- Tmin

Q
TC,in
FCpC < FCpH
Golden rule for pinch matches below the pinch.
Tmin
Tmin
Violation when FCpC > FCpH
CONCLUSION
Since matches at the pinch need to satisfy these rules, one should start locating these matches first. Thus, our first design rule:
START BY MAKING PINCH MATCHES
QUESTION
Once a match has been selected how much heat should be exchanged?
ANSWER
As much as possible! This means that one of the streams has its duty satisfied!! THIS IS CALLLED THE
TICK-OFF RULE
HANDS ON EXERCISE
H=27 MW T=140 0C T=230 0C REACTOR 2 T=200 H=32 MW T=20 0C REACTOR 1 T=180
0C 0C
H=-30 MW T=80 0C
H=-31.5 MW T=250 0C T=40 0C
Stream
Type
Cold Hot Cold Hot
Supply T
(oC) 20 250 140 200
Target T
(oC) 180 40 230 80
H
(MW) 32.0 -31.5 27.0 -30.0
F*Cp
(MW oC-1) 0.2 0.15 0.3 0.25 PINCH=150 oC
HANDS ON EXERCISE
FCp=0.15 FCp=0.25 H1 H2 180 0C 230 0C 140 0C 250 0C 200 0C 150 0C 40 0C 80 0C
FCp=0.2 FCp=0.3
20 0C
C1 C2
Stream
Type
Cold Hot Cold Hot
Supply T
(oC) 20 250 140 200
Target T
(oC) 180 40 230 80
H
(MW) 32.0 -31.5 27.0 -30.0
F*Cp
(MW oC-1) 0.2 0.15 0.3 0.25 PINCH=150 oC
ABOVE THE PINCH

FCp=0.15 FCp=0.25 H1 H2 250 0C 200 0C 150 0C
180 0C FCp=0.2 FCp=0.3 230 0C 140 0C
C1 C2
Which matches are possible?
ANSWER (above the pinch)

FCp=0.15 FCp=0.25 H1 H2 250 0C 200 0C 150 0C
FCp=0.2 FCp=0.3
180 0C C1 230 0C 140 0C C2
The rule is that FCpH < FCpC . We therefore can only make the match H1-C1 and H2-C2.
ANSWER (above the pinch)

FCp=0.15 FCp=0.25 H1 H2 250 0C 200 0C 203.3 0C 150 0C
FCp=0.2 FCp=0.3 230 0C
180 0C 181.7 0C 12.5 C1 8 140 0C C2
The tick-off rule says that a maximum of 8 MW is exchanged in the match H1-C1 and as a result stream C1 reaches its target temperature. Similarly 12.5 MW are exchanged in the other match and the stream H2 reaches the pinch temperature.
BELOW THE PINCH

FCp=0.15 FCp=0.25 H1 H2 150 0C 40 0C 80 0C
FCp=0.2
140 0C
20 0C
C1
Which matches are possible?

The rule is that FCpC < FCpH . Thus, we can only make the match H2-C1
ANSWER (below the pinch)

FCp=0.15 FCp=0.25 H1 H2 150 0C 40 0C
80 0C
FCp=0.2
140 0C 17.5
52.5 0C
20 0C
C1
The tick-off rule says that a maximum of 17.5 MW is exchanged in the match H2-C1 and as a result stream H2 reaches its target temperature.
COMPLETE NETWORK AFTER PINCH MATCHES

FCp=0.15 H1 H2 250 0C 203.3 0C 150 0C 40 0C
FCp=0.25
200 0C
80 0C
FCp=0.2 FCp=0.3 230 0C
180 0C 181.7 0C 12.5 8 140 0C
140 0C 17.5 C2
52.5 0C 20
0C
C1
Streams with unfulfilled targets are colored.
WHAT TO DO NEXT?
FCp=0.15 H1 250 0C 203.3 0C 150 0C 40 0C FCp=0.25 H2 200 0C 80 0C
FCp=0.2 FCp=0.3 230

0C
180 0C 181.7 0C 12.5 8 140 0C
140 0C 17.5 C2
52.5 0C 20 0C
C1
Away from the pinch, there is more flexibility to make matches, so the inequalities do not have to hold. The pinch design method leaves you now on your own!!!!! Therefore, use your judgment as of what matches to select!!
ANSWER
FCp=0.15 H1 250 0C 203.3 0C 150 0C 40 0C FCp=0.25 H2 200 0C 80 0C
FCp=0.2 FCp=0.3 230 0C
180 0C 181.7 0C 12.5 8 140 0C
140 0C 17.5 C2
52.5 0C 20
0C
C1
We first note that we will use heating above the pinch. Thus all hot streams need to reach their inlet temperature. We are then forced to look for a match for H1. Please locate it.
ANSWER
The match is H1-C1. We finally put a heater on the cold stream
FCp=0.15
H1
250 0C
150 0C
40 0C
FCp=0.25
H2
200 0C
80 0C
FCp=0.2 FCp=0.3 230 0C
180 0C 8 H 7.5 7 12.5 140 0C
140 0C 17.5 C2
52.5 0C 20 0C
C1
ANSWER
Below the pinch we try to have the cold streams start at their inlet temperatures and we later locate coolers (one in this case).
FCp=0.15 H1 250 0C 150 0C C 10 FCp=0.25 H2 200
0C
40 0C
80 0C 180 0C 230 0C 8 H 7.5 7 12.5 140 0C 140 0C 17.5 6.5
FCp=0.2 FCp=0.3
20 0C
C1
C2
EXAMPLE
FCp=0.15 H1 250 0C 150 0C C 10 FCp=0.25 H2 200 0C 80 0C 180 0C 230 0C 8 H 7.5 7 12.5 140
0C
40 0C
FCp=0.2 FCp=0.3
140 0C 17.5 6.5
20 0C
C1
C2
Nmin= (S-P)above pinch+ (S-P)below pinch = =(5-1) + (4-1) = If we do not consider two separate problems Nmin= (6-1)= 5, which is wrong
Note: A heat exchanger network with 5 exchangers exists, but it is impractical and costly. This is beyond the scope of this course.
UNEQUAL NUMBER OF STREAMS AT THE PINCH

Indeed, if the number of hot streams is larger than the number of cold streams, then no pinch matches are possible.
FCp=0.15 FCp=0.25 FCp=0.1 H1 H2 H3 FCp=0.2 FCp=0.4 150 OC 140 OC 130 OC 100 OC
Target=170 OC Target=140 OC
127.5 OC 122.5
OC
90 OC C1 7.5 10 C2
Assume the matches H1-C1 and the matches H2-C2 have been selected. Since H3 needs to go to the pinch temperature, there is no cold stream left to match, even if there is portions of C1 or C2 that are left for matching. Such matching would be infeasible.
What is then, the solution?
ANSWER
Split cold stream until the inequality is satisfied.
FCp=0.15 FCp=0.25 FCp=0.1 H1 H2 H3 150 OC 140 OC 130 OC 100 OC
FCp=0.2 FCp=0.25 FCp=0.15
127.5 OC 130 OC 110 OC 10 3 7.5
90 OC
C1 C2
Notice that different combinations of flowrates in the split satisfy the inequality.
INEQUALITY NOT SATISFIED

Consider the following case:
FCp=0.5 H1 150 OC 100 OC
Target=170
OC
FCp=0.2 FCp=0.4
90 OC C1 C2
Target=140 OC
ANSWER
Split the hot stream
FCp=0.2 FCp=0.3 H1 150 OC 100 OC
FCp=0.2 FCp=0.4
140 OC 127.5 OC 15 10
90 OC
C1 C2
SOLVE THE FOLLOWING PROBLEM

Below the Pinch :
FCp=0.5 FCp=0.3 H1 H2 100 OC Target=40 OC Target=20 OC
FCp=0.7
90 OC
30 OC
C1
ANSWER
Below the Pinch :
FCp=0.5 FCp=0.3 H1 H2 100 OC 40 OC Target=40 OC Target=20 OC
60
OC
FCp=0.5 FCp=0.2
90 OC 30 12
30 OC
C1
COMPLETE PROCEDURE
ABOVE THE PINCH
Start
Yes
FCpHFCpC
at pinch?
Yes
SH SC No Split Cold Stream
No
Place matches
Split Hot Stream
COMPLETE PROCEDURE
BELOW THE PINCH
Start
Yes
FCpH FCpC
at pinch?
Yes
SH SC No Split Hot Stream
No
Place matches
Split Cold Stream
HANDS ON EXERCISE
Type Hot Hot Cold Cold Supply T (oC) 750 550 300 200 Target T (oC) 350 250 900 550 F*Cp (MW oC-1) 0.045 0.04 0.043 0.02
Tmin=50 oC Minimum Heating Utility= 9.2 MW Minimum Cooling Utility= 6.4 MW
ANSWER
FCp=0.04 750 0C FCp=0.045 H1 0.4 FCp=0.04 H2 686.05 0C FCp=0.043 FCp=0.02 900
0C
550 0C 358.89 0C 350 0C
250 0C
400 0C
6 300 0C
C1 C2
550 0C
9.2 1
8 500 0C 6
8.6 200 0C
TRANSSHIPMENT MODEL (Papoulias and Grossmann, 1983)

0
q1 q2
1
We will now expand the mathematical model we presented to calculate the minimum utility.
S min = Min 0 s. t
qi qi+1
i i+1
i = i 1 + q i i 0
Where
i = 1,... mI
qi =
kiH
H H F cp k k (Ti 1 Ti )
siC
C C F cp s s (Ti 1 Ti )
q
n
TRANSSHIPMENT MODEL
ri,1 i,1 ri,2 si,k,1 si,k,2 pk,2 pk,1
Assume now that we do the same cascade for each hot stream, while we do not cascade the cold streams at all. In addition we consider heat transfer from hot to cold streams in each interval. The material balances for hot streams are:
ri,j i,j ri,j+1 i,j+1
si,k,j si,k,,j+1
pk,j
i ,0 = 0 i , j = i , j 1 +ri , j si ,k , j j = 1,...mI
k
pk,j+1
The material balances for cold streams are:

pk , j = si ,k , j j = 1,...mI
i
ri,n i,n
si,k,n
pk,n
Where ri,j and pk,j are the heat content of hot stream I and cold stream k in interval j.
TRANSSHIPMENT MODEL
Although we have a simpler model to solve it, in this new framework, the minimum utility problem becomes:
Min U , 0 s.t
si,k,j si,k,,j+1
i ,0 = 0
pk,j
i, j = 1,...mI
k
i , j = i , j 1 +ri , j si ,k , j i, j = 1,...mI
pk , j = si ,k , j
i
pk,j+1
k , j = 1,...mI
ri,n i,n
si,k,n
pk,n
Note that the set of hot streams now includes process streams and the utility U. Cold streams include cooling water.
TRANSSHIPMENT MODEL
We would like to have a model that would tell us the si,k,j such that the number of units is minimum. We now introduce a way of counting matches between streams. Let Yi,k be a binary variable (can only take the value 0 or 1). Then we can force Yi,k to be one using the following inequality
si,k,j si,k,,j+1
pk,j
pk,j+1
si ,k , j Yi ,k 0
ri,n i,n
si,k,n
indicating therefore that heat has been transferred from stream i to stream k in at least one interval.
pk,n
TRANSSHIPMENT MODEL
ri,1 i,1 ri,2 si,k,1 si,k,2 pk,2
The complete model would be:

pk,1
Min s.t
i k
Yi ,k
si,k,j si,k,,j+1
* U ,0 = U ,0
pk,j
i ,0 = 0
pk , j = si ,k , j
k
i, j = 1,...mI
pk,j+1
k , j = 1,...mI i, k
ri,n i,n
si,k,n
si ,k , j Yi ,k 0
pk,n
The model can only be solved above and below the pinch separately. Why???
TRANSSHIPMENT MODEL
We are minimizing the number of matches. Different answers can be obtained if separate regions are not considered. These answers are not guaranteed to be realistic.
GAMS MODEL
Min s.t
* U ,0 = U ,0
i k
Yi ,k
TABLE P(K,J) J0 C1 0 C2 0 W 0
load of cold stream K1 in interval J J1 J2 J3 8.6 6.45 2.15 0 0 1 0 0 6.4 ;
i ,0 = 0
pk , j = si ,k , j
k
i, j = 1,...mI
k , j = 1,...mI i, k
i
VARIABLES S(I,K,J) heat exchanged hot and cold streams D(I,J) heat of hot streams flowing between intervals Y(I,K) existence of match Z total number of matches ; POSITIVE VARIABLE S POSITIVE VARIABLE D BINARY VARIABLE Y ; EQUATIONS MINMATCH objective function-number of matches HSBAL(I,J) heat balances of hot stream I in INTERVAL J CSBAL(K,J) heat balances of cold stream J1 in K HTINEQ1(I,K) heat transferred inequalities; MINMATCH .. Z =E= SUM((I,K), Y(I,K)); HSBAL(I,J)$(ORD(J) NE 0) .. D(I,J)-D(I,J-1)+ SUM(K,S(I,K,J)) =E= R(I,J); CSBAL(K,J)$(ORD(J) NE 0) .. SUM(I, S(I,K,J)) =E= P(K,J) ; HTINEQ1(I,K) .. SUM(J, S(I,K,J))-GAMMA*Y(I,K) =L= 0 ; MODEL TSHIP /ALL/ ; SOLVE TSHIP USING MIP MINIMIZING Z; DISPLAY S.L, D.L, Y.L;
si ,k , j Yi ,k 0
GAMS MODEL
SETS I hot streams above pinch / S, H1 / K cold streams above pinch / C1,C2,W/ J temperature intervals / J0*J3 / ; SCALAR GAMMA /10000/; TABLE R(I,J) load of hot stream I1 in interval K J0 J1 J2 J3 S 9.2 0 0 0 H1 0 0 6.75 2.25;
GAMS MODEL
SOLUTION
---- VARIABLE S.L J1 J2 S .C1 8.600 0.600 H1.C1 5.850 H1.C2 ---- VARIABLE D.L J0 J1 S H1 9.200 0.600 0.900 FCp=0.043 FCp=0.02 900 0C 550 0C 9.2 1 8 500 0C J3 2.150 1.000 750 0C FCp=0.045 H1 H2 550 0C
J2
FCp=0.04
---- VARIABLE Y.L C1 C2 S H1 1.000 1.000 1.000 =
EXECUTION TIME
0.090 SECONDS
PART 4
UTILITY PLACEMENT HEAT AND POWER INTEGRATION
UTILITY PLACEMENT
We now introduce the GRAND COMPOSITE CURVE, which will be useful to analyze the placement of utilities.
1.5
T
Start at the pinch 250 240 200 190
- 6.0
1.0
-4.0
Pinch
14
150 80 40 30
-2.0
-2.0
GRAND COMPOSITE CURVE

T
Total heating utility
250 240 200 190 150 80 40 30
These are called pockets Process-to Process integration takes place here
Total cooling utility
UTILITY PLACEMENT
We now resort to a generic grand composite curve to show how utilities are placed.
T
HP Steam MP Steam
LP Steam
Cooling Water
H
Transshipment model for multiple utilities

Min s.t
mS
W S Qm + cnQn nW
i ,0 = 0
S m , j = m , j 1 Qi ,n , j + Qm k mS
i, j = 1,...mI
i , j = i , j 1 +ri , j si ,k , j Qi ,n , j i, j = 1,...mI
mS
i, j = 1,...mI k , j = 1,...mI k , j = 1,...mI

HOT UTILITY 2 = MP STEAM HU1( i ) HU2( i ) CU1( i )
pk , j = si ,k , j + Qm ,k , j
mS
mS
m ,k , j
W = Qn
Results
Interval I0 I1 I2 I3
HOT UTILITY 1 = HP STEAM T( i ) 250 200 150 30 Q( i ) ( i )
-4.5 -3 10
0 0 0
4.5 3 10
HOT UTILITY 1 HOT UTILITY 2 COLD UTILITY
UTILITY PLACEMENT
Hot Oil placement and extreme return temperatures
T
Hot oil from furnace
Oil minimum return temperature Water maximum return temperature

Process
Cooling water
UTILITY PLACEMENT
Furnace T
Tstack
Theoretical Flame Temperature
Tstack
Air Fuel Process Stream
Ambient Temperature
Stack Loss Fuel heat value H
COMBINED HEAT AND POWER

Integration of a Heat Engine below the Pinch.
QH,min
T T
Pinch W Note that in this case there is no gain. The heat engine can be arranged separately and the utility usage will not change. QHE
QHE -W
QC,min +( QHE W)

Integration of a Heat Engine Across the Pinch.
QH,min -( QHE W) QHE TOTAL HEN ENERGY INTAKE QH,min -( QHE W) W QHE -W
(Smaller)
Pinch
SYSTEM TOTAL ENERGY INTAKE QH,min+W vs.

(separate)
QH,min+QHE
QC,min
INTEGRATION WITH DISTILLATION

Placement below the pinch.
QH,min
T In this case there is a gain of (Qcond - Qreb) in the cooling utility.

Qreb Qcond QC,min + (Qcond - Qreb)
Pinch
HEAT PUMPS/REFRIGERATION CYCLES

QH,min-(QHP + W) QHP +W TOTAL HEN INTAKE QH,,min (QHP+W) (smaller)
Pinch W QHP
TOTAL SYSTEM INTAKE QH,,min -QHP vs. QH,,min +W (separate) Savings in cooling utility QHP QC,min - QHP

Utility Placement
T
QH,min ( QHP+QLP) QHE
T
QLP
QHP
QHP Pinch QLP
TOTAL HEN INTAKE
QH,min ( QHP+QLP)
(smaller) TOTAL SYSTEM INTAKE
QC,min
QC,min
QH,min +W
vs. QH,min+W+(QHP + QLP) (separate)

Gas Turbine Placement
TOTAL ENERGY INTAKE QH,min + W+ QLOSS
vs.
TEX
T
QH,min + W+ QLOSS+QS
QH,min -QS
QF W Air
Pinch
QS
TEX QLOSS QC,min T0
T0 QLOSS QS QF -W
H
PART 5
DISTILLATION PLACEMENT
PLACEMENT OF DISTILLATION
Placement across the pinch.
QH,min + Qreb
Qreb
Pinch
Qcond
Note that in this case there is no gain. The distillation column can be arranged separately and the utility usage will not change.
QC,min + Qcond
PLACEMENT OF DISTILLATION
Placement above the pinch.
QH,min + Qreb - Qcond
Qreb Qcond
Pinch
Note that in this case there is a possible gain in the heating utility.
QC,min
ADJUSTING PRESSURE FOR PROPER PLACEMENT

Heating Utility
T T
Pinch
Pinch
As pressure increases utility usage decreases.
CRUDE FRACTIONATION EXAMPLE

We now show a complete analysis of an atmospheric crude fractionation unit. We start with the supply demand diagram
CO NDENSER w a te r n a p h th a PA1 ste a m PA2 k erosen e
ste a m PA3 w a te r cru d e HEN so u r w a te r HEN FURNACE ste a m r e s id u e d ie s e l
DESALTER
ste a m g a s o il

We now show how to determine the heat load of pumparounds. We start with a column with no pumparound (results from are from a rigorous simulation)
1.2 1.0 M*Cp, MMW/C 0.8 0.6 0.4 1 0.2 0 0 PRODUCTS 200 TEMPERATURE, C 300 400 RES COND CRUDE PINCH

We move as much heat from the condenser to the first pumparound as possible. The limit to this will be when a plate dries up. If the gap worsens to much, steam is added.
1.4 1.2 M*Cp, MMW/C 1.0 0.8 0.6 0.4 0.2 0
0
PRODUCTS
PINCH
PA1 CRUDE
COND
RES
100 200 300 400
TEMPERATURE , C

We continue in this fashion until the total utility reaches a minimum. .
1.4 1.2 1.0 M*Cp, MMW/C 0.8 0.6
COND
PINCH PA1
CRUDE
0.4 0.2 0
0 100
PA2
RES
200
300
400
TEMPERATURE, C

Especially when moving heat from PA2 to PA3, steam usage increases so that the flash point of products is correct and the gap is within limits.
1.2 1.0 M*Cp, MMW/C 0.8
PA1
CRUDE
0.6
COND
0.4
PA1
PA2
PA3
0.2 0
0 100
RES
200
300
400
TEMPERATURE, C

Situation for a heavy crude
0.8
0.6 M*Cp, MMW/C
CRUDE
PA3
0.4
COND
SW PA1
RES PA2
0.2
0 0 100 200 300 400 TEMPERATURE,
PART 6
ENERGY RELAXED NETWORKS
ENERGY RELAXATION
Energy relaxation is a name coined for the procedure of allowing the energy usage to increase in exchange for at least one of the following effects : a) a reduction in area b) a reduction in the number of heat exchangers c) a reduction in complexity (typically less splitting)
ENERGY RELAXATION IN THE PINCH DESIGN METHOD

LOOP: A loop is a circuit through the network that starts at one exchanger and ends in the same exchanger PATH: A path is a circuit through the network that starts at a heater and ends at a cooler
ENERGY RELAXATION
Illustration of a Loop
H1 175 0C 125 0C C 280 FCp=0.040 H2 65 0C
FCp=0.010
FCp=0.020
155 0C
H 360 500 112 0C 1840
20 0C
C1
40 0C 560 520
FCp=0.015
C2
(*) Heat exchanger loads are in kW
Tmin=13 oC
ENERGY RELAXATION
Illustration of a Path
H1 175 0C 125 0C C 280 FCp=0.040 H2 65 0C
FCp=0.010
FCp=0.020 FCp=0.015
155 0C
H 360 500 1840
20 0C
C1
40 0C 112 0C (*) Heat exchanger loads are in kW 560 520
C2
ENERGY RELAXATION
Procedure : Find a loop and move around heat from exchanger to exchanger until one exchanger is eliminated.
175 0C H1 H2 125 0C C 280 65 0C 155 0C H 360 500 -X 112
0C
20 0C 1840 +X 40 0C 560 -X 520 +X
C1
C2
If one wants to eliminate one exchanger: X=500. Note that X could have been negative, but we chose the smallest possible in absolute value.
ENERGY RELAXATION
H1
Result: Notice that the result is infeasible!!!

73 0C 175 0C 65 0C C 45 0C
H2
280 65 0C 65 0C
155 0C
H 360 2340 112

0C
20 0C
C1
40 0C 60 1020 108 0C
C2
This exchanger is in violation of the minimum approach
ENERGY RELAXATION
H1
We use a path to move heat around to restore feasibility

73 0C 175 0C 65 0C C 45 0C
280 +X 65 0C 65 0C
H2
155 0C
H 360 +X 2340 -X 112 0C 60 +X 1020 -X
20 0C
C1
40 0C
C2
108 0C
The value of X needed to restore feasibility is X=795
ENERGY RELAXATION
H1
Final Network
175 0C 65 0C C 45 0C 1075 65 0C 65 0C
H2
155 0C
H 1155 1545 112

0C
20 0C
C1
40 0C 855 55 0C 225
C2
TEMPERATURE APPROACH (T) RELAXATION

We recall stating NO HEAT ACROSS THE PINCH. Being more specific, we should say, NO NET HEAT ACROSS THE PINCH. Thus we allow the following situations.
Pinch
as long as the NET heat transferred across the pinch is zero.
However this implies allowing the temperature difference to be lower than Tmin
T RELAXATION
We thus define two types of Minimum Temperature Approach. HRAT: (Heat Recovery Approach Temperature): This is the Tmin we use to calculate minimum utility. EMAT: (Exchanger Minimum Approach Temperature): This is the minimum approach we will allow in heat exchangers.
When EMAT< HRAT networks can have 1. less splitting 2. less number of units 3. No significant increase in the total area.
T RELAXATION
Consider the following problem
Stream
H1 H2 C1 C2
Type
Hot Hot Cold Cold
Supply T
(oC) 175 125 20 40
Target T
(oC) 45 65 155 112
F*Cp
(MW oC-1) 0.010 0.040 0.020 0.015
We now consider HRAT=20 oC and EMAT= 13 oC. The corresponding minimum utility are: Tmin 20 (HRAT) 13 (EMAT)
Hot Utility 0.605 MW 0.360 MW
Cold Utility Pinch 0.525 MW 0.280 MW 132 OC 112 OC
PSEUDO-PINCH METHOD
We now consider that the difference (245 kW= 605 kW-360 kW) needs to go across the pinch of a design made using EMAT. Thus we first look at the solution of the pinch design method (PDM) for Tmin =13 oC
FCp=0.010 FCp=0.040 H1 H2 155 0C 175 0C 125 0C 45 0C 280 65 0C 20 0C C 1 500 112
0C
FCp=0.020 FCp=0.015
H 360 1840 560 520
40 0C
C2
PSEUDO-PINCH METHOD
To relax this network by 245 kW we extend the only heat exchanger above the pinch by this amount. We then proceed below the pinch as usual.
FCp=0.010 FCp=0.040 H1 H2 155 0C 175 0C 149.5 0C 125 0C 45 0C C C 215 FCp=0.020 FCp=0.015 H 605 255 112
0C
310 65 0C
112 0C 1840 735 345
20 0C 40 0C
C1 C2
Note that the matching rules (FCp inequalities) can be somewhat relaxed.
PSEUDO-PINCH METHOD
We know the solution of the pinch design method (PDM) for Tmin =20 oC
FCp=0.010 FCp=0.040 H1 H2 155 0C 112 0C 175 0C 125 0C 125 0C 45 0C 525 65 0C
FCp=0.020 FCp=0.015
H 500 H 105 500
105 0C
20 0C C 1 1700 700 275 40 0C C 2
The PDM produces one additional split, and two heaters, while the PPDM features two coolers
DIFFICULTIES IN THE PPDM METHOD

No clear indication what to do when there is many hot streams above the pinch. How to distribute the difference in heat? Even if the above is clarified it is not practical for more than a few streams.
T RELAXATION USING AUTOMATIC METHODS

One can use the Transshipment model fixing the level of hot utility and creating the intervals using EMAT instead of HRAT. More sophisticated methods add area estimation to the model (This has been called the Vertical model) The number of units can also be controlled and sophisticated techniques have been used to explore all the flowsheets with the same number of matches. Finally, once a flowsheet is obtained a regular optimization can be conducted. This will be explored in the next Part.
PART 7
MATHEMATICAL PROGRAMMING APPROACHES
RECENT REVIEW PAPER

(until 2000)
Furman and Sahinidis. A critical review and annotated bibliography for Heat Exchanger Network Synthesis in the 20th Century. Ind. Eng. Chem. Res., 41 pp. 2335-2370, (2002).
PINCH DESIGN METHOD

It is a DECOMPOSITION approach (3 steps)
Perform Supertargeting and obtain the right HRAT, the pinch (or pinches) and the minimum utility usage Pick matches away from the pinch using the tick-off rule Evolve into higher energy consumption solutions by loop breaking and adjusting loads on paths.
SUPERSTRUCTURE APPROACH
CONCEPT: A single optimization model, if solved
globally, provides all the answers simultaneously. Superstructure of matches.
Possible flow sheets embedded (recycles/by-passes excluded)
Possible flow sheets embedded (continued)
Model Constraints
Objective
(no fixed costs)
This is an MINLP formulation with which several researches have struggled. (MINLP methods could not be easily solved globally until recently (?). Therefore it needs some initial points.
ALTOUGH A ONE-STEP CONCEPT IT BECAME IN REALITY AN ITERATIVE PROCESS
Some Strategies to overcome the curse of non-convexity
Hasemy-Ahmady et al., 1999.
Many other methodologies attempted this goal (provide good initial points) like evolutionary algorithms, simulated annealing, etc.
STAGE SUPERSTRUCTURE APPROACH

With isothermal mixing. Yee and Grossmann (1990, 1998) Note on the side: This
is a remarkable coming back to origins.
From Grossmann and Sargent (1978)
In the 90s the mathematical programming/ superstructure approach emerged as the dominant methodology
From Grosmann and Sargent (1978)
LATEST MILP APPROACH

(Barbaro and Bagajewicz, 2005)
Counts heat exchangers units and shells Approximates the area required for each exchanger unit or shell Controls the total number of units Implicitly determines flow rates in splits Handles non-isothermal mixing Identifies bypasses in split situations when convenient Controls the temperature approximation (HRAT/EMAT or Tmin) when desired Allows multiple matches between two streams

m
1 7 2 5 8 3 6
Hot stream i
z,H ijm q
z qim , jn
z ,C ijn q
Cold stream j
1 6
2 7 8
3 9
Transportation Model Approach

Heat Exchanger counting
z ,H Y z ,H K ijm ijm
z , H 2 Y z , H Y z , H K ijm ijm ijm +1
First interval m
1 2 3 4
z, H Yijm
0 0 1 1 1 1 1 1 0 0
z,H K ijm
z,H K ijm
0 0 0 0 0 0 0 1 0 0
0 0 1 0 0 0 0 0 0 0
z ,H Y z ,H K ijm ijm
z , H Y z , H Y z , H K ijm ijm ijm +1
Rest of intervals
5 6 7 8 9 10
z ,H 0 K ijm
10

Flowrate Consistency
z ,H ijm q U L Cpim( Tm Tm )
z ,H ijm q 1 U L Cpim1( Tm 1 Tm 1 )
z,H ijm q U L Cpim (Tm Tm )
z,H ijm q 1 U L Cpim1 (Tm 1 Tm1 )
Heat exchanger spanning m

1 8 2 6 9 3 4 7
z,H ijm q
Cpim (T T )
U m L m
z,H ijm q 1 U L Cpim1 (Tm T 1 m1 )
PART 8
INDUSTRIAL IMPORTANCE OF USING THE RIGHT MODEL
Crude fractionation case study

CO NDENSER w a te r n a p h th a PA1 stea m PA2 k erosen e
ste a m PA3 w a te r cru d e HEN so u r w a te r HEN FURNACE ste a m r e s id u e d ie s e l
DESALTER
stea m g a s o il

Light Crude
400 350
Heavy Crude 400 350 T emp eratu re (C) 300 250 200 150 100 50 0 0 50 100 Enthalpy (MW) 150 200
Temperature ( C)
300 250 200 150 100 50 0 0 50 100 150 200 250
Enthalpy (MW)
Cooling water is already included in the graphs.
The light crude exhibits what is called a continuous pinch. The heavy crude is unpinched.
CRUDE FRACTIONATION
C2
Cooling water
FURNACE
H8
H2
H3
H7
H6
H5
H1
DESALTER
H9
H10 H4
MER network for the light crude.
CRUDE FRACTIONATION
C2 Cooling water FURNACE H8
H7
H6
H2
DESALTER
H5 H4 H3 H10 H1
C1
MER network for the heavy crude.
CRUDE FRACTIONATION
NOT USED FOR HEAVY CRUDE
C2 FURNACE
NOT USED FOR LIGHT CRUDE
Cooling water H8
H2
H3
H7
H6
H5
H1
DESALTER
H4 H10
H9
C1
MER network efficient for both crudes.
CRUDE FRACTIONATION
It is clear from the previous results that efficient MER networks addressing multiple crudes can be rather complex and impractical.
Alternatives to the Pinch Design Method (PDM) are clearly needed.

This does not mean that the PDM fails all the time. It is still capable of producing good results in many other cases.

We now illustrate the use of HRAT/EMAT procedures for the case of crude fractionation units. We return to our example of two crudes. The problem was solved using mathematical programming. The networks have maximum efficiency for both crudes. Only the vertical model and the control on the number of units was used. No variation in the matches was done (not really necessary in this case) and no further optimization was performed.
CRUDE FRACTIONATION
C2 NOT USED FOR HEAVY CRUDE Cooling water H8 H7 H3 H6 H2 H5 FURNACE
18 units
DESALTER
H1 NOT USED FOR HEAVY CRUDE H9 H10 H4
C1
Solution for HRAT/EMAT = 20/10 oF
CRUDE FRACTIONATION
NOT USED FOR HEAVY CRUDE Cooling water H8 H3 H6 H7 H2 FURNACE
18 units
H5
DESALTER
H1 NOT USED FOR HEAVY CRUDE H4 H9 H10
C1
CRUDE FRACTIONATION
NOT USED FOR HEAVY CRUDE Cooling water FURNACE H3 H8 H6 H2 DESALTER H7
17 units
H1 H5 H4 NOT USED FOR HEAVY CRUDE H10 H9
C1
CRUDE FRACTIONATION
Cost, MM$/yr
Combined Multiperiod Multiperiod+ Multip+Des.Temp Network Model Desalt.Temp. +Higher HRAT
HRAT/EMAT Operational Fixed Total
20/20 3.96 3.14 7.10
20/10 3.96 3.63 7.59
20/10 3.96 3.32 7.28
40/30 4.94 1.37 6.32

We now illustrate the use of more sophisticated models that allow the control of splitting. These are essentially transshipment models that are able to control the level of splitting (something that regular transshipment models cannot do).
CRUDE FRACTIONATION Two branches unrestricted

HRAT = 40 oF EMAT = 30 oF
H3 H6 FURNACE H8
H7
23 units
H5 H2
H4 DESALTER
5% More Energy Consumption

H9 C1
H1 H10
CRUDE FRACTIONATION restricted

HRAT = 40 oF EMAT = 30 oF
H2 H5 H1 FURNACE H7 H8 H3 H6
21 units
H4 DESALTER
5% More Energy Consumption

H9 C1
H10
CRUDE FRACTIONATION
Cost, MM$/yr
Multiperiod Two-branch Model Unrestricted Operational 4.32 4.52 Fixed 2.07 1.90 Total 6.39 6.42
Two-branch
Restricted 4.53 2.01 6.54
CRUDE FRACTIONATION
The two-branch design
Is efficient for all feedstocks proposed. Consumes only a few more millions Btu/hr Has many solutions of similar energy consumption.
Complexity can be reduced at a relatively small energy increase and with some reduction of capital. All these models suggest that there is a lot of flexibility to perform an effective retrofit because there are these many options of similar cost to explore.
PART 9
RETROFIT AND TOTAL SITE INTEGRATION
RETROFIT
The big question in trying to do a retrofit of a HEN is whether one really wants to achieve maximum efficiency.
Original System Operating Costs ($/yr)
HORIZON
Capital Investment ($)
Usually retrofits are too expensive and have a long payout.
RETROFIT
It is desired to produce the largest reduction of cost with the smallest capital investment
Present Condition
Retrofits
HORIZON
Capital Investment ($)
The question is how to identify the most profitable.
EXAMPLE
Retrofits involve a) relocation, and b) addition of new units.
NEW-1 DESALTER 9T-1 NEW-3 REB-T7 9T-7 RELOC NEW-4 9T-9 9T-1 NEW-2 9T-2
RELOC DESALTER
NEW-5 9T-9
D101
9T-7
This particular study produced a) 700,000 annual savings with 1.2 years
payoff, b) Additional 12% capacity (not counted in the $700,000 savings)
TYPES OF RETROFIT
By inspection. Perform pinch design or pseudo pinch design and determine heat exchangers to add Systematic methods using tables and graphs exist They are outside the scope of this course. Mathematical programming approaches also exist but they have not passed the test of usability and friendliness
RECENT WORK ON RETROFIT

Asante, N. D. K.; Zhu, X. X. An Automated and Interactive Approach for Heat Exchanger Network Retrofit. Chem.Eng. Res. Des. 75 (A), 349-360 (1997). Briones, V.; Kokossis, A. C. Hypertargets: A Conceptual Programming Approach for the Optimisation of Industrial Heat Exchanger Networks II. Retrofit Design. Chem. Eng. Sci. 54, 541-561 (1999). Barbaro, Bagajewicz, Vipanurat, Siemanond. MILP formulation for the Retrofit of Heat Exchanger Networks. Proceedings of Pres 05. (2005)
TOTAL SITE INTEGRATION

USE OF GRAND COMPOSITE CURVES TO PLACE UTILITIES.
Plant 1
Plant 2
Pockets are eliminated and curves are shifted

Site sink and source profiles are constructed.
LP Steam HP Steam
Source Profile
Sink Profile
Overlap region. These are savings.
Energy integration is performed by placing utilities. We will see how this method can be wrong.

Consider two plants. We would like to know under what conditions one can send heat from one plant to the other.
PLANT 1 PLANT 2 C O M B IN E D PLANT
A b o v e b o th p in c h e s
P in c h P o in t P la n t 2
B e tw e e n p in c h e s
P in c h P o in t P la n t 1
P o s s ib le L o c a t io n o f P in c h
B e lo w b o th p in c h e s

T
U1,min- QT
U2,min
Effective integration takes place between pinches.

Pinch 2
QT
Pinch 1
From where plant 2 is heat source to where plant 1 is heat sink.
W1,min
W2,min- QT

T
U1,min- QT
U2,min + QT
QT
Pinch 2
Integration outside the inter pinch region leads to no effective savings.
Pinch 1
W1,min
W2,min
GRAND COMPOSITE CURVES

PLANT 1 18 = 30 - 12 PLANT 2 20 = 20
-12
6 = 18 - 12
-19
1 = 20 - 19
-1
5=6-1 Pinch 10 0 = 5 - 15 + 10
-1
0=1-1
-15 -2
Pinch
10
0 = 10 - 10
2 0=0-2+2
5
3=0+5-2
2
2=2
1
4=3+1
GRAND COMPOSITE CURVES

140 120 Temperature 100 80 60 40 -20
Plant 1
Plan t2
Maximum possible savings

-15 -10 -5 0 Enthalpy 5 10 15 20
ASSISTED HEAT TRANSFER

PLANT 1 7 = 20 + 4 - 17 PLANT 2 16 = 20 - 4
-7
If heat is not transferred above the two pinches only 13 of the maximum 17 can be saved.
0=7-7
-10
6 = 16 - 10 4 1 = 0 + 5 - 4 Pinch
5 -15 -3
-10
0 = 6 - 10 + 4
14 0 = 1 - 15 + 14 3 0=0-3+3
14
0 = 14 - 14
10
7 = 0 + 10 - 3
Pinch
3
3=3
5
12 = 7 + 5

140 120 Temperature 100 80 60 40 -10
Pla nt 1 Assisted Transfer
Pocket
Plan t2

-5 0 5 10 Enthalpy 15 20 25 30

140 120
Pla nt 1
Plan t2
Typical solutions call for sealing the pocket preventing thus the savings.
Temperature
100 80 60 40 -10 -5 0 5 10 Enthalpy 15 20 25 30
140 120 Temperature 100 80 60 40 -10
Pl a
Assisted Transfer
nt 1
Pocket
P lan t2

-5 0 5 10 Enthalpy 15 20 25 30
HEAT EXCHANGER NETWORKS

Heat Exchanger networks should be such that both plants can work at maximum efficiency when integrated and when they stand alone. We now show a result of a case study. An integration between a Crude unit (heat sink ) and an FCC unit (heat source).
H9 H5 H8 C1 H4 H3 H7 H6 H2 H1
CW
Above the Pinch
Plant 1:
Crude Unit
H10
H11
H15
H13
H14
Direct Integration
(two stream circuits)
C2
Pinch location Original HEN Additional heat exchangers used during integration
CW
H12
Below the Pinch
Plant 2: FCC
Unit
HEAT EXCHANGER NETWORKS

Heat Exchanger networks should be such that both plants can work at maximum efficiency when integrated and when they stand alone. We now show a result of a case study. An integration between a Crude unit (heat sink ) and an FCC unit (heat source).
H9 H5 H8 C1 H4 H3 H7 H6 H2 H1
Utility (MMBtu/hr)
CW
Above the Pinch
No Integration Direct Integration
Heating 252.9 201.4
Cooling 147.7 96.2
Plant 1: Crude Unit
H10
H11
H15
H13
H14
Direct Integration
(two stream circuits)
C2
Savings
1,000,000 $/year
Pinch location Original HEN Additional heat exchangers used during integration
CW
H12
Below the Pinch
Plant 2: FCC Unit

Multiple plants can also be analyzed. We show below one example of such studies. Alternative solutions exists. Grand composite curves cannot be used anymore.
PLANT 1 PLANT 2 ( T e s t C a s e # 2 ) ( T r iv e d i)
0 300 C 2 5 4 .9
PLA N T 3 (C & F )
4 2 6 .4
PLA N T 4 (4 sp 1 )
128
249 C
9 8 .3 1 2 0 .7 5 2 .9 1 0 4 .5
200 C
160 C
1 0 7 .5
90 C
40 C
40
5 8 1 .1
1 9 9 5 .5
3 1 .1
FUTURE TRENDS
Mathematical programming will be the dominant tool. Software companies are struggling to make the proper choice of existing methods for each case and most important numerically reliable. The best option for the time being is to intelligently interact with experts while using existing software.

Bag A Jew I CZ Heat Integration

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Bag A Jew I CZ Heat Integration

Uploaded by

Copyright:

Available Formats

PART 1

PINCH AND MINIMUM UTILITY USAGE

WHAT IS THE PINCH?

WHAT IS A PINCH DESIGN

IS PINCH TECHNOLGY CURRENT?

TEMPERATURE-ENTHALPY (T-H) DIAGRAMS

TH, out TH,in TH, out TH, out

Slopes are the inverse of F*Cp. Recall that Q=F Cp T

TH, out TH,in TH, out

TC,out T TH,in TC,out

QC TH, out TH,in C

TH, out TH, out

Notice the vertical arrangement of heat transfer

Moving the cold composite stream to the right

H=32 MW T=20 0C REACTOR 1 T=180 0C

Answer: Hot Streams

Answer: Cold Streams

230 180 140

Answer: Both Curves Together.

UTILITY COST vs. Tmin

Note: There is a particular overlap that requires only cooling utility

20 250 140 200

32.0 -31.5 27.0 -30.0

0.2 0.15 0.3 0.25

80 40 30 Hot streams Cold streams

1.5 - 6.0 -4.5 1.0 -3.5 -4.0 -7.5 14.0 6.5

This is the minimum cooling utility

DO NOT TRANSFER HEAT ACROSS THE PINCH

Heating utility is larger than the minimum

Heat is transferred across the pinch

Heating utility at the largest temperature is now zero.

Let q i be the surplus or demand of heat in interval i . It is given by:

TOTAL AREA TARGETING

(TH1-TC2)-(TH2-TC1) ln (TH1-TC2) (TH2-TC1)

TOTAL AREA TARGETING

The above scheme of heat transfer is called VERTICAL HEAT TRANSFER

Furnace (300 oC)

250 230 200 180 Pinch 140 80 40 20

Obtain the total area estimate

Furnace (300 oC)

Pinch Cooling Water

TH1 80 90 150 200 250 300

TH2 40 80 90 150 200 250

TC1 15 20 20 140 180 205

TC2 20 30 140 180 205 230

TOTAL AREA TARGETING

We will see later how the number of units can be calculated

QUESTIONS FOR DISCUSSION

YES, Within 10-15%

Target T (oC) (oC) 180 150 180 150

F*Cp (MW) 8.0 0.2 0.15 0.3 0.25

Reactor 1 feed Reactor 1 product Reactor 2 feed Reactor 1 product

Cold Hot Cold Hot

140 200 140 200

-7.5 12.0 -12.5

This implies at least three heat exchangers, just in this interval.

HEAT EXCHANGER NETWORK

R1 feed, FCp=0.2 R2 feed, FCp=0.3

180 205 230

HEAT EXCHANGER NETWORK

180 205 230

Called Spaghetti design

PREDICTING THE NUMBER OF UNITS