Lecture 8 - Hen II - Pta GCC

Lecture outline
Problem table algorithm

1. Shifted temperature
Heat exchanger network II

Problem Table Algorithm & Grand
Composite Curve
2. Energy balance
3. Heat cascade
Grand composite curve (GCC)

Utility selection & steam
generation with GCC
Copyright@Dominic Foo
The composite curves
PTA & GCC - 2
Its limitation & alternative

Limitation of composite curves
QHmin
T (C)
H82PLD - Plant Design

Pinch
Heat
sink
Heat
source
Graphical construction inconvenient

Inaccuracy
Computational ineffective
Software interaction is limited
Another targeting tool the problem table

algorithm (PTA)
Tmin
Numerical alternative to locate energy targets

Accurate and rapid
H (MW)
QCmin
PTA & GCC - 3
PTA & GCC - 4
The basic principles of PTA
Calculation steps
1. Set up shifted temperature intervals from original
stream TS & TT values:
Hot stream: subtract Tmin/2 to make it colder

Cold stream: add Tmin/2 to make it hotter
H
If the composite curve is divided into temperature intervals, driving
forces are not feasible throughout the interval.

Some heat recovery is possible, but not all heat can be recovered
This problem can be overcome if:
Hot composite is shifted Tmin/2 colder than it is in practice
Cold composite is shifted Tmin/2 hotter than it is in practice
The shifted composite curves will touch at the pinch

Note: shifting is just for the sake of PTA calculation, no actual shifting!
PTA & GCC - 5
Back to the previous example

Feed 2
230C
140C
Feed 1
180C
20C
Reactor 1
Reactor 2
200C
Product 2
Off gas, 40C
PTA & GCC - 6
Set up shifted temperature intervals from original stream

TS & TT values:
Hot stream: subtract Tmin/2 to make it colder
Cold stream: add Tmin/2 to make it hotter
Product 1, 40C
Target
Supply
H Heat capacity
temp,
temp,
Steam
Type
flowrate, CP
(MW) (MW.K-1)
TS (C)
TT (C)
1. Reactor 1 feed
Cold
20
180
32.0
0.20
2. Reactor 1 product
Hot
250
40
31.5
0.15
3. Reactor 2 feed
Cold
140
230
27.0
0.30
Hot
200
80
30.0
0.25
Note: Heat capacity flowrate, CP = m.Cp
3. Cascade the heat down the temperature interval,

provide external hot utility if needed
Tmin = 10C
40C
Q = mC p T = mC p (TT TS )
H i = CPH CPC Ti
Cold
Hot
If hot stream dominate: H in +ve heat surplus

If cold stream dominate: H in -ve heat deficit
PTA Step 1 Shifted T intervals

80C
250C
2. Calculate energy balance in each shifted

temperature intervals i:
PTA & GCC - 7
Stream
Type
TS
TT
T* S
T* T
Cold
20
180
25
185
Hot
250
40
245
35
Cold
140
230
145
235
Hot
200
80
195
75
PTA & GCC - 8
PTA Step 1 Shifted T intervals
PTA Step 2 H balance
Shift temp
interval, T* (C)
T* (C) Stream population

H2
235
195
185
145
C3
145
75
75
35
25
35
C1
25
PTA & GCC - 9
PTA Step 3 Heat cascade

245
Hot utility
245
0 MW
H = 1.5
235
1.5 MW
-4.5 MW
H = 1.0
185
-3.5 MW
H = -4.0
145
Negative heat 235

cascade
infeasible (heat 195
is transferred
from lower to 185
higher temp)
H = -2.0
35
Cold utility
C3
10
0.15
1.5
Surplus
40
-0.15
-6.0
Deficit
10
0.1
1.0
Surplus
40
-0.1
-4.0
Deficit
70
0.2
14.0
Surplus
40
-0.05
-2.0
Deficit
10
-0.2
-2.0
Deficit
C1
Hot utility
PTA & GCC - 10
QHmin =
7.5 MW
T (C)
9.0 MW
H = -6.0
250
230
3.0 MW
Pinch
H = 1.0
4.0 MW
H = -4.0
0 MW
Tmin = 10C
H = 14.0
6.5 MW
Largest heat
deficit
4.5 MW
75
H = -2.0
35
H = -2.0
25
Surplus/
Deficit
Match values obtained from CC
145
-7.5 MW
H = 14.0
75
H = 1.5
H = -6.0
195
CP = 0.2
185
H4
CP = 0.25
195
CP = 0.15
235
H4
CPH - CPC
H2
245
CP = 0.3
245
T*
14 MW
12.0 MW
40
20
H = -2.0
Pinch temp:
25
2.5 MW
Hot stream = 145+5 = 150C
Cold stream = 1455 =140C
Cold utility
10.0 MW
QCmin =
PTA & GCC - 11
QCmin = 10
QREC = 51.1
QHmin = 7.5
H (MW)
PTA & GCC - 12
Heat cascade & shifted CC

QHmin
Working session
Calculate the hot & cold utility requirements and the pinch
location
Assuming Tmin = 5C
QHmin
Cold composite
when QHmin = 0
Shifted
composite
curves
QCmin
Maximum
overlap
QCmin
PTA & GCC - 13
PTA & GCC - 14
Convention of H in Step 2
Conventional Process Integration books (Linnhoff
et al., 1982; Smith, 1995, 2005) follow standard
thermodynamics convention
Practice makes perfect!

perfect!
Energy balance calculation in Step 2:
H i = CPC CPH Ti
Hot
Cold
If cold stream dominate: H in +ve heat deficit

If hot stream dominate: H in -ve heat surplus
Consistent with HR of exothermic reaction in

positive value
All calculation steps remain the same
PTA & GCC - 19
PTA & GCC - 20
Alternative heat cascading
Composite Curve
QHmin = 7.5
QCmin = 10
PTA & GCC - 21
PTA & GCC - 22
In conventional PDF
Network to achieve the targets
Network design is not our concern

now, we will learn how to design the
network 2 weeks from now.
PTA & GCC - 23
PTA & GCC - 24
Hot Utility Systems
The Onion diagram

diagram
Stream system
Reactor
Separation &
recycle
Heat exchanger
network
Utilities
Hot oil system
We are
finally here
(Linnhoff et al., 1982;

Smith, 1995, 2005)
PTA & GCC - 25
Cold Utility Systems
PTA & GCC - 26
Back to the previous example

Feed 2
230C
140C
Cooling water
system
Feed 1
180C
20C
Reactor 1
Reactor 2
200C
Product 2
80C
250C
Off gas, 40C
40C
Q = mC p T = mC p (TT TS )
Target
Supply
H Heat capacity
temp,
temp,
flowrate, CP
(MW) (MW.K-1)
TS (C)
TT (C)
1. Reactor 1 feed
Cold
20
180
32.0
0.20
Hot
250
40
31.5
0.15
3. Reactor 2 feed
Cold
140
230
27.0
0.30
Hot
200
80
30.0
0.25
Note: Heat capacity flowrate, CP = m.Cp
Steam
Refrigeration
system
PTA & GCC - 27
Product 1, 40C
Type
PTA & GCC - 28

245
Shift temp, T* (C)
Hot utility
Shift temp,
T* (C)
7.5 MW
H = 1.5
235
QHmin = 7.5 MW
9.5 MW
H = -6.0
195
3.0 MW
Heat
sink
H = 1.0
185
4.0 MW
H = -4.0
145
Pinch
0 MW
75
H = -2.0
35
Pinch
145
H = 14.0
14 MW
Heat
source
12.0 MW
H = -2.0
25
10.0 MW
Cold utility
QCmin = 10 MW
H (MW)
PTA & GCC - 29
Utility selection
H (MW)
PTA & GCC - 30
PTA & GCC - 32
Utility selection
For 2 levels of steam @ saturated condition & temperature

of 240 & 180C, determine the loads on the 2 stream levels
that maximises the use of lower pressure steam.
Hot utility
245
7.5 MW
H = 1.5
235
9.5 MW
H = -6.0
195
3.0 MW
H = 1.0
185
4.0 MW
H = -4.0
145
0 MW
H = 14.0
75
H = -2.0
35
14 MW
12.0 MW
H = -2.0
25
10.0 MW
Cold utility
PTA & GCC - 31
Utility selection
Steam generation
Instead of using steam, a hot oil circuit is to be used with a

supply temperature of 280C & CP = 2.1 kJ/kg.K. Calculate
the minimum flowrate of hot oil [Ans: 27.5 kg/s].
How much low pressure steam @ 120C may be generated

by exploring the use of the rejected heat? [Ans: ~4.2 MW].
PTA & GCC - 33
Practice makes perfect!

perfect!
PTA & GCC - 35
PTA & GCC - 34

Lecture 8 - Hen II - Pta GCC

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Lecture outline

Problem table algorithm

Heat exchanger network II

Grand composite curve (GCC)

generation with GCC

The composite curves

PTA & GCC - 2

Its limitation & alternative

H82PLD - Plant Design

Graphical construction inconvenient

Another targeting tool the problem table

Numerical alternative to locate energy targets

H82PLD - Plant Design

PTA & GCC - 3

H82PLD - Plant Design

PTA & GCC - 4

The basic principles of PTA

Hot stream: subtract Tmin/2 to make it colder

If the composite curve is divided into temperature intervals, driving

forces are not feasible throughout the interval.

The shifted composite curves will touch at the pinch

H82PLD - Plant Design

PTA & GCC - 5

Back to the previous example

Off gas, 40C

H82PLD - Plant Design

H82PLD - Plant Design

PTA & GCC - 6

Set up shifted temperature intervals from original stream

3. Cascade the heat down the temperature interval,

If hot stream dominate: H in +ve heat surplus

PTA Step 1 Shifted T intervals

2. Calculate energy balance in each shifted

PTA & GCC - 7

H82PLD - Plant Design

PTA & GCC - 8

PTA Step 1 Shifted T intervals

PTA Step 2 H balance

T* (C) Stream population

PTA & GCC - 9

PTA Step 3 Heat cascade

Negative heat 235

H82PLD - Plant Design

PTA & GCC - 10

Match values obtained from CC

H82PLD - Plant Design

PTA & GCC - 12

Heat cascade & shifted CC

H82PLD - Plant Design

PTA & GCC - 13

H82PLD - Plant Design

PTA & GCC - 14

Practice makes perfect!

Energy balance calculation in Step 2:

If cold stream dominate: H in +ve heat deficit

Consistent with HR of exothermic reaction in

H82PLD - Plant Design

PTA & GCC - 19

H82PLD - Plant Design

PTA & GCC - 20

Alternative heat cascading

H82PLD - Plant Design

PTA & GCC - 21