Lecture 9 - Hen III - PDM

Lecture outline
The grid diagram for HEN design

The pinch design method (PDM)
Heat exchanger network III Pinch

design method & network evolution
Minimum unit targeting

Stream splitting
Network evolution
Copyright@Dominic Foo
Heuristics for HEN design
H82PLD - Plant Design
PDM - 2
The composite curves

QHmin
Cost
T (C)
Total
Energy
Pinch
Capital
Heat
source
Tmin
No individual heat exchanger should have a temp

difference < than Tmin
To achieve energy targets, must not transfer heat across the
pinch by:
Tmin
Process-process heat transfer

Inappropriate use of utility
Heat
sink
H (MW)
QCmin
PDM - 3
PDM - 4
Heat transfer across pinch
Don
Dont cold above the pinch
QHmin +XP
T (C)
XP
QHmin +XP
T (C)
Heat
sink
Heat
sink
Heat
source
Heat
source
H (MW)
QCmin+XP
XP
H (MW)
QCmin
PDM - 5
Don
Dont heat below the pinch
QHmin
T (C)
XP
Let
Lets design together while
we go along
Heat
sink
Heat
source
H (MW)
QCmin+XP
PDM - 7
PDM - 6
Back to the previous example

Feed 2
230C
140C
Feed 1
180C
20C
Reactor 1
Reactor 2
200C
The grid diagram

Product 2
80C
250C
Off gas, 40C
To comply with the rules, process should be

divided at the pinch
The grid diagram:
40C
Q = mC p T = mC p (TT TS )
Below pinch
Product 1, 40C
Supply
Target
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
4. Reactor 2 product
Hot
200
80
30.0
0.25
Note: Heat capacity flowrate, CP = m.Cp
PDM - 9
Pinch
40
150
250
80
150
200
20
140
180
140
230
3
QC, min = 10 MW
1. Start design at the pinch

Pinch is the most constrained region of the network
At the pinch, Tmin exists between all hot & cold
streams number of feasible matches is limited
Start design at the pinch avoid trouble in stream
matching at later stage
0.15
31.5
0.25
30.0
0.20
32.0
0.30
27.0
QH, min = 7.5 MW
PDM - 10
T (C)
Above pinch:
CPH CPC
Pinch
2. The CP inequality for individual match
Tmin
Above pinch: CPH CPC

Below pinch: CPH CPC
Below pinch:
CPH CPC
3. The CP table
H (MW)
4. The tick-off heuristic

H
(MW)
CP inequality
The pinch design method (PDM)
CP
(MW/C)
Above pinch
PDM - 13
PDM - 14
CP inequality
Below pinch
The CP table
Pinch
Above pinch
40
150
250
80
150
200
20
140
180
3 140
230
Below pinch:
CPH CPC
Note:
CPH CPC
0.25
0.2
Generalisation:
CPout CPin
PDM - 15
The ticktick-off
off heuristic
Proceed to other streams away from pinch

Complete the design with hot & cold utility:
Only use hot utility above the pinch
Only use cold utility below the pinch
40
150 2
80
150 4
20
140
0.15
0.2
Pinch CP
0.15
0.25
1
0.20
150
250 2
0.15
150
200 4
0.25
140
180
140
230
0.20
0.30
PDM - 16
Pinch
CP H
2 0.15 15.0
200
4 0.25 12.5
1 140
180
0.20 8.0
3
PDM - 17
250
150
150
140
203.3
7.5
8.0
181.7
12.5
0.3
Region above the pinch
Minimum number of heat exchanger units leads to

reduced capital cost achieved by tick-off
heuristic
Individual units are made as large as possible, i.e.
smaller of the 2 heat duties on the matched stream
Tick-off the stream where heat is fully recovered
0.25
Pinch CP
Above pinch:
CPH CPC
CPH CPC
CPs in
descending
order
0.15
Only apply at the pinch & when both end of the match are at pinch
conditions
Away from the pinch, temp differences increase no longer
essential to obey CP inequalities
Above pinch
Below pinch
205 H
7.0
230
14.5
0.30 27.0
7.5
PDM - 18
Region below the pinch
A complete network
Pinch
Pinch CP H
40
80
106.7
10.0
52.5
20
6.5
150
150
140
10
2 0.15 16.5
80
C
10.0
6.5
0.20 24.0
1 20
6.5
PDM - 19
Minimum number of heat exchanger units:

The tick-off heuristic of PDM steers the network design towards
the minimum number of heat exchanger units
The stream that has been ticked-off is no longer part of the
remaining design problem ensures that a stream is removed
from the problem once a unit is placed.
150
200
140
180
8.0
140
12.5
H 230
7.0
7.5
PDM - 20
Minimum number of heat exchanger in a HEN:

Nunits = S 1
where S = number of streams including utilities

Due to the existence of the pinch point, unit targets is
applied to both sides of the pinch:
Nunits = [SAbove pinch 1] + [SBelow pinch 1]
The grid diagram:
Below pinch
General steps of PDM:

Divide the region at the pinch (i.e. above/below pinch)
Start design at the pinch, moving away.
At the pinch, temp feasibility requires that CPout CPin
Loads of heat exchangers are determine by using tick-off heuristic.
Away from pinch, design is more flexible consider other
practical factors, e.g. operability, plant layout, etc.
250
Number of heat exchange units
Tick-off heuristic occasionally may cause problem, be aware
17.5
Utility targets matched 3

(refer to CC & PTA for this
problem in earlier lecture)
Some remarks on PDM

150
4 0.25 17.5
17.5
40
PDM - 21
Pinch
Above pinch
Steam
1
2
CW
Nunits = (5 1) + (4 1) = 7
PDM - 22
The highway analogy
Do we have min # of HX?

Nunits = (4 1) + (5 1) = 7
Kajang
KL
Kajang
KL
Semenyih
80
Semenyih
KLIA
Kajang
KL
Semenyih
1.
2.
3.
4.
Hot
Hot
Cold
Cold
10.0
What is the
minimum no of
road needed to
connect all cities?
250
150
200
1 20
140
180
6.5
8.0
17.5
3 140
12.5
PDM - 23
H 230
7.0
7.5
PDM - 24
Min # of HX units
Supply temp, Target temp, Heat capacity

flowrate, CP
TS (C)
TT (C)
(MW.K-1)
0.3
400
60
0.5
210
40
20
160
0.4
100
300
0.6
H
(MW)
Design a HEN for maximum recovery that feature the

minimum number of units.
Targeting from PTA:
QH,min = 15 MW
QC,min = 26 MW
Nunits = _____ + _____ = ____

60
400
40
210
3 20
160
4 100
Tmin = 20C:
Hot pinch temp = 120C

Cold pinch temp = 100C
150
Putrajaya
Working session
Type
Putrajaya
Steam
40
PDM - 25
300
PDM - 26
Complete network
60
400
40
210
3 20
160
4 100
Practice makes perfect!

perfect!
300
PDM - 29
Stream splitting
Number of streams above pinch
The PDM allows for minimum utility (or maximum

energy recovery) using minimum number of
units.
Pinch
100
Stream splitting needs to be considered in the

following situations:
100
4
5
PDM - 31
100
90
T > 90
90
T > 90
100
100
Number of streams at the pinch

CP inequality cannot be met at the pinch
Pinch
100
4
5
1
2
3
90
90
PDM - 32
CP inequality above pinch
Number of streams below pinch
Above pinch
Pinch
100 T < 100
100 T < 100
3
4
5
100 T < 100
100 T < 100
90
90
90
CPH CPC
SH SC
Pinch
100
90
Pinch
100
90
90
PDM - 33
CPH CPC
SH SC
5
4
Pinch CP
90
90
4
3
Yes
CPout CPin
for pinch
matches?
Yes
100
100
PDM - 34
No
No
Split out
stream
Split in
stream
90
Place
matches
Remark: New CP values may vary, so long as CP inequalities are satisfied.

Nout Nin?
Pinch CP
Stream data
at pinch
4
3
Stream splitting algorithms

CPH CPC
SH SC
90
Below pinch
90
Below pinch
CP
CP inequality below pinch
100
4
3
90
100
3
2
5
CP
5
4
4
3
Pinch
Above pinch
CPH CPC
SH SC
PDM - 35
PDM - 36
Working session
Steam
Type
1.
2.
3.
4.
Hot
Hot
Cold
Cold
Complete network
Supply temp, Target temp, Heat capacity

flowrate, CP
TS (C)
TT (C)
(MW.K-1)
720
320
0.045
520
220
0.040
300
900
0.043
200
550
0.02
H
(MW)
QH,min = 9.2 MW
QC,min = 6.4 MW
Tmin = 20C:
Hot pinch temp = 520C

Cold pinch temp = 500C
PDM - 37
720
320
220
Design a HEN for maximum recovery that feature the

minimum number of units.
Targeting from PTA:
Nunits = _____ + _____ = ____
520 2
3 300
900
4 200
550
PDM - 40
Network optimisation

perfect!
None of the heat exchangers in a HEN synthesised

by PDM should have a temp difference < Tmin.
Once a HEN is synthesised, it can undergo
continuous optimisation, the constraints of no heat
exchangers having temp difference < Tmin can be
relaxed (pinch is ignored).
Heat exchanger duties will be redistributed:
Some become bigger
Some become smaller or removed (new duty = 0)
Useful tools:
Utility paths lines that connects between 2 utilities
Heat loops path that begins & ends at the same point
PDM - 42
Heat loops
Heat loops
Pinch is
ignored
40
+U
250 2
40
80
200 4
80
20
180
U
Heat loop
+U
3
+V
250 2
C
V
+V
200 4
20
180
V
230
+V
3
230
+V
Heat loop
PDM - 43
Utility paths
40
+W
C
PDM - 44
Utility paths
Utility path
+X
C
+X
250 2
40
80
200 4
80
200 4
20
180
20
180
3
W
H
+W
230
Utility path
PDM - 45
250 2
+X
3
X
H
+X
230
PDM - 46
Some remarks
Working session
For heat exchanger with new heat duty = 0, the exchanger is

removed from the network
Evolve the HEN designed earlier by PDM to
During optimisation, design is no longer constrained to

have temp difference > Tmin (very small Tmin should be
avoided for practical reasons)
Pinch no longer divides design in independent
thermodynamic regions (above & below pinch) main
concern is to reduce cost
Heat loops, utility paths & stream splits offer degree of
freedom for manipulating network cost
To optimise network:
simplify its structure:

Remove smallest unit from the network by exploiting
degree of freedom in a loop
Recalculate the network temp & identify any violations
of Tmin = 10C constraint
Restore the original Tmin = 10C throughout the
network by exploiting a utility path
At fixed energy consumption: loops & stream splits

Varying energy consumption is allowed: include utility paths

perfect!
PDM - 47
PDM - 48

Lecture 9 - Hen III - PDM

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

Lecture 9 - Hen III - PDM

Uploaded by

Copyright:

Available Formats

Lecture outline

The grid diagram for HEN design

Heat exchanger network III Pinch

Minimum unit targeting

Heuristics for HEN design

H82PLD - Plant Design

The composite curves

No individual heat exchanger should have a temp

Process-process heat transfer

H82PLD - Plant Design

H82PLD - Plant Design

Heat transfer across pinch

H82PLD - Plant Design

H82PLD - Plant Design

H82PLD - Plant Design

Back to the previous example

The grid diagram

Off gas, 40C

To comply with the rules, process should be

H82PLD - Plant Design

1. Start design at the pinch

QH, min = 7.5 MW

H82PLD - Plant Design

2. The CP inequality for individual match

Above pinch: CPH CPC

4. The tick-off heuristic

The pinch design method (PDM)

H82PLD - Plant Design

Proceed to other streams away from pinch

H82PLD - Plant Design

H82PLD - Plant Design

Region above the pinch

Minimum number of heat exchanger units leads to

H82PLD - Plant Design

H82PLD - Plant Design

Region below the pinch

Minimum number of heat exchanger units:

H82PLD - Plant Design

Minimum number of heat exchanger in a HEN:

where S = number of streams including utilities

The grid diagram:

General steps of PDM:

Number of heat exchange units

Tick-off heuristic occasionally may cause problem, be aware

Utility targets matched 3

Some remarks on PDM

H82PLD - Plant Design

H82PLD - Plant Design

The highway analogy

Do we have min # of HX?

H82PLD - Plant Design

H82PLD - Plant Design

Supply temp, Target temp, Heat capacity

Design a HEN for maximum recovery that feature the

Nunits = _____ + _____ = ____

Hot pinch temp = 120C

H82PLD - Plant Design

H82PLD - Plant Design

H82PLD - Plant Design

Practice makes perfect!

Number of streams above pinch

The PDM allows for minimum utility (or maximum

Stream splitting needs to be considered in the

Nunits = ___ + _ = __

Nunits = ___ + _ = __