Introduction of Process Integration

Pinch Diagram and Heat Integration

Reference: Notes from course on Modelling, design and

control for process integration, CAPEC, August 2000 (R.
Dunn)

Computer Aided process Engineering - Lecture 11 (R. Gani) 1

Process Integration Tools Allow Analysis of the Enterprise
The optimal allocation of mass and energy within a unit operation, process and/or site.
Optimal allocation can be based on economic, environmental or other important objectives.
Energy
Heating Power Pressure
Cooling
Feed Stock Products

Solvents By-Products
Mass Chemical
Mass
Plant Effluents
Catalysts
(Enterprise)
Material for Utilities Spent Materials
(Water, Coal)
Heating Power Pressure
Cooling

Energy
Mass Integration (Mass Exchange Network MEN)
Energy Integration (Heat Exchange Network HEN)

Computer Aided process Engineering - Lecture 11 (R. Gani) 2

 Process Integration Techniques
Mass Reactive Mass
Exchange Mass Exchange ExchangeNetworks
Heat
Networks Networks with Regeneration
Exchange
(MENs) (REAMENs) (MEN/REGEN) Combined Heat and
Networks
(HENs) Reactive Mass
Exchange Networks
(CHARMENs)
Pervaporation
Networks
(PERVAPs) Process
Process
Waste Interception
and Allocation
Reverse Integration
Integration Networks
(WINs)
Osmosis
Networks
(RONs) Energy-Induced
Separation
Heat-Induced Heat-Induced Networks
Waste Minimization Energy-Induced Separation
Waste Minimization (EISENs)
Networks Networks
(HIWAMINs) Networks
(EIWAMINs) (HISENs)

Computer Aided process Engineering - Lecture 11 (R. Gani) 3

 Heat Exchange Network (HEN)
(Linnhoff, Grossmann et al, 1978-Present)
A Heat Exchange Network is a System of One or More Heat Exchangers
Hot and Cold Utilities

Hot Streams In
Heat
Exchanger
Network
Cold Streams In

Plant Products
Raw Materials & A
Unit Operations By-Products

Cold Streams Out

Want to Identify: Hot Streams Out

Optimal matching between hot and cold streams to

minimize utility consumption
Minimum number of heat exchangers needed 4
 Consider the problem of two hot stream and two cold streams:

Table 1*

Stream Q available
No. Condition FCp, BTU/(hroF) Tin Tout 103 BTU/hr

1 Hot 1000 250 120 130

2 Hot 4000 200 100 400
3 Cold 3000 90 150 -180
4 Cold 6000 130 190 -360
-10

First Law Analysis (Conservation of Energy):

1000 BTU
Q1 = F1Cp1T1 = o
(250 120) o F = 130 x103 BTU / hr
hr F
Calculate Q3 and Q4
4000 BTU
Q2 = F2Cp2 T2 = (200 100) o F = 400 x103 BTU / hr
hr o F

Therefore, 10x103 BTU/hr must be supplied from utilities (if there are no restrictions on temperature driving force)

How can we check driving force restrictions? Second Law Analysis (You can not transfer heat from a lower
temperature to a higher temperature)

5
*Ref. Douglas, 1988, Conceptual Design of Chemical Processes, McGraw-Hill Publishers, p. 218.
Shifted Temperature Scales (using Table 1 data):
Hot Temperature Scale Cold Temperature Scale
250 240

200 190

150 140

100 90

Sources Sinks

These streams These streams

need to be cooled need to be heated

Computer Aided process Engineering - Lecture 11 (R. Gani) 6

Temperature Interval Diagram (TID)
Hot Temperature Scale Cold Temperature Scale

250 240

200 190

160 150

140 130

120 110
100 90

Computer Aided process Engineering - Lecture 11 (R. Gani) 7

 Net Energy Required at Each Interval
Hot Temperature Scale Cold Temperature Scale Heat Duty Within Intervals
Interval, i
FCp 1000 4000 250 240 3000 6000 1000 Q

1 50

200 190

2 -40
160 150
3 -80
140 130

120
4 110 40

100 5 90 20

Total = -10

Qi = [ ( FCp) hot ,i ]
( FCp ) cold ,i Ti
Therefore,
Q1 = (1000)(250 200) = 50 x103
Q2 = (1000 + 4000 6000)(200 160) = 40 x103
Q3 = (1000 + 4000 3000 6000)(160 140) = 80 x103

Computer Aided process Engineering - Lecture 11 (R. Gani) 8

 Heat Transfer to and from Utilities for Each Temperature Interval
Hot Temperature Scale Cold Temperature Scale

250 240

50
200 190

Hot -40 Cold

160 Utility Utility 150
-80
140 130

120
40 110
100 20 90

Computer Aided process Engineering - Lecture 11 (R. Gani) 9

 Cascade Diagram
Hot Temperature Scale Cold Temperature Scale

250 240

50
200 50 190

Hot -40 Cold

160 Utility 10 Utility 150
70
-80 Pinch
140 0 130
40 40
100 20 60 90

Computer Aided process Engineering - Lecture 11 (R. Gani) 10

Hot Composite Curve
Table 2*

Hot streams, oF Cumulative H

T=100 H0=0 0
T=120 H1=4000(120-100)=80,000 80,000
T=140 H2=(1000+4000)(140-120)=100,000 180,000
T=160 H3=(1000+4000)(160-140)=100,000 280,000
T=200 H4=(1000+4000)(200-160)=200,000 480,000
T=200 H5=1000(250-200)=50,000 530,000

Since FCp values are constant, we could have replaced the calculation for H2, H3, H4 with a single expression:
H2,3,4=(1000+4000)(200-120)=400,000

Temperature
(oF) Plot Becomes the Hot Composite Curve

Enthalpy (1000 BTU/hr) 11

*Ref. Douglas, 1988, Conceptual Design of Chemical Processes, McGraw-Hill Publishers, p. 218.
 Hot Composite Curve

270
250
230
Temperature (deg F)

210
190
170
150
130
110
90
0 100 200 300 400 500 600
Enthalpy, 1000 BTU/hr

Computer Aided process Engineering - Lecture 11 (R. Gani) 12

Cold Composite Curve
Table 2.3*

Cold streams, oF Cumulative H

T=90 H0=60,000 60,000
T=130 H1=3000(130-90)=120,000 180,000
T=150 H2=(3000+6000)(150-130)=180,000 360,000
T=190 H3=6000(190-150)=240,000 600,000

Temperature
(oF) Plot Becomes the Cold Composite Curve

Enthalpy (1000 BTU/hr)

*Ref. Douglas, 1988, Conceptual Design of Chemical Processes, McGraw-Hill Publishers, p. 218.

Computer Aided process Engineering - Lecture 11 (R. Gani) 13

 Cold Composite Curve

210

190
Temperature (deg F)

170

150

130

110

90
0 100 200 300 400 500 600 700
Enthalpy, 1000 BTU/hr

Computer Aided process Engineering - Lecture 11 (R. Gani) 14

 Hot Composite Stream
Cold Composite Stream at 10 deg F
Composite Curves minimum temperature driving force

270
250
Temperature, deg F

230
210
190
170
150
130
110
90
0 200 400 600
Enthalpy, 1000 BTU/hr
Computer Aided process Engineering - Lecture 11 (R. Gani) 15
 Hot Composite Stream
Cold Composite Stream at 10 deg F
Composite Curves minimum temperature driving force
Cold Composite Stream at 20 deg F
minimum temperature driving force
270
250
Temperature, deg F

230
210
190
170
150
130
110
90
0 200 400 600
Enthalpy, 1000 BTU/hr
Computer Aided process Engineering - Lecture 11 (R. Gani) 16
 Composite Pinch Diagram

Pinch or
Tminimum

Temperature Minimum Minimum

Amount of Amount of
Cold Utility Hot Utility
Required Required

Process to Process
Heat Integration

Enthalpy
Computer Aided process Engineering - Lecture 11 (R. Gani) 17