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BagajewiczHeatIntegration PDF
BagajewiczHeatIntegration PDF
TC,in T TH,in
TC,out
Q
TC,out
TH, out
TH, out Slopes are the
TH,in TH, out TC,in inverse of F*Cp.
Recall that Q=F Cp T
TC,out TC,in H
Q
Q
T-H DIAGRAMS
Assume one heat exchanger and a heater
TH,in
TH, out
TH, out
TH,in TH, out TC,in
TC,out H
TC,in
H Q QH
QH Q
T-H DIAGRAMS
Assume one heat exchanger and a cooler
TH,in
TC,in TC,out
Q
T TH,in
TC,out
QC
TH, out TH, out
TH,in TH, out TC,in
C
QC
TC,out H
TC,in QC Q
Q
T-H DIAGRAMS
Two hot-one cold stream
TH1,in
TH2,in
T TH2,in
TC,in TC,out
Q1 Q2 TH1,in
TC,out
TH2,out TH2,out
TH2,out
TC,out H
TC,in
Q1 Q2
Q2 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
H H
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
H H
Smallest T Smallest T
TH1,in TH2,in
TH1,in TH2,in TC,in
TC,in Q1 Q2 QH TC,out
Q1 Q2
TC,out TH2,out
QC
TH1,out TH2,out TH1,out
T-H DIAGRAMS
T Moving the cold composite
stream to the right
Cooling
Increases heating and cooling BY
THE SAME AMOUNT
Heating Increases the smallest T
Decreases the area needed
Smallest H A=Q/(U* T )
T TH1,in TH2,in
TC,in Notice that for this simple
Q1 Q2 QH TC,out
example the smallest T
takes place in the end of the
QC TH2,out
cold stream
TH1,out
T-H DIAGRAMS
REACTOR 2
T=140 0C T=230 0C T=80 0C
0
T=200 C
H=32 MW H=-31.5 MW
REACTOR 1
T=20 0C T=40 0C
T=180 0C T=250 0C
Tmin=10 oC
Answer: Hot Streams
250 250
200 200
15
5
.
0.2 FCp=0.15
p=0
.4
=0
p=
p
FC
FC
FC
80 80
40 40 FCp=0.15
31.5 30 H 6 48 7.5 H
Answer: Cold Streams
0 .3
230 .3 230 p=
= 0 F C
Cp
180 F 180 =0.5
F Cp
140 140
.2
0.2
=0
p=
p
FC
FC
20 20
H H
32 27 24 20 15
Answer: Both Curves Together.
250
230
200
180 T= Tmin
Pinch
140
80
40
20
H
10 51.5 7.5
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
H
Utility
TOTAL OVERLAP
Tmin H
PARTIAL OVERLAP
STEPS:
1. Divide the temperature range into intervals and
shift the cold temperature scale
2. Make a heat balance in each interval
3. Cascade the heat surplus/deficit through the
intervals.
4. Add heat so that no deficit is cascaded
PROBLEM TABLE
We now explain each step in detail.
Consider the example 1.1
Tmin=10 oC
PROBLEM TABLE
1. Divide the temperature range into intervals and shift the
cold temperature scale
250
250
240
230
200 200
190
180
150
140
80 80
40 40
30
20
Hot Cold Hot Cold
streams streams streams 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 Hinterval Surplus/Deficit?
250 F Cp=0.15
10 1.5 Surplus
240
F Cp=0.25 40 - 6.0 Deficit
200
10 1.0 Surplus
190
40 -4.0 Deficit
150
F Cp=0.3 70 14.0 Surplus
80
40 -2.0 Deficit
40
30 10 - 2.0 Deficit
F Cp=0.2
Hot Cold
streams streams
PROBLEM TABLE
3. Cascade the heat surplus through the intervals. That is,
we transfer to the intervals below every surplus/deficit.
1.5 1.5
This interval has a 1.5 The largest deficit
- 6.0 surplus. It should - 6.0 transferred is -7.5.
transfer 1.5 to
interval 2. -4.5 Thus, 7.5 MW of
1.0 1.0 heat need to be
This interval has a -3.5 added on top to
-4.0 deficit. After using prevent any deficit
-4.0
the 1.5 cascaded it to be transferred to
-7.5 lower intervals
transfers 4.5 to
14.0 14.0
interval 3.
6.5
- 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
14.0 14.0
14.0
This is the
6.5
minimum cooling
-2.0 -2.0
utility
4.5 12.0
-2.0 -2.0
2.5 10.0
IMPORTANT CONCLUSION
7.5 +
10. 0 +
PROBLEM TABLE
Heating utility of smaller temperature. Heating utility at
0.0 the largest
7.5
temperature is
1.5
1.5 now zero.
1.5 + 4.5
9.0
- 6.0
- 6.0
0.0
3.0
1.0
1.0 These are the
4.0
1.0 + 3.0 minimum values
-4.0 of heating utility
-4.0
0.0
needed at each
0.0
14.0
temperature
14.0
level.
14.0
14.0
-2.0
-2.0
12.0
12.0
-2.0
-2.0
10.0
10.0
MATHEMATICAL MODEL
0 Let q i be the surplus or demand of heat in interval i .
It is given by:
q1
1
qi = F k
H
cp kH (Ti 1 Ti ) F s
C
cp sC (Ti 1 Ti )
k iH siC
q2
The minimum heating utility is obtained by solving
the following linear programming (LP) problem
qi S min = Min 0
i
qi+1 s. t
i = i 1 + q i i = 1,... mI
i+1
i 0
qn
n
PART 2
TH1
TC2
TH2 (TH1-TC2)-(TH2-TC1)
Tml=
(TH1-TC2)
ln
(TH2-TC1)
TC1
H
Q
TOTAL AREA TARGETING
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
H
A1 A2 A3 A4 A5 A6
80
Obtain the total
40 area estimate
20
Cooling
Water H
Q1 Q2 Q3 Q4 Q5 Q6
EXERCISE
COMPOSITE CURVE Furnace
(300 oC)
300
250
200 I II III IV
T, C
Pinch 150 V VI
100
Cooling 50 T= Tmin
Water
0
0 10 20 30 40 50 60 70 80 90
Q, MW
HOT COLD
Units:
Interval Q TH1 TH2 TC1 TC2
Q= MW
I 6 80 40 15 20
T= oC
II 4 90 80 20 30
A= m2 III 24 150 90 20 140
IV 20 200 150 140 180
V 7.5 250 200 180 205
VI 7.5 300 250 205 230
EXERCISE
Units: Q= MW T= oC , A= m2
U= 0.001 MW m-2 oC
TOTAL AREA TARGETING
Drawbacks
Fixed costs associated with the number of units
are not considered.
R1 prod, FCp=0.15
FCp=0.09
FCp=0.16
R2 prod, FCp=0.25
FCp=0.1875
R1 feed, FCp=0.2
R2 feed, FCp=0.3
FCp=0.1125
I II III IV V VI
15 20 30 140 180 205 230
20
HEAT EXCHANGER NETWORK
300
R1 prod, FCp=0.15
FCp=0.16
R2 prod, FCp=0.25
20 R1 feed, FCp=0.2
FCp=0.075
R2 feed, FCp=0.3
FCp=0.1125
I II III IV V VI
15 20 30 140 180 205 230
TOTAL= 10 Exchangers
Called Spaghetti design
PREDICTING THE NUMBER OF
UNITS
We can anticipate very simply how many exchangers we should have!!!
Warehouses 30 50 17
Consumer 25 16 56
Centers
ANSWER
You need five trucks, possibly less in some other cases. Here is how
you solve the problem specifically.
30 50 17
25 5 11 39 17
25 16 56
25 55 17
25 16 39 17
25 16 56
COST
Total
Utility
Capital
Optimum Tmin
SPECIAL CASES
There is total overlap for some values of Tmin
T
COST
Total H
TOTAL
Utility 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
Minimum
Heat is obtained from 7.5
heating utility
the heating utility 1.5
9.0
-6.0
T
3.0
1.0
4.0
-4.0
0.0 Pinch
14.0
14.0
-2.0
12.0
H
-2.0
Minimum
Heat Source 10.0
cooling utility
Heat is released to
cooling utility
CONCLUSION
One can analyze the two systems separately,
that is,
TC,out Q Tp- Tmin FCpH < FCpC Golden rule for pinch
matches above the pinch.
Tmin Tmin
As much as possible!
This means that one of the streams has its duty
satisfied!!
TICK-OFF RULE
HANDS ON EXERCISE
H=27 MW H=-30 MW
T=230 0C REACTOR 2
T=140 0C T=80 0C
T=200 0C
H=32 MW H=-31.5 MW
REACTOR 1
T=20 0C
T=250 0C T=40 0C
T=180 0C
Tmin=10 oC PINCH=150 oC
HANDS ON EXERCISE
250 0C 150 0C 40 0C
FCp=0.15 H1
200 0C
80 0C
FCp=0.25 H2
180 0C 140 0C 20 0C
FCp=0.2 C1
FCp=0.3 230 0C C2
Tmin=10 oC PINCH=150 oC
ABOVE THE PINCH
250 0C 150 0C
FCp=0.15 H1
200 0C
FCp=0.25 H2
180 0C
C1
FCp=0.2
230 0C
FCp=0.3
C2
140 0C
200 0C
FCp=0.25 H2
180 0C
FCp=0.2 C1
230 0C
FCp=0.3 C2
140 0C
200 0C
FCp=0.25 H2
180 0C
FCp=0.2 C1
230 0C 181.7 0C 8
FCp=0.3 C2
140 0C
12.5
FCp=0.25 H2 80 0C
FCp=0.2 140 0C 20 0C C1
FCp=0.15 H1 150 0C 40 0C
FCp=0.25 H2 80 0C
17.5
H2 200 0C 80 0C
FCp=0.25
140 0C
180 0C 52.5 0C
FCp=0.2 C1
20 0C
181.7 0C 8 17.5
FCp=0.3 230 0C C2
140 0C
12.5
H2 200 0C 80 0C
FCp=0.25
140 0C
180 0C 52.5 0C
FCp=0.2 C1
20 0C
181.7 0C 8 17.5
FCp=0.3 230 0C
C2
140 0C
12.5
H2 200 0C 80 0C
FCp=0.25
140 0C
180 0C 52.5 0C
FCp=0.2 C1
20 0C
181.7 0C 8 17.5
FCp=0.3 230 0C C2
140 0C
12.5
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
250 0C 150 0C 40 0C
FCp=0.15 H1
H2 200 0C 80 0C
FCp=0.25
140 0C
180 0C 52.5 0C
FCp=0.2 C1
20 0C
230 0C 8 17.5
FCp=0.3 C2
H
140 0C
7.5 7 12.5
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).
250 0C 150 0C 40 0C
FCp=0.15 H1 C
10
H2 200 0C
FCp=0.25
80 0C
180 0C 140 0C 20 0C
FCp=0.2 C1
180 0C 140 0C 20 0C
FCp=0.2 C1
7.5 7 12.5
127.5 OC 90 OC
Target=170 OC FCp=0.2 C1
130 OC 7.5
Target=140 OC FCp=0.25 C2
FCp=0.15 110 OC 10
90 OC
Target=170 OC FCp=0.2 C1
Target=140 OC FCp=0.4 C2
ANSWER
Split the hot stream
FCp=0.3
140 OC 90 OC
Target=170 OC FCp=0.2
C1
127.5 OC 10
Target=140 OC FCp=0.4
C2
15
SOLVE THE FOLLOWING
PROBLEM
Below the Pinch :
100 OC
FCp=0.5 H1 Target=40 OC
FCp=0.3 H2 Target=20 OC
90 OC 30 OC
FCp=0.7 C1
ANSWER
Below the Pinch :
100 OC 40 OC
FCp=0.5 H1 Target=40 OC
FCp=0.3 H2 Target=20 OC
60 OC
90 OC 30 OC
FCp=0.5 C1
30
FCp=0.2
12
COMPLETE PROCEDURE
ABOVE THE PINCH
Start
No No
Split Cold
Stream
Start
No No
Split Hot
Stream
Place
Split Cold
matches
Stream
HANDS ON EXERCISE
Type Supply T Target T F*Cp
(oC) (oC) (MW oC-1)
Hot 750 350 0.045
Hot 550 250 0.04
Cold 300 900 0.043
Cold 200 550 0.02
Tmin=50 oC
Minimum Heating Utility= 9.2 MW
Minimum Cooling Utility= 6.4 MW
ANSWER
FCp=0.04 550 0C
750 0C 358.89 0C
350 0C
FCp=0.045 H1
0.4
250 0C
FCp=0.04 H2
686.05 0C 6
400 0C
300 0C
FCp=0.043 900 0C C1
9.2 8 8.6
FCp=0.02 550 0C C2
200 0C
1 500 0C 6
TRANSSHIPMENT MODEL
(Papoulias and Grossmann, 1983)
0
We will now expand the mathematical model
q1 we presented to calculate the minimum utility.
1
q2 S min = Min 0
s. t
i = i 1 + q i i = 1,... mI
qi i 0
i Where
qi+1
i+1 qi = k k (Ti 1 Ti )
F H
cp H
s s (Ti 1 Ti )
F C
cp C
kiH siC
q
n
TRANSSHIPMENT MODEL
Assume now that we do the same cascade for
si,k,1 each hot stream, while we do not cascade the
ri,1 pk,1 cold streams at all. In addition we consider
i,1 si,k,2
heat transfer from hot to cold streams in each
ri,2 pk,2
interval.
pk , j = si ,k , j k , j = 1,...mI
ri,j+1 pk,j+1
i
i,j+1
i,j si,k,,j+1
j
si ,k , j Yi ,k 0
ri,j+1 pk,j+1
i,n
TRANSSHIPMENT MODEL
si,k,1 The complete model would be:
ri,1 pk,1
i,1 si,k,2
Min Yi ,k
ri,2 pk,2 i k
s.t
U ,0 = U* , 0
si,k,j
ri,j pk,j i ,0 = 0 i, j = 1,...mI
i,j si,k,,j+1 i , j = i , j 1 +ri , j si ,k , j i, j = 1,...mI
k
ri,j+1 pk,j+1
pk , j = si ,k , j k , j = 1,...mI
i,j+1 i
si ,k , j Yi ,k 0 i, k
si,k,n j
ri,n pk,n
i ,0 = 0 i, j = 1,...mI VARIABLES
S(I,K,J) heat exchanged hot and cold streams
i , j = i , j 1 +ri , j si ,k , j i, j = 1,...mI D(I,J) heat of hot streams flowing between intervals
k
Y(I,K) existence of match
pk , j = si ,k , j k , j = 1,...mI Z total number of matches ;
i
j
si ,k , j Yi ,k 0 i, k POSITIVE VARIABLE S
POSITIVE VARIABLE D
BINARY VARIABLE Y ;
EQUATIONS
GAMS MODEL MINMATCH objective function-number of matches
HSBAL(I,J) heat balances of hot stream I in INTERVAL J
SETS CSBAL(K,J) heat balances of cold stream J1 in K
I hot streams above pinch / S, H1 /
HTINEQ1(I,K) heat transferred inequalities;
K cold streams above pinch / C1,C2,W/
J temperature intervals / J0*J3 / ;
MINMATCH .. Z =E= SUM((I,K), Y(I,K));
HSBAL(I,J)$(ORD(J) NE 0) .. D(I,J)-D(I,J-1)+ SUM(K,S(I,K,J)) =E= R(I,J);
SCALAR GAMMA /10000/; CSBAL(K,J)$(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 ;
TABLE R(I,J) load of hot stream I1 in interval K
J0 J1 J2 J3 MODEL TSHIP /ALL/ ;
S 9.2 0 0 0 SOLVE TSHIP USING MIP MINIMIZING Z;
H1 0 0 6.75 2.25; DISPLAY S.L, D.L, Y.L;
GAMS MODEL
SOLUTION
S 9.200 0.600
H1 0.900 900 0C
FCp=0.043
9.2 8
---- VARIABLE Y.L FCp=0.02 550 0C
C1 C2 1 500 0C
S 1.000
H1 1.000 1.000
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
- 6.0
240
1.0 200
190
-4.0
150
Pinch
14
80
-2.0 40
30
-2.0
H
GRAND COMPOSITE CURVE
T Total heating utility
250
240
200
190 These are called
150 pockets
Process-to Process
80
integration takes
40
30 Total cooling utility place here
H
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 c
mS
m QmS + cnQnW
nW
s.t
i ,0 = 0 i, j = 1,...mI
i , j = i , j 1 +ri , j si ,k , j Qi ,n , j i, j = 1,...mI
k mS
m , j = m , j 1 Qi ,n , j + QmS i, j = 1,...mI
mS
pk , j = si ,k , j + Qm ,k , j k , j = 1,...mI
i mS
Q
mS
m ,k , j = QnW k , j = 1,...mI
I0 250
I1 200 -4.5 0 4.5 HOT UTILITY 1
I2 150 -3 0 3 HOT UTILITY 2
I3 30 10 0 10 COLD UTILITY
UTILITY PLACEMENT
Hot Oil placement and extreme return temperatures
H
UTILITY PLACEMENT
Furnace Theoretical Flame
Temperature
Tstack
Air
Tstack
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
QHE
Pinch
W Note that in this case
there is no gain. The heat
engine can be arranged
QHE -W separately and the utility
usage will not change.
QC,min +( QHE W)
COMBINED HEAT AND POWER
Integration of a Heat Engine Across the Pinch.
QH,min -( QHE W) TOTAL HEN
QHE
ENERGY INTAKE
QH,min -( QHE W)
T
W (Smaller)
QC,min
INTEGRATION WITH
DISTILLATION
Placement below the pinch.
QH,min
Qcond
QHP +W (smaller)
TOTAL SYSTEM
Pinch
INTAKE
W QH,,min -QHP
vs. QH,,min +W (separate)
QHP
QHP W QLP
Pinch QLP
QH,min ( QHP+QLP)
(smaller)
QC,min
TOTAL SYSTEM INTAKE
QC,min QH,min +W
vs. QH,min+W+(QHP + QLP) H
(separate)
COMBINED HEAT AND POWER
Gas Turbine Placement
TOTAL ENERGY INTAKE
TEX
QH,min + W+ QLOSS
Air
QS
Pinch TEX
T0
QLOSS QS
QLOSS
QF -W H
QC,min T0
PART 5
DISTILLATION PLACEMENT
PLACEMENT OF DISTILLATION
Placement across the pinch.
QH,min + Qreb
T Qreb
Pinch
QC,min + Qcond
PLACEMENT OF DISTILLATION
Placement above the pinch.
QH,min + Qreb - Qcond
T 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
w a te r
n a p h th a
PA1
ste a m
PA2 k erosen e
ste a m
PA3 d ie s e l
w a te r
cru d e DESALTER ste a m
HEN
g a s o il
so u r w a te r ste a m
HEN FURNACE r e s id u e
CRUDE FRACTIONATION
EXAMPLE
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 PINCH
1.0
M*Cp, MMW/C
0.8 COND
CRUDE
0.6
0.4
1
0.2 RES
0
0 200 300 400
PRODUCTS TEMPERATURE, C
CRUDE FRACTIONATION
EXAMPLE
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 PINCH
M*Cp, MMW/C
1.0
0.8
PA1
0.6 CRUDE
COND
0.4
0.2
RES
0
0 100 200 300 400
PRODUCTS TEMPERATURE , C
CRUDE FRACTIONATION
EXAMPLE
We continue in this fashion until the total utility reaches a minimum. .
1.4
PINCH
1.2
PA1
1.0
M*Cp, MMW/C
0.8 CRUDE
0.6
COND
0.4
PA2
0.2
RES
0
0 100 200 300 400
TEMPERATURE, C
CRUDE FRACTIONATION
EXAMPLE
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
1 PA2
PA1
PA3
0.2
RES
0
0 100 200 300 400
TEMPERATURE, C
CRUDE FRACTIONATION
EXAMPLE
Situation for a heavy crude
0.8
0.4
RES
COND
0.2
SW PA1
PA2
0
0 100 200 300 400
TEMPERATURE, C
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
175 0C 125 0C
FCp=0.010 H1 C
280
FCp=0.040 H2
65 0C
155 0C 20 0C
FCp=0.020 C1
H
175 0C 125 0C
FCp=0.010 H1 C
280
FCp=0.040 H2
65 0C
FCp=0.020 155 0C 20 0C
H C1
155 0C
20 0C
H C1
40 0C C2
112 0C
560 -X 520 +X
H1 175 0C 45 0C
C
65 0C 280
H2 65 0C
65 0C
155 0C 20 0C C1
H
360 2340
112 0C
40 0C C2
60 1020
108 0C
This exchanger is in
violation of the
minimum approach
ENERGY RELAXATION
We use a path to move heat around to restore feasibility
73 0C
H1 175 0C 45 0C
C
65 0C 280 +X
H2 65 0C
65 0C
155 0C 20 0C C1
H
360 +X 2340 -X
112 0C 40 0C C2
60 +X 1020 -X
108 0C
155 0C 20 0C C1
H
1155 1545
112 0C
40 0C C2
855 225
55 0C
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
175 0C 125 0C 45 0C
FCp=0.010 H1
280
FCp=0.040 H2
65 0C
155 0C 20 0C C
FCp=0.020 H 1
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
175 0C 125 0C 45 0C
FCp=0.010 H1
525
125 0C 65 0C
FCp=0.040 H2
155 0C 20 0C C
FCp=0.020 H 1
105 0C
500 500 1700
FCp=0.015 112 0C 40 0C C
H 2
MATHEMATICAL
PROGRAMMING
APPROACHES
RECENT REVIEW PAPER
(until 2000)
z,H
qijm
qimz , jn
z ,C
qijn
Cold stream j
n 1 2 3 4 5
6 7 8 9
K ijm
z ,H
Yijm
z ,H
Yijm
z ,H
+1
6 1 0 0
7 1 0 0
K ijm
z ,H
0 8 1 0 1
9 0 0 0
10 0 0 0
m 1 2 3 4 5 6 7 8 9 10
LATEST MILP APPROACH
(Barbaro and Bagajewicz, 2005)
Flowrate Consistency
z ,H z ,H z,H z,H
qijm qijm 1 qijm qijm1
Cpim( TmU TmL ) Cpim1( TmU1 TmL1 ) Cpim (TmU TmL ) Cpim1 (TmU1 TmL1 )
m 1 2 3 4
6 7
8 9
z,H z,H
qijm qijm1
=
Cpim (T T )
U
m m
L
Cpim1 (TmU1 TmL1 )
PART 8
INDUSTRIAL IMPORTANCE
OF USING THE RIGHT MODEL
w a te r
n a p h th a
PA1
stea m
PA2 k erosen e
ste a m
PA3 d ie s e l
w a te r
cru d e DESALTER stea m
HEN
g a s o il
so u r w a te r ste a m
HEN FURNACE r e s id u e
CRUDE FRACTIONATION EXAMPLE
Light Crude Heavy Crude
400
400
350 350
300 300
Temperature ( C)
250 250
200 200
150 150
100 100
50
50
0
0
0 50 100 150 200
0 50 100 150 200 250
Enthalpy (MW) Enthalpy (MW)
FURNACE
H8
H2 H3 H7
H6
H5
H1
DESALTER
H9 H10
H4
Cooling water
FURNACE
H8
H7
H6
H2
DESALTER
H5
H4
H3 H1
H10
C1
Cooling water
H8
H2 H3 H7
H6
H5
H1
DESALTER
H4
H10
H9
C1
This does not mean that the PDM fails all the time. It is still
capable of producing good results in many other cases.
CRUDE FRACTIONATION
EXAMPLE
We now illustrate the use of HRAT/EMAT procedures for the
case of crude fractionation units.
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 FURNACE
Cooling water
H8
H7
H3 H6
H2
18 units H5
DESALTER
H1
NOT USED
FOR HEAVY H10
CRUDE
H4
H9
C1
Cooling water
H8
H7
H3 H6
H2
H5
18 units
DESALTER
H1
NOT USED FOR
HEAVY CRUDE H10
H4
H9
C1
DESALTER
17 units
H1 H5
H4
C1
Cost, MM$/yr
Combined Multiperiod Multiperiod+ Multip+Des.Temp
Network Model Desalt.Temp. +Higher HRAT
HRAT/EMAT 20/20 20/10 20/10 40/30
Operational 3.96 3.96 3.96 4.94
Fixed 3.14 3.63 3.32 1.37
Total 7.10 7.59 7.28 6.32
CRUDE FRACTIONATION
EXAMPLE
We now illustrate the use of more sophisticated models
that allow the control of splitting. These are essentially
transshipment models that are able to control the level of
splitting (something that regular transshipment models
cannot do).
CRUDE FRACTIONATION
Two branches unrestricted
HRAT = 40 oF FURNACE
EMAT = 30 oF H8
H7
H3
H6
23 units H2
H5
H4
DESALTER
5% More Energy H1
Consumption H10
H9
C1
CRUDE FRACTIONATION
restricted
HRAT = 40 oF FURNACE
EMAT = 30 oF
H7
H8
H3
H6
H2
H5
H1
21 units
H4
DESALTER
5% More Energy
H10
Consumption
H9
C1
CRUDE FRACTIONATION
Cost, MM$/yr
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
Retrofits
HORIZON
NEW-1
REB-T7
9T-7
RELOC
NEW-4
9T-9 9T-1
RELOC NEW-5
9T-9
DESALTER
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
Plant 1 Plant 2
H H
Sink Profile
Source Profile
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
P o s s ib le
B e tw e e n
L o c a t io n o f
p in c h e s
P in c h
P in c h P o in t
P la n t 1
B e lo w b o th
p in c h e s
TOTAL SITE INTEGRATION
T U1,min- QT U2,min
Effective integration
takes place between
pinches.
Pinch 2
QT
From where plant 2 is
Pinch 1 heat source to where
plant 1 is heat sink.
W1,min W2,min- QT
TOTAL SITE INTEGRATION
T U1,min- QT U2,min + QT
QT Integration outside
Pinch 2 the inter pinch region
leads to no effective
savings.
Pinch 1
W1,min W2,min
GRAND COMPOSITE
CURVES
PLANT 1 PLANT 2
18 = 30 - 12 20 = 20
-12 -19
6 = 18 - 12 1 = 20 - 19
-1 -1
5=6-1 Pinch 0=1-1
-15 10 10
0 = 5 - 15 + 10 0 = 10 - 10
-2 2 5
Pinch 0=0-2+2 3=0+5-2
2 1
2=2 4=3+1
GRAND COMPOSITE CURVES
140
120 Plant
1
Temperature
100 Plan
t2
80
60 Maximum
possible savings
40
-20 -15 -10 -5 0 5 10 15 20
Enthalpy
ASSISTED HEAT TRANSFER
PLANT 1 PLANT 2
7 = 20 + 4 - 17 16 = 20 - 4
-7 -10
0=7-7 6 = 16 - 10
If heat is not transferred
above the two pinches 5 4 -10
only 13 of the maximum 1 = 0 + 5 - 4 Pinch 0 = 6 - 10 + 4
17 can be saved. -15 14 14
0 = 1 - 15 + 14 0 = 14 - 14
-3 3 10
Pinch 0=0-3+3 7 = 0 + 10 - 3
3 5
3=3 12 = 7 + 5
ASSISTED HEAT TRANSFER
140
Pla
nt 1
120
Assisted
Temperature
Transfer Pocket
100
Plan
t2
80
Maximum
60
possible savings
40
-10 -5 0 5 10 15 20 25 30
Enthalpy
ASSISTED HEAT TRANSFER
140
Pla
120 nt 1
Temperature
Typical solutions call for 100
sealing the pocket Plan
t2
preventing thus the savings. 80
Maximum
60 possible savings
40
-10 -5 0 5 10 15 20 25 30
Enthalpy
140
Pl a
nt 1
120
Assisted
Temperature
Transfer Pocket
100
P lan
t2
80
Maximum
60
possible savings
40
-10 -5 0 5 10 15 20 25 30
Enthalpy
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 H4 H3 H7 H6 H2 H1
H5
H8
C1
CW
Above the Pinch
Direct Integration
(two stream circuits)
C2
CW
Original HEN
Additional heat exchangers Below the Pinch
used during integration
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 H4 H3 H7 H6 H2 H1
H5
H8
C1 Utility (MMBtu/hr)
Heating Cooling
CW No Integration 252.9 147.7
Above the Pinch Direct Integration 201.4 96.2
CW
Original HEN
Additional heat exchangers Below the Pinch
used during integration
Plant 2: FCC Unit
TOTAL SITE INTEGRATION
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 PLA N T 3 PLA N T 4
( T e s t C a s e # 2 ) ( T r iv e d i) (C & F ) (4 sp 1 )
0 2 5 4 .9 4 2 6 .4 128
300 C
249 C
9 8 .3
1 2 0 .7
5 2 .9
200 C
1 0 4 .5
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.